View Full Version : Corona Virus Projects
JohnnyEgo
04-14-2020, 18:52
Sort of like an extended version of the 'Bored Yet' thread. Since I have more shop-time than usual, I decided to take on a larger project that I had been putting off for a while, which was to make a small card catalog for my son's Pokeman collection. Over the last few weeks, I made some progress on the easier (relative) parts of my project, and figured I'd post up some of it here. I also have no objections to anyone sharing their long term Corona virus projects as well, or answering any questions I can about what I have done, both well and foolishly.
So first, the chaos I plan to address:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/pokechaos02.JPG
I figured for this I'd go with solid cherry. Ply would be easier, faster, and more stable, but I figure I've got some time and wanted to build something that might last a while. Maple and walnut are my usual domestic hardwoods of choice, and aside from some cherry veneer ply, I cannot think of the last time I worked with the stuff. But that didn't stop me from buying a big old plank of the stuff.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/jointedcherry01.JPG
Rough lumber is bought in board-feet, which is a measure of volume. I picked a plank that was about 10 feet long, mostly 7-8 inches wide, and about 2" thick, also known as 8/4 when buying rough lumber. Then I started with the first of many rounds of stock prep to come.
First, I chopped it up to rough length, plus a couple inches:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/jointedcherry02.JPG
Then on to the jointer-planer set in jointer mode, to make one face flat:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/jointedcherry03.JPG
First pass didn't quite flatten it, so it went through again:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/jointedcherry04.JPG
Once the face was flat, I flipped the board on edge and ran it through a couple times. This gave me a board with one flat face and one flat edge at 90 degrees to one another:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/jointedcherry05.JPG
Then I ran them across the tablesaw to clean up the opposite edge:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/jointedcherry06.JPG
Ran them through the planer and then stacked them up to get some air:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/jointedcherry02.JPG
I let them rest in the shop for a day at this point. When you take down solid stock like this, it changes the equilibrium of the water distribution in the wood, as well as any hidden tensions. It is very easy for wood to warp, cup, or bow, particularly as you make it thinner. I don't know that it makes too much difference at this point when the pieces are still fairly thick, but I do it anyways.
Next to come: Making the first box joints.
JohnnyEgo
04-20-2020, 10:35
I had a bunch of big boards where I last left off, but I needed thinner boards, so I set up my bandsaw to split them, also known as resawing.
First, put in my big (for this smaller bandsaw) resaw blade, and squared it to the table.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/resawing01.JPG
Then, split some big boards into littler ones:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/resawing02.JPG
I had hoped to get four 3/8" boards out of each segment of plank, but that didn't happen. The plank I bought was nominally 8/4, or 2" thick, but it was skip-planed at the lumber yard to give some indication of the face grain, which reduced it to about 1.9". I lost another 1/8" to jointing and planing, and my resaw blade ate up 1/8" in each slice. By the time I was done planing off the drift after resawing, I ended up with three 3/8" boards and one 1/4" board out of each piece, or 25% less drawer material than I had planned for. This would be the first in a comedy of many, many errors that happened that day, and will no-doubt happen throughout the project.
Now that I had my stock dimensioned for thickness, I could start cutting parts to length. I usually use my tablesaw sled for this, but I didn't feel like swapping out my ripping blade for a cross-cut blade, so I figured I'd just knock it out on my compound miter:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/1stboxes01.JPG
That was a bad choice. I have had my compound miter for many years, and it has served me well for things like framing and rough carpentry. It's been knocked around many times, and I haven't been great about keeping it tuned up, because it mostly hasn't mattered in a while. But it mattered now, and I didn't check before I cut. As a result, none of the ends were square. Had to clean them all up with a miter plane:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/1stboxes02.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/1stboxes03.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/1stboxes04.JPG
Could have avoided all of that if I had just spent the time swapping blades on the tablesaw or checking the alignment on the miter saw before I started cutting.
Anyways, I now had a pile of cut parts, and it was time to join them together. I decided on a box joint as being one of the simplest ways to add strong, functional, and decorative joint that wouldn't crush my soul to batch out 13 drawers with. I set my dado stack to 3/8 of an inch, and then screwed a couple of boards and a 3/8" piece of walnut directly to an old dado sled to get my box joint jig. Then I just ran them through:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/1stboxes05.JPG
And my first run of boxes, setting on top of the material for the next run:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/1stboxes06.JPG
I always enjoy your detailed break down and attention to detail.
JohnnyEgo
04-20-2020, 16:50
I appreciate the compliment, but if I paid that much attention to detail, I wouldn't have to fix so many mistakes. If I had a show, I'd call it 'Attention Deficit Woodworking'.
whitewalrus
04-20-2020, 18:22
I appreciate the compliment, but if I paid that much attention to detail, I wouldn't have to fix so many mistakes. If I had a show, I'd call it 'Attention Deficit Woodworking'.
The mistakes is how you learn you need to pay more attention to that step :)
JohnnyEgo
04-22-2020, 19:28
Another day, another round of stock prep. Going to try and finish the remaining drawers out of this plank:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/nextjointing01.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/nextjointing02.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/nextjointing03.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/nextjointing10.JPG
Not bad at all. I did my resawing considerably better on this round. Got enough of a yield on the first couple of pieces that I was left with plenty of stock to cut the face frames, runners, and dust panels that will eventually be needed for this one.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/nextjointing11.JPG
JohnnyEgo
04-22-2020, 19:46
Last Sunday was nice and quiet, and I had about a three hour run in the shop. Started by stacking up all the boxes and spacing them out so I could get some relative measurements:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork01.JPG
I was ready to cut the drawer stock, but I had a measurement locked into my compound miter that I didn't want to change, and my tablesaw was set up for cutting the box joints, so I decided to go old-school. My grandfather was a carpenter who could eyeball a straight line and free cut it to the nearest thousandths. I didn't get that gene. So I marked my real measurement, and then a cut line with a comfortable safety margin:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork02.JPG
Then over to the bench hook to cut it. This is a $5 saw. I bought 6 of them when the Cub Scouts came over to work on their woodworking merit badges.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork03.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork04.JPG
Came out closer to square than normal, but still needs some work to be furniture-grade:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork05.JPG
So I used my $10 block plane to square it up.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork06.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork07.JPG
You do not need to spend a bunch of money on tools to make simple, clean, and precise joints. Just takes a little bit of sweat. Power tools save you that sweat and speed you up, but they can also speed up the pace of your mistakes.
