The front and side panels were fabricated from 1/2" birch
plywood, given a white pickling stain for better contrast with
the cherry. One of the most difficult steps was fabrication of
the "omega" piece for the front panel, a semi-circular arc of
cherry with short wings to mirror the glulam beam arcs in the
sanctuary itself. I glued up short lengths of 3/4" cherry
boards into a rough stepped arch, jig-sawed it into a a rough
approximation of a semi-circular arc, then attached that to a
temporary plywood base with offset spacers. I then made up
a special router radius jig so I could use the router to machine
both inner and outer arcs to perfect circles, leaving a 4" wide
"omega". This took considerable time, but ultimately worked
very well. I sanded the "omega", put finish coats on it, then
fastened it to the birch front panel with wood screws. The
cross was made from cocobolo, a member of the rosewood
family. The circular ring behind the cross was turned on a
lathe, and is maple.
For the rear of the altar, I made two paneled doors from
cherry, allowing access to an interior shelf that can be used
for storage.
All cherry surfaces were finished with four or five coats of
wipe-on Minwax plus four coats of hard furniture wax.
To allow the altar to be moved, I made special internal box
structures on the bottom frame to receive four heavy-duty
casters, one for each leg. These casters can be locked into
place, and also can be removed so that altar rests on the
chancel floor. I recommend that the casters be removed in
normal use so that the weight of the top and side is
transmitted through the frame directly to the floor, not
through the casters to the floor.