Cut out the mirror hody on the handsaw, then round over and smooth the edges.
against die inside edge of the template.
Once the recess is done, I cut out the mirror body on a handsaw (see photo above), then round over the edges with a round-over bit and smooth die edges with a sanding drum.
To make my mirrors look more like sculpture, I shape a gentle crown on the back. I do this freehand on an inflatable sanding drum, but you can also shape it with a belt sander and then by hand with 60grit paper. To finish sand, work up to 400 grit.
I prefer polymerized mng oil for the finish because I find it more durable than other oils. 1 work it in by hand, sanding lightly between coats with 600-grit paper. To hold onto the mirror while I'm oiling, I hot-glue a 2-in. by 2-in. scrap block in the recess.
For the glass, I use S-in.-ilia. beveled mirror glass (available from Shapes and Surfaces Ltd., 1649 Sycamore Ave., Bohemia, NY 11716, 800647-7672). To install it I put a few dabs of clear silicone sealer in die recess. Tliis flexible adhesive helps prevent the glass from cracking when the wood moves with changes in humidity. I rotate the glass while inserting it to spread the sealer into a uniform, resilient base. ▲
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