While I enjoyed the sweat equity, I had 7 more edges to square up, and didn't want to do them all with the block plane, so I pulled out my #5 1/2 bench plane to speed things up.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork09.JPG
505mm right on the money.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork08.JPG
JohnnyEgo
04-23-2020, 00:01
In between each row of drawers is the rail that they rest on. In traditional solid wood construction, that rail is actually a frame, rather than a solid board shelf. The reasons were that using a solid wood shelf between each row of drawers make a piece of furniture heavy, more expensive, and then you have to allow for a lot more wood movement in your casework and back boards. So rather than use a solid board shelf, cabinets of this sort use a frame. A light-weight panel inside the frame gives it some rigidity, and also stops the contents of the drawer below from interfering with the drawer above, while also keeping out any dust between the drawers. Hence, the dust panel.
Not as common in contemporary furniture, where ply and MDF are both very cheap and very stable. Here is an example of a plywood dresser I made my wife about 18 years ago. It uses a face frame and drawer runners. If there was a panel in-between each drawer, that would be the dust panel.
http://www.johnnyego.com/wood/projects/lowboy1.jpg
http://www.johnnyego.com/wood/projects/lowboy3.jpg
http://www.johnnyego.com/wood/projects/lowboy5.jpg
I've got some work to do to get to the dust panels for this guy. Mostly, I need to finish shaping all the boxes, get the bottoms in them, glue them square, and flush sand the joints first. Then I will make the face frames and size them to the case. Once that is done, I will turn the rails of the face frames into dust panels. That part will actually be pretty easy and fast, but the all those other things before it are tedious. Going to put some time into the boxes this weekend.
I am pretty useless when it comes to woodwork. Everything I put together looks like it was made out of unrefinished used pallets, regardless of the time or care I put into it. Metal is a much friendlier medium for me.
Thanks for the break down.
In between each row of drawers is the rail that they rest on. In traditional solid wood construction, that rail is actually a frame, rather than a solid board shelf. The reasons were that using a solid wood shelf between each row of drawers make a piece of furniture heavy, more expensive, and then you have to allow for a lot more wood movement in your casework and back boards. So rather than use a solid board shelf, cabinets of this sort use a frame. A light-weight panel inside the frame gives it some rigidity, and also stops the contents of the drawer below from interfering with the drawer above, while also keeping out any dust between the drawers. Hence, the dust panel.
Not as common in contemporary furniture, where ply and MDF are both very cheap and very stable. Here is an example of a plywood dresser I made my wife about 18 years ago. It uses a face frame and drawer runners. If there was a panel in-between each drawer, that would be the dust panel.
http://www.johnnyego.com/wood/projects/lowboy1.jpg
http://www.johnnyego.com/wood/projects/lowboy3.jpg
http://www.johnnyego.com/wood/projects/lowboy5.jpg
I've got some work to do to get to the dust panels for this guy. Mostly, I need to finish shaping all the boxes, get the bottoms in them, glue them square, and flush sand the joints first. Then I will make the face frames and size them to the case. Once that is done, I will turn the rails of the face frames into dust panels. That part will actually be pretty easy and fast, but the all those other things before it are tedious. Going to put some time into the boxes this weekend.
Nice work. Is the top fixed to the crown, or is it a hinged hidey-hole for jewelry and such?
JohnnyEgo
04-23-2020, 13:42
Hinged hidey-hole for porn.
Actually, I think my wife ended up filling hers with college papers and notebooks.
Man, of all the things that probably aren't worth keeping around....
http://www.johnnyego.com/wood/projects/lowboy1.jpg
http://www.johnnyego.com/wood/projects/lowboy3.jpg
http://www.johnnyego.com/wood/projects/lowboy5.jpg
Ok, I've just skimmed this thread, but I think you skipped a few steps between photos #2 and #3................
We?re going to try a garden this year. I really have the worst outcomes with growing plants, but the kids are excited anyway. We?ll see where it goes.
https://uploads.tapatalk-cdn.com/20200423/ee479c1b5a3e0086723adbe8904804d3.jpg
https://uploads.tapatalk-cdn.com/20200423/6f31414edba7c6f4abd96c4f4fa9614a.jpg
https://uploads.tapatalk-cdn.com/20200423/50d7087d856ca415aadc589473635296.jpg
https://uploads.tapatalk-cdn.com/20200423/47bb1bce7e7e3b7b15d3191d5c5029e2.jpg
https://uploads.tapatalk-cdn.com/20200423/a74459b942a6a54c46d50ac66c40f171.jpg
https://uploads.tapatalk-cdn.com/20200423/39ef596593b50dea2d4f437714517f22.jpg
I like it. Will your yard sprinklers water it?
I'm putting together a pre-fabbed bunk bed this afternoon with directions and everything. I suspect I'll screw it up. :)
I like it. Will your yard sprinklers water it?
No irrigation out back, hence the awful looking lawn. I'm not even sure the kids will water it. LOL
JohnnyEgo
04-23-2020, 17:17
Very nice! I couldn't tell from the bucket what you used to seal it. Was it Thompson's?
