The Sane Man's Approach
As I'm about to remove a wall I have to add a steel I-Beam as a post to support the ceiling. My plan is to cover all four sides so that it looks like a wooden post. Normally I would cut mitered angles and try to make the seams as unobtrusive as possible or just glue and brad nail boards together in place as there is only exposed long grain and I think that wouldn't look too bad either.
My Delusions Of Grandeur
While mulling this idea around in my head I came up with the idea of joining the boards with box joints. Although they wouldn't need any strength to speak of, I think this would give the post a nice look. I'm even considering using two or four different types of wood to maximize the effect.
There are a ton of guides, tutorials, discussions out there on how to make box joints with the table saw or a router table and some kind of jig. By now it feels like I watched and read ALL of them :). While being excellent for cutting box joints for their intended size and application, none of them suit me and my idea. The room is somewhere under three meters (ten feet) high and so would the boards be.
- Is the grain direction a problem for me? Box joints are usually cut into end-grain, I would cut them into long-grain.
- If I use different wood(species), would the joints explode all over my living room while they probably expand at different rates/times?
- What is the best tool to use?
- What would be the best jig to use?
- Is this completely loony or is there already an established way of doing this that I simply didn't find?