Don Weisman writes:
Most repair people run into this identical problem from time to time.
Sometimes simple regluing of the broken loose ply or plies is all it
takes. Sometimes as in this case, the repair called for a replacement
back splat since one or two pieces were completely broken through.
(My guy cut in half to fit the trash container after the tracing.
I Hot Shot it together for the photo)
This particular splat was the first time for a new method. It looks like it
will work quite well and saved quite a bit of time. The difference being in
coming up with the exact original thickness. Which if you have replaced
any, you already know how important that is and how time consuming it
can be to lay up your own plywood.
Essentially what we did was after removing the crest rail:
1. take a normal piece of Mahogany plywood, good both sides.
2. lay up an equal number of Mahogany sheet veneer
to each face, which was one.
3. cut out the pattern on a scroll saw and
set in the simple straight line pattern.
4. install and remove any excess thickness at the seat rail mortise.
5. reinstall the crest rail.
Total time, 2.5 hours.
We were happy and no doubt the customer will even be happier.
Don Weisman
TX