I have not done much in the way of outdoor furniture, but I do plan to get around to building a picnic table eventually. Have to figure out what will stand up to the direct sunlight best where it is going. I've got severe fade on everything in my back yard.
I'm putting together a pre-fabbed bunk bed this afternoon with directions and everything. I suspect I'll screw it up. :)
Ouch! [facepalm]
Chicken coop with the daughter. Not taking pictures until done since you guys? work is so on point. But it should look good when done.
plus I’m essential so it’s getting done in the evenings.
Ha, I'm sure you saw my chicken coop. Same thing in that it was not your standard construction method, but turned out fancy when it was done. You can buy mine for $500. We just might need a crane to get it out of my backyard.
JohnnyEgo
04-23-2020, 21:47
First thing I ever built, I'll call it an armoire. Was in the Navy making nothing as an E3. In the time-honored tradition of youthful bad choices, I decided to move off the ship and into an apartment with my girlfriend and my two best friends. But furniture was expensive on an E3 salary. So I figured I could just build something. I owned a hammer and a Philips head screwdriver, and I had a budget of $35. After pricing out a sheet of plywood and a box of screws, I had spent $30 of it. But then I saw a sign that said the first two cuts on the panel saw were free, and then it was 25 cents a cut thereafter. I looked at my plan, did some quick math, and realized I could pester the Home Depot employee into making all 20 cuts for me on the panel saw for the $5 I had left. It was not a happy day for him, and those last 10 cuts were not exactly on the mark, but it was still a lot cheaper than a Skilsaw.
Went back to the apartment and ferried my load of cut panels into the living room. Didn't own a drill. Twisted two screws in by hand and realized it wasn't going to happen. So I borrowed $5 from my buddy and went back to the Home Depot to pick up a box of nails. My two friends and I nailed that thing together until two cases of Natty Light and the clock striking 2:00 AM, much to the delight of my neighbors all around, I am sure. It looked... Magnificient! Sure, it wasn't exactly square, and in point of fact it had a healthy bit of lean to one side. And there were the jagged splinters that accompanied the un-sanded surface. But I had beaten the overpriced furniture monopoly with my own two hands, and the hands of my friends, and the tired hands of the angry Home Depot Guy who had to work the panel saw for an hour, but whatever, we still won. Until we tried to move it into my bedroom, where we realized it was too wide for the doorway.
We beat it apart in the hallway, and then hammered it back together on the other side of the door. The hammer marks really added texture to the design. For the next two months, I pulled splinters out of my clothes on a daily basis. It was a glorious mess, but every time I looked at it, I felt a sense of pride in what I had done.
So go ahead and swing a hammer at a random pile of wood and build something profoundly structurally unsound. You don't have to be good, you just have to be bold. And you may even enjoy it.
Ha, I'm sure you saw my chicken coop. Same thing in that it was not your standard construction method, but turned out fancy when it was done. You can buy mine for $500. We just might need a crane to get it out of my backyard.
Is that the two layer dog house? Lol. Mine is supposed to look like a barn. That way my wife May allow us to keep my preps. I mean peeps.
Nah, I built a second one that got pretty fancy.
I have vanquished the pre-fab bunk. They are sleeping fine and no one has broken an arm or leg yet in a failed attempt at, “Geronimo!”
However, I could not find my power tools due to the partially unpacked moved. So I have hand tool hotspots.
811668116781165
Chicken coop with the daughter. Not taking pictures until done since you guys? work is so on point. But it should look good when done.
plus I’m essential so it’s getting done in the evenings.
About $225 in cost with lots of scrap including the roofing. The shingles have been sitting alongside my house, I hope they lay down over time. I wanted the birds to have a run and coop combined. Last time we had chickens we got tired of poop on the porch.
Very nice! I couldn't tell from the bucket what you used to seal it. Was it Thompson's?
I have not done much in the way of outdoor furniture, but I do plan to get around to building a picnic table eventually. Have to figure out what will stand up to the direct sunlight best where it is going. I've got severe fade on everything in my back yard.
Thanks! I sealed the cedar with the same stain we put on the fence. It is a Sherwin Williams WoodScapes 5yr semi-transparent.
And that chicken coup is looking good!
Good work. Poop on the porch is the reason I had to get rid of my chickens.
Anyone ever actually save money raising chickens vs. buying meat and eggs at the store?
Question 2: Anyone successfully gotten an AG exemption with chickens?
Lol. The eggs have orange yolks, a slightly richer flavor, and are kind of fun to gather.
Stores wont be open after the zombies/hyperinflation start.
No, at sams club 5 dozen eggs is $7
buffalobo
04-26-2020, 19:08
Depends on the value you place on having your own food supply chain.
MSM report tonite about food supply chain issues and lengthening food lines in some places.
newracer
04-26-2020, 20:41
A good friend just got 30 chicks, Ill let them do the work and get fresh eggs.
newracer
04-26-2020, 20:43
Installed the new to me Warn Zeon 10s Platinum on the JK. Had to mod my bumper a little.
I got this bumper from TnT, it is one of the originals that was on one of there rigs. I had to drill some new mounting holes, others were close so I welded them in.
http://i.imgur.com/xAgCxITl.jpg
For some reason the hole for the fair lead was huge and off center.
http://i.imgur.com/fCMESFQl.jpg
Cut some plates to fill it in.
http://i.imgur.com/ICb2Uxql.jpg
http://i.imgur.com/V04sVdDl.jpg
http://i.imgur.com/7me6Vysl.jpg
http://i.imgur.com/0Dm8L8Pl.jpg
Just need to install the synthetic rope.
https://i.imgur.com/V1mvdTJl.jpg
Everything is controlled from the wireless remote, even accessory lights.
https://i.imgur.com/fgLlCLTl.jpg
Looks nice all cleaned up. Think I'm going to start working on getting my 2-stroke cleaned up to see if I can get it to run.
