Constructing the Shell

The shell of the dollhouse is constructed from seven ply marine grade plywood - an extremely stable wood under changing temperature and humidity conditions.
Since I had neither the skills nor the equipment to build the shell, it was contracted out to a pair of wooden boat builders at a cost of $7,000. The complete dollhouse is much too large to pass through a door frame, therefore we needed to construct it three sections; the base, the first floor and the second floor, so that it can be disassembled for moving.

The Base
The base measures 43" by 55" and is reinforced with 1" by 4" oak sides and bracing under the platform to maintain rigidity and to keep it from warping. The base also contains the foundation which is made from 1" by 3" birch strips. In each corner of the foundation is a 3" by 3" block with a 1" diameter hole to receive a 1" diameter round peg mounted under the base of the first floor. This allows proper positioning of the first floor on the foundation.

The First Floor
The first floor base measures 40" by 40". Slots 3/8" wide and 1/8' deep are routed in the floor and in the interior and exterior walls to properly position the walls. The walls were then glued into place using West System Epoxy. In places where the routing overruns the walls, the space is filled in with West System Epoxy and sanded to a flat surface. Underneath the first floor are mounted 1" diameter pegs to fit into the holes on the base. In addition, the outer walls overhang the foundation by approximately 1".

The Second Floor
The second floor also measures 40" by 40". Again, slots are routed  into the base and walls to position both the interior and exterior walls which are glued with West System Epoxy. In addition, the outer walls extend beyond the base of the second floor by about 1/4" and has a lip routed into the wall. This lip fits into an opposite directed lip routed into the top of the exterior walls of the first floor so that the second floor can be properly positioned. The second floor also contains the ceiling of the second floor which also serves as the floor of a small attic. All of the electrical wiring leads to this attic where the switches are mounted.

Click on photograph to enlarge

The first photograph shows a position check of the interior walls. The slots have been routed into the first floor base and interior walls, but the walls have not yet been glued into place. Note that the interior doors have not yet been cut. The view is of the south side or rear of the house showing the kitchen, dining room and library. Since this plywood has a very slight tendency to warp, the four corners are braced into position on the foundation.
The second photograph shows the interior walls glued into place. The doors have now been cut in the interior walls.  The view is of the east side of the house showing the front hallway, first floor bathroom and the library. The exterior walls have not yet been glued into place.
The third photograph shows the exterior walls glued into place. The view is of the south side or rear of the house.  Note that the window openings have been cut and that there are large missing sections in the exterior walls where the panel openings will be. One may also note the double wall between the kitchen and dinning room. This double wall contains the main chimney and serves as the route for the electrical wires to pass up to the attic where the switches are located. If you click on the photograph to get an enlarged view, you can see the exterior wall overhanging the foundation.
The next photograph shows the north elevation or front of the house. Again the movable panels are missing. Note that the wall containing the front door and east wall facing the front porch extends all the way to the base. The miniature's front porch is a removable and separate section from the first floor and will fit into this space which is approximately 9" by 15". It was constructed this way so that when the dollhouse is being moved, it is not necessary to hold onto the more delicate decorative gingerbread brackets that adorn the front porch.
This photograph shows the construction of the second floor. The second floor was positioned and clamped down while the front wall is glued into place. Note the bracing needed to keep the second floor flat. One may also note the cellophane wrapping around parts of the first floor. This is to prevent and excess epoxy oozing out and gluing the second floor to the first floor.
This photograph shows the completed shell with the panel openings in place. These panels are attached to the exterior walls with piano hinges. These hinges are recessed into the wall so that they lie flush with the outer surface of the wall. The view is of the south elevation showing the openings to the kitchen, dinning room and library. The view also shows the dormers in place.
This figure shows a crossection (not to scale) of  a corner and the construction used to position the first floor properly on the foundation. A 1" diameter wooden peg mounted under the first floor fits into a 1" diameter hole drilled into a 3" by 3" block. In addition the outer walls of the first floor overhang the foundation by 1".
The second floor is held in place using the construction shown on the figure to the right. Note how the overlapping notches position the second floor onto the first floor.
In addition, the panels that open to expose the interior of the dollhouse have a 3/8" wide by 1/8" deep grove. When the panel is closed, this grove fits exactly into the first floor.
The last photograph shows the completed shell temporarily stored in our upstairs guest room. The view is of the north east corner of the house. If you click on the photograph to get an enlarged view, you can see the exterior molding under the eaves and dormers which were milled from white pine. All of the exterior moldings are exactly the same shapes as on the full size house.




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