To ensure that fully understand the case binding process, I am going to execute a few attempts at creating one using cheaper materials than what I plan to use during the process of completing my final publication.
This will involve creating a text block out of blank pages and then by using grey board as the 'case', I will create a 'perfect bound/case' book, just like the final thing. This will give me valuable experience in the binding process for this particular technique and will ensure I can iron out any mistakes now rather than later.
Specifications:
To keep material cost lower, I decided to do a simple notebook with the smaller size of 6x4.5" (1/3 smaller than what I want the final piece to be) I may try another attempt at this to eliminate any errors made this time and instead of covering the case with stock, use thread to stitch the whole thing together rather than PVA'ing the whole thing to simulate what making the final piece would be like (And also do it to scale).
Text Block:
Using cartridge paper that I cut down to size, I separated each page into sets of 3 with a total of 6 sets, this makes up 72 pages when either side of the paper is accounted for. To ensure they were folded firmly enough, I used a bone folder.
I then pierced holes in each signature in exactly the same place, I set the holes 1" apart.
These are all of the completed holes ready for stitching.
For this part, I had to use a simple stitching tread. Not the strongest of material but it did the job. For the final book, I will ensure I have the proper wax thread that is used to make the book secure enough.
Here is the final stitch all complete for the text block. The finished pice isn;t as tight as I'd have original hoped, but this won't be an issue once I've used PVA to join each signature together.
This is where I measured up the greyboard for the outer casing. As you can see, the image shows a colossal error which I only realised when I was assembling the case, I didn't leave enough space for the join, affectively cutting the case slightly larger than the block making the case far to large for the block.
PVA'ing the block together, using thin but multiple layers of glue to ensure a tight finish.
Preparing the backing. I simply used 150gsm paper for this. I also added the 1/4" in-between the spine which I did not account for in the greybeard measurements.
Glueing the block in place is a simple process, however, another error I made was glueing the inner page too close to the spine which caused an issue, when the book was opened flat, it put extra tension on the text block spine. This can be avoided by simply not gluing too close to the edge of the greybeard and glueing the block instead of the case.
As you can see, the issue I stated above is obvious in this shot.
Just some images of the completed specimen:
Overall, I am extremely impressed with the outcome of my mock-up. Although some human errors were made, I can now be sure to avoid this when I'm in the final stages of completing the book. The process for the final piece will be slightly different, this being that I'd have to use wood instead of grey board, this meaning there is much less room for error as I will only be able to stitch the case together using heavy duty thread/string instead of using PVA, so the text block will be attached to the wooden case with thread and not PVA preserving the wood effect I want to have in my outcome.
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