I am pretty useless when it comes to woodwork. Everything I put together looks like it was made out of unrefinished used pallets, regardless of the time or care I put into it. Metal is a much friendlier medium for me.
Yeah, pretty much anything I've ever tried to build as "furniture" ends up looking like something that Gilligan and the Skipper knocked together on the island.
Great-Kazoo
04-27-2020, 07:51
Yeah, pretty much anything I've ever tried to build as "furniture" ends up looking like something that Gilligan and the Skipper knocked together on the island.
I've honed my woodworking skills in to 2 categories.
toothpicks or door stops
OK i lied 3 categories.
#3 firewood
JohnnyEgo
04-27-2020, 08:00
Some more handwork to assemble the bottom drawer. It's made of 1/2" stock instead of 3/8", because I wanted it to be a little more stout due it's size. Those cards get heavy when packed into a drawer of this size. Problem is, with the added thickness, I'd have to cut the box joints deeper on the 3/8" setting, and they would look more rectangular than the box joints on all the other boxes. I could cut them on 1/2" spacing, and they would be square, but still a little bigger than all the other boxes. Instead, I cut a little ledge into each end, also known as a 'rabbet' in wood-working terms, 3/8" wide by 1/8" deep, across the ends of each board. The quick way would have been to cut them on the router, or on the table saw with a dado blade, but I'd have to nail the setting perfectly the first time, and I just wasn't feeling it that morning. So I used a rabbet block plane, followed by a router plane, to make each rabbet one sliver at a time:
First, marked out where each rabbet should go:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork10.JPG
Then clamped a board adjacent to the marking line to serve as a fence for the rabbet plane. Back and forth a couple of times with the rabbet plane until I was roughly to depth.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork11.JPG
Then my small router plane to clean up and make sure everything was level.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork12.JPG
Repeat 7 more times
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork13.JPG
Check for fit. Fit is good. It's tighter than it appears. A little bit of 'spelching' or tear-out at the end of the board, where the unsupported wood grain tore before being cut makes the gap appear wider at the corner than it is through the rest of the joint. Will fill it with sawdust and glue later on to clean up the appearance.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork14.JPG
Then over to the tablesaw to cut the box joints:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork15.JPG
That fit fairly nicely. Three of the four came out about perfect. One back corner joint is tight under clamping pressure, but has enough warp to pull out the upper corner when not clamped. It will get clamped and glued in the appropriate position, and the glue bond will hold it in position, but that is asking a lot of the glue bond over the next 50 years. Not sure what I am going to do about it, if anything, but I have tossed around the idea of pinning that back joint with a pin nail for added strength.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork16.JPG
About two hours worth of sweat and wood shavings. Not a bad time at all.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/handwork17.JPG
Slow progress:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/slowprogress01.JPG
Right when you finish, he's going to announce he's into Digipets now and all the stuff fits in your pocket!
Simple, elegant, clever.
Nice work! That?s going to be a fantastic cabinet! It reminds me of one by Dad built for his collection of router bits. Unfortunately, evil stepmom decided she wanted to keep it and never use it.
Looks better than anything I’ve ever made with wood! Except maybe my children...
I plan to get this running. I'm going to start by draining the fuel tank. The 2-stroke tank is dry. Then I'm going to remove the carb and make sure the jets are clear.
https://lh3.googleusercontent.com/rV6V4ACIPKSDaPxca-RPM5ryuhCORiIPv0AKD8nEY3q0KKoenYtnZUKsiL7SXSxunHUQ PyESQ35Czs6g-x3oVVLlX_paOuJjgnxEvMvH69hH90u3QWPjJJf1uQ5hOhbZ3Zi 9bENcHSXu01WgOwCzQgJeIambzdpnaTc1YVhuOzCga8O5RQSne _FZ4GWJ8bKFZgtzEgwNy8N_s7Athh86Gl_2uKKfW2xlGEdS-Ozij2a3MjvQxV-ssDju1CDmB_V3bQZs-KB56GM0OH1DfXHBuXHPX3N3DOYSfd0uzMfZVfdAbNR_q-iTaMCXlDqpHO_dZgo56N0bkhjp8UDzVH-s6FONOH0oU52XgzfHYg2Tgkn0kp8dGakR_K1NAePnduDo9i1-14rNXKn9zxyQDtFbOKULtGUVkrTTjwAM37mA-ZHyZdsfJykZ56b07a3Bd-6aG2ikh_GLpJAEjqv2sQAsKHN9z2M4yCgzyEW2haEjloxP10HX olqjg9nuLRmCYYs0bfd7IezD-aDAQWn7fO5rjYIXICK-xN5N7NfGcdKVQtDIQPoCLK_MjKPoUtATCkbxanwP6-Z7WUKNykmkJbJEJ7EvUOAKWdcPAgo7NFfuAoqevL3rYAESep85 uiA8nTP0T10bOc54mpIz8Qxhcn0wODy6QMtYWDbuCpEAB80rn4 jx6j0MTf1q8sN_8DNzYIn9XkgSA4V9vQCP4BsRYz55wOs_YTUR rhzlhZV4FvFI371_fKI9OwDpy7B0=w1112-h625-no
Well, I put 2-stroke oil and fresh gas in it and it started on the second kick. It works. On paper it says that this old yellow bike has twice the horse power of my newer blue bike. It's definitely faster and has more usable gearing for the street.
https://youtu.be/imab5NGyIBA
Great-Kazoo
04-27-2020, 20:38
Well, I put 2-stroke oil and fresh gas in it and it started on the second kick. It works. On paper it says that this old yellow bike has twice the horse power of my newer blue bike. It's definitely faster and has more usable gearing for the street.
https://youtu.be/imab5NGyIBA
those clutch plates free up after running a few?
Great-Kazoo
04-27-2020, 20:48
needed a thin 1 1/8" wrench for the dillon 1500 trimmer. Standard wrench is too thick, so i made my own. 1 hr later
Rough cut and it was a tad too wide so i built it up with some welding. then hand filed to fit
https://i.imgur.com/9lAG4Mym.jpg
https://i.imgur.com/NMpbhQCm.jpg
https://i.imgur.com/O3xk2HVm.jpg
added a handle and eyelet to hang on back board
https://i.imgur.com/GNYicoOm.jpg
https://i.imgur.com/dFTDjVFm.jpg
https://i.imgur.com/e6RneDem.jpg
those clutch plates free up after running a few?
Yep! Finished product on that wrench looks good by the way.
Great-Kazoo
04-27-2020, 21:16
Yep! Finished product on that wrench looks good by the way.
thanks, i'm happy with the finished product. Buying 1 to fit would have cost more in s&h than the scrap materials i have, plus welding consumables.
Eventually i'll start practicing with the tig welder.
JohnnyEgo
05-04-2020, 17:22
Contemplated the look of the face of the cabinet the other day. Solid plain looks pretty traditional, and would be quick to execute, but I think I might like something with a little more character. As I don't feel like screwing up any of my existing pieces yet and having to buy another plank of cherry (though I am sure that moment is coming), I figured I'd try out the look and solve some construction mysteries with a small-scale prototype in pine.
First, cut down a 1x8 pine firring strip into a couple of test pieces:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/faceframeproto01.JPG
Then ran the blanks through the router with a 1/8 radius beading bit until I found a profile I liked:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/faceframeproto02.JPG
Then sit there and stared at them for about 20 minutes contemplating how I was going to join them:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/faceframeproto03.JPG
The case ends were easy enough. Simple 45? miter joint. I use what is known as a 'donkey's ear', which is a jig that holds the stock at 45?. I could have cranked my tablesaw over to 45?, but then I would have to crank it back if I wanted to go back to cutting straight 90s. The donkey's ear lets me make more consistent cuts without that hassle.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/faceframeproto04.JPG
The center rails were more of a quandry. Didn't want to miter the width of all the pieces, because that would make for a really weak joint on the cross pieces, and they will need to support a lot of weight. So right or wrong, I decided I would just miter to the depth of the bead. Couldn't think of a better way to do that than with a chisel and the world's easiest jig; a scrap of board butt-jointed to another scrap of the same board with super-glue, with a 90 degree notch carved into it.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/faceframeproto05.JPG
Couple taps with the chisel and then pare out the waste.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/faceframeproto06.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/faceframeproto07.JPG
I got better at it as I went along. The notches are actually the easy part. I can align them across multiple rails, and I can cut them out at about 8 per hour with a couple of breaks and one resharpening of the chisel. The vertical pieces are the challenge, because you have to get the length just about perfect to fit them. I screwed that up a couple of times in the prototype, and some of the joints are a little sloppy. They could be filled with sawdust and glue, but it isn't easy to sand these tight profiles. So I will have to be very careful when I cut them. The good news is that being on the short pieces, I have enough material to recut at least four or five of them if I really mess up.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/faceframeproto08.JPG
Liked the look well enough to mill the cherry rails:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/beadmolding01.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/beadmolding02.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/beadmolding03.JPG
JohnnyEgo, that is so friggin' awesome. I love your posts where you share photos of how you do things. Your work is amazing.
JohnnyEgo
05-21-2020, 19:48
Been making slow progress on the card catalog, and I will post some more pictures, but the part I am doing now is tedious, low-reward, and not very visually interesting. So I put it aside last weekend and helped my kid make a box for his teacher.
Time was fairly limited, but we decided to keep it very simple, with no miter keys or dovetails this year. Just a straight mitered box.
I picked up some Orange Agate from Woodcraft after their 20% off Covid sale. I've never worked with it before, or quite frankly even heard of it before. On the outside, it looked like a fairly tight, dense grain with a creamy color, not unlike holly, and then a very red heartwood core. I'm a sucker for contrast. I didn't have any plans for it other than a vague notion of making some sort of stool, bench, or side table out of it. But making a box for my son's teacher seemed like as good an idea as any.
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox01.JPG
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox07.JPG
Quick trip to the jointer-planer to clean it up. Noticed right away that it had lost that cream-colored surface, and started showing some signs of spalting and interlocking grain.
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox08.JPG
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox09.JPG
Had my son rip it to width:
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox10.JPG
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox11.JPG
Things got a lot weirder when I resawed the blanks for a four-corner book match. A lot more spalting in the white sapwood. Meanwhile, the red heartwood was on such a tight radius that even just taking out the width of the resaw blade, the grain didn't line up in a bookmatch. The heartwood would be present on 3/4 of the width of the front face of the board, and almost non-existent on the back face, within half of an inch. I don't know if that is a common thing with exotics, but I'd never seen it before.
The grain just didn't line up right for a bookmatch, so I decided to just align it to the upper boundary of the heartwood. A little off the bottom of one piece, off the top of the other, until I had a reasonably decent match at each corner. Then I ran a top and bottom groove for the lid and bottom on the router, and turned them over to my son to cross-cut:
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox15.JPG
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox17.JPG
JohnnyEgo
05-21-2020, 19:51
Much to my pleasant surprise, the end grain planed like butter. Beautiful shavings, minimal effort. Because it was so smooth and I had cheap labor available, I didn't even bother pre-mitering the ends at the table saw, just put my son on the miter plane and donkey's ear (the stand that holds the work piece at 45 degrees).
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox20.JPG
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox21.JPG
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox22.JPG
Next came glue, tape, and a lot of shellac. I learned from someone on here that alcohol removes pencil marks, and I am now grateful for that knowledge. I hate shellac. I used it here because it dries fast and doesn't stink, but there is an art to applying it, and I have not acquired that art yet. I did better this time, though. Thinned it out of the can by about 50%, then used a rag instead of a brush. Far fewer streaks than I had on last year's box, though I still ended up with some build-up and runs at the board ends. Not as bad as previous efforts, but it reminded me of why shellac always frustrates me.
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox24.JPG
Given that I couldn't truly bookmatch it, the corners still flow quite well. The sapwood is busy enough that it obscures the fact that it doesn't truly align.
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox28.JPG
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox29.JPG
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox31.JPG
Anyways, the whole thing going surprisingly fast this time. We spent three hours from the raw plank to the first coat of shellac, and a fair chunk of that was machine set-up. The longest part of the whole thing was planing the miters, and that took about an hour, of which there were several breaks. We put on eight coats of thinned Shellac over the course of the next day on about 30 minute intervals. Came together very quick, and my wife and son both commented on wishing they could keep it.
The most important customer is pretty happy, though, and that's all that really matters:
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox37.JPG
https://www.johnnyego.com/wood/2020Projects/teacherbox/tbox45.JPG
newracer
07-20-2020, 00:04
I have had these plow discs for years, I got them to make Discada cookers. Finally got around to it.
The rancher I got them from had cut the centers out to repair other discs, the hardest part was filling tho holes.
Ended up making two, they still need a lot of grinding and sanding before they can be used.
https://i.imgur.com/OzHPTus.jpg
https://i.imgur.com/s1gkrIb.jpg
https://i.imgur.com/6gfWWBg.jpg
https://i.imgur.com/fGhPzQV.jpg
https://i.imgur.com/dxMVc2A.jpg
https://i.imgur.com/tdkhv5V.jpg
https://i.imgur.com/bpTBR6m.jpg
https://i.imgur.com/fY486u3.jpg
https://i.imgur.com/kxIstf8.jpg
https://i.imgur.com/fDf8hSB.jpg
https://i.imgur.com/48P2Do4.jpg
https://i.imgur.com/sGUTBFc.jpg
^^ That'll be a cool cazo when you're finished!
When learning to weld aluminum, first make sure that you don't have a roll of fluxcore steel wire in your spool gun for some reason. There is an aluminum weld in the middle of all that crap.
https://lh3.googleusercontent.com/pw/ACtC-3c3YG0_C2EIiPQNHcaC4SVeGTmtj4UUBG4Ws3uH5nMPUkfXFaG VHZWUC27Tbx8bWlN2QlqTVvx35EccmicgvwGxtzj-IYFTVO4uUSjRAVBDAkXUCkPNV-dsZcrLbq2y1Htn3PVMHITvozZbDqVcvBdL0A=w1112-h625-no?authuser=0
Harbor Freight maul comes completely useless from the store.
https://lh3.googleusercontent.com/pw/ACtC-3cEY9iNz2f-qzU1QOhQI73BXED2RQ9ZnmtMsKS8I5yFn04O3JySDsjqpTkJQ3 hYZGzlIepKNYOkkXhd7nM-YGBmFaUjJJsgAQNHdxoTy_DvddUqh94u55OVKz7MgnKMZAhQ6j PwaTr-R9R3Pj0IEUpJOA=w1112-h625-no?authuser=0
After about a year of putting off filing this down, I remembered that I have a grinder and flap discs. So while the not the ideal angle, 100 times better than before. This maul flew through the big stumps that we could only make dents in last year. Although, I really think letting them dry for an additional year helped the most.
https://lh3.googleusercontent.com/pw/ACtC-3eouRVCA4G-46gH_AImapFE28TsApdftMtt7FEDHZuEWFSZEKPuL43Vn2d31g 3y1P708CxaNMkHtKOGKX3fH4PFUMrlsqae3ygyYDDclh8hNTkS K5YGV0ifhB8wk8pUGdX6U64a8U1qQ3TXz1R49N8WHw=w1112-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3eB3AzXoANLqPL4MRveJ3lnzSOrgvGF0OpZQV7QxYCh2-S96PpYAClN6mxSvyYaXgdOhe-uzqwEZ6yJc9azx04zlGxdEmoDirBvBwK--gNAoozrPAzvCTyaART6o4GF0R0SvyVB8v-fZuXIqhxZFsQJ8A=w1112-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3fX_90Bv90zrHn0pqFlr-_yifNHzO9f7o4A3GxbcuVSZCXwePUmFDqRL6fllGk8krIdd1Pj fwH-EujjdAjy7U-eF1SclSBHKr7zdMRUn6Jawm_MMzdQQ1h8OFhwbqtbnzdGQf7E6-qemFnfRhP2wVSmpA=w1112-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3fTA2RjbHGoikxV6OwIRYNXTylO96cgDkS9ahMzVUWpF1A42vr SgQkZII5z9MK__trLmSX6_uk6O7OaLiGQu9F3IvRYwnJTr5Q8f 9yiABSkj-etG3Hy_oSdGED_3p9eHvPd5PwTKL0R0uKAegNv7_X-4w=w1112-h625-no?authuser=0
Stimulating the economy.
https://uploads.tapatalk-cdn.com/20200902/f11a7492796bc0e471b1cfbfa28b40a0.jpg
Fentonite
09-01-2020, 20:07
JohnnyEgo -I missed your posts from 5/21. That’s an awesome project, and really cool to see your son learning the craft! Kudos.
Stimulating the economy.
https://uploads.tapatalk-cdn.com/20200902/f11a7492796bc0e471b1cfbfa28b40a0.jpg
Thanks for sharing that photo. I was feeling pretty bad about my lawn but now I?m feeling much better.
LOL
Yes, south facing and no irrigation. It is impossible to grow grass near the house. The patio goes in next summer.
Yeah, July and August were brutal for my grass. I am watering every other day for 45 minutes per station. That means my sprinklers run for over five and a half hours every other day. My last water bill was $300. It still isn?t very green. Think I?d rather have a dead yard and save the money but my wife disagrees.
Yeah, July and August were brutal for my grass. I am watering every other day for 45 minutes per station. That means my sprinklers run for over five and a half hours every other day. My last water bill was $300. It still isn?t very green. Think I?d rather have a dead yard and save the money but my wife disagrees.
I water the front yard 3 hours per week and my bill is $120-ish. I can't imagine what I would pay to water 5 hours a day, every other day. The wife hates all of the dirt that gets tracked in, but even when I run a manual sprinkler back there the grass doesn't survive past May. I do plan to expand the irrigation back there next year along with the patio project.
I'd look into xeriscape options. Watering grass in CO is like making sculptures out of rice during a food shortage.
I?d do fake grass in that area and combine it with some xeriscaping so doggo has a place to go.
I?d do my south facing front lawn but the HOA are pricks. That side always dies off in late winter and it?s a pain to get it back.
Sent from my iPhone using Tapatalk
I?d do fake grass in that area and combine it with some xeriscaping so doggo has a place to go.
I?d do my south facing front lawn but the HOA are pricks. That side always dies off in late winter and it?s a pain to get it back.
Sent from my iPhone using Tapatalk
Yes, that is exactly what I was just telling the wife. I?m ready to put down artificial turf over the dirt for now. The back half of the yard grows great. It is a combination of the runoff from my neighbor over watering and being far enough away from the house that the hardiboard doesn?t bake it.
JohnnyEgo
09-06-2020, 23:31
t's been a while since I've updated this thread, but that's because it's been a while since I did anything on the cabinet. I've had the busiest work year I've had in 15 years, and what limited shop time I had got redirected into my wife's sewing shelf that I'd also put off forever. So nothing happening until this weekend. When last we left off, here is what I had:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/slowprogress01.JPG
The next few weekends are going to be all about finishing the drawers. Broke them all down so I could reshape the drawers. They have to be fairly deep to hold the two types of Pokemon boxes my son has, but little fingers still need to be able to scoop them out.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/drawerpattern06.JPG
I normally use double-sided carpet tape to hold pieces together for pattern routing, but I was worried that it would be too strongly adhered to these thin pieces, and I didn't want to risk that. So instead, I stuck two pieces of blue painter's tape to each piece, and then put a few drops of Cyano-Acrylate glue (CA glue, aka Super Glue) on the tape. Mated them up, pressed them together, and got a good hold while still being easy to release when the time comes.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/drawerpattern07.JPG
Trace the drawer shape onto the blanks with the routing template.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/drawerpattern08.JPG
Since I am scared of my patterning bit, and don't want to create a small mountain of shavings at the router table, I pre-cut most of the waste. Started with a forstner bit in the drill press to clear out the two curves:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/drawerpattern09.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/drawerpattern10.JPG
Then over to the bandsaw to rough out the larger waste:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/drawerpattern01.JPG
Then I attach the pattern to each pair of drawer sides, and route it out. I use a very large pattern bit running at a good bit of speed. It will hog through just about anything, and when things are going well, it's smooth and can cut thick stock without hesitation. But the moment it encounters something it doesn't like, all hell breaks loose. It will grab a piece and throw it with remarkable force, so fast you won't realize what happened. If your thumb is in the wrong place, you have now lubricated the bit and your table pretty thoroughly. Likewise, I have seen it catch and split huge chunks out of both stock and template before. It has my respect. Mostly, it hates hard corners, so I usually ease those transitions on the bandsaw or sander. Then one light pass to make sure the transitions are smooth, and then I can hog out the rest. But this is the scariest bit in the scariest tool I have in my shop.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/drawerpattern02.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/drawerpattern03.JPG
JohnnyEgo
09-06-2020, 23:33
Once it is routed to the pattern, I take it over to the spindle sander to smooth out any rough parts and remove most of the burn marks.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/drawerpattern04.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/drawerpattern05.JPG
Next is a trip back to the router table with a round-over bit installed, to ease the top edge of the drawer.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/drawerpattern11.JPG
This is about the point where I realized I had flipped the pattern on one of the twelve pairs of drawer blanks, so I will have the joy of spending several hours cutting replacement parts in a future weekend.
Now that all the shaping is done, I clean up the inside faces of any markings, and file and sand any agregious burn marks remaining, until I lose interest.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/drawerpattern12.JPG
JohnnyEgo
09-27-2020, 20:04
So when last we left off, I had finished most major construction on the drawer pieces. It's kind of a pain to apply stain or finish evenly in the interior of boxes once they are assembled, so I usually prefer to pre-finish all the insides before clamp and glue.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/insidedrawer01.JPG
I'm using Watco Danish Oil here. I like it for a couple of reasons. It's a clean, natural finish with just a bit of amber. It's oil based, and you just wipe it on with a rag, let the wood absorb whatever it's going to take, and wipe it off. Do that twice, and that's it.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/insidedrawer02.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/insidedrawer03.JPG
Another nice thing about Danish Oil is that it is very easy to refinish. I found a box where I forgot to remove some pencil marks before I applied finish. I just waited until it dried, sanded down the finish and the marks, and hit it with a little more Watco. Watco is super-easy to blend with, because it doesn't care. The wood is going to take whatever it takes, and that's it.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/insidedrawer05.JPG
This stuff dries to the touch in a couple of hours, but it still takes a couple of days to fully cure.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/insidedrawer06.JPG
Finally ended up with a small pile of half pre-finished parts.
Next comes glueing and clamping.
With the large box, I used some extra care for the glue-up. Taped all the inside corners before I hit it with TiteBond III glue. After realizing what it would take in terms of patience for the next 13 boxes, this is the only one I taped.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/clampup01.JPG
Some folks might wonder how many clamps a guy needs. The answer is always at least one more than you actually have. It took a lot of clamps per box to pull everything in and make it reasonably square.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/clampup02.JPG
The smaller boxes took about the same number of clamps. I had enough to do about two boxes at a time, so I did a pair a night over the course of the week.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/clampup03.JPG
The cluster box I cut upside down with the template. Also known as box L. I will get the priveledge of recutting this eventually.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/clampup04.JPG
All glued up!
http://www.johnnyego.com/wood/2020Projects/cardcabinet/clampup05.JPG
Some folks might wonder how many clamps a guy needs. The answer is always at least one more than you actually have.
Ain?t that the truth!
Nice work as always.
JohnnyEgo
09-28-2020, 23:46
Much appreciated!
Next comes the part of any project I hate most. Finish sanding. Anyways, all the boxes need some work, and some of the joints look pretty gnarly:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/finishsand04.JPG
The answer comes via a cup of sawdust and a bottle of superglue.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/finishsand01.JPG
I pack the larger gaps, and surface sand until the smaller ones are full of dust, then hit it with a few drops of CA glue to lock the filler in place.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/finishsand02.JPG
Once the glue dries, I use sanding blocks with 100, 150, and 220 grit and hand-sand everything flush. I have 80 grit in my rotary sander which I use to take down the most proud of the dovetail fingers, but I use it very sparingly, because it has a tendency to round over sharp corners. The 100 grit on the sanding block actually takes down the end-grain cherry pretty quickly. It probably only took me 10-15 minutes of sanding per box.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/finishsand03.JPG
Hit the outside of the box with some Watco Danish. Box joints cleaned up quite nicely, all things considered.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/finishsand06.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/finishsand07.JPG
Same process for the smaller boxes. Nibbled away at them over a couple of nights.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/outsidefinish03.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/outsidefinish04.JPG
Great-Kazoo
09-28-2020, 23:57
Much appreciated!
Next comes the part of any project I hate most. Finish sanding. Anyways, all the boxes need some work, and some of the joints look pretty gnarly:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/finishsand04.JPG
The answer comes via a cup of sawdust and a bottle of superglue.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/finishsand01.JPG
I pack the larger gaps, and surface sand until the smaller ones are full of dust, then hit it with a few drops of CA glue to lock the filler in place.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/finishsand02.JPG
Once the glue dries, I use sanding blocks with 100, 150, and 220 grit and hand-sand everything flush. I have 80 grit in my rotary sander which I use to take down the most proud of the dovetail fingers, but I use it very sparingly, because it has a tendency to round over sharp corners. The 100 grit on the sanding block actually takes down the end-grain cherry pretty quickly. It probably only took me 10-15 minutes of sanding per box.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/finishsand03.JPG
Hit the outside of the box with some Watco Danish. Box joints cleaned up quite nicely, all things considered.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/finishsand06.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/finishsand07.JPG
Same process for the smaller boxes. Nibbled away at them over a couple of nights.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/outsidefinish03.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/outsidefinish04.JPG
Nice job, as always.
Now, tell us about the L box ;)
BladesNBarrels
09-29-2020, 08:29
Thank you for the filling technique. I have been using wood filler and am not really happy with the end result.
BladesNBarrels
09-29-2020, 09:18
My summer project was building an adjustable height stand-up desk.
With everything becoming virtual meetings, I bought a web camera, then needed an updated computer from the 10-year old desktop HP I was running.
So, I did a lot of Google searching and reading.
I ended up with a PowerSpec by Micro Center Gaming Computer (for the Nvidia Graphics Card) they pre-built and offered on sale.
Watching the astronauts and their ground control, I saw that it was 3 monitors that were the norm.
I am waiting for cataract surgery (along with 1500 other Kaiser members) so I needed bigger monitors - 27" seemed about right.
But, when I started putting all of my new toys together, I realized my desk was not big enough.
So, internet searches showed no one made a 3' x 6' desk that was adjustable height.
More searches and I bought a butcher block top from New York - sent by freight at over 125 lbs. I had to get help to move it down into my basement shop.
Then, I had the problem of tearing apart a 8' x 4' pallet made from the junkiest scrap wood I have seen. Cut it up small enough to fit into the trash tub required by my HOA.
The butcher block itself was finished to about 80 grit on one side and unfinished, really rough with gaps, on the bottom.
Lots of sanding to 220 grit, filling with wood filler, and then 2 weeks of finishing, sanding to 400 grit, finishing, buffing on both sides to prevent cupping.
The frame and lifting mechanism came from Portland in multiple UPS packages. Lots more weight in the steel frame, but no pallets required.
Then locating and fastening accessory hangers on the bottom of the desktop.
Finally, yesterday, I got help to turn the table over and set it up with my new computer system.
There is a control panel for the motorized lifting (2 motors for all that weight) that allows 4 preset heights, so I can adjust to stand up, or sit down, as the day progresses.
The computer and the UPS power supply are mounted to the bottom of the desktop so I don't need to worry about the wires as I adjust the height.
And yes, my basement stays around 65 degrees year round, so that really is a space heater under the table.
https://i.imgur.com/8IBh54U.jpg
https://i.imgur.com/lvaOMIJ.jpg
https://i.imgur.com/eFT5Ggl.jpg
That's awesome. My wife has space heaters at every desk she's ever worked at.
JohnnyEgo
09-29-2020, 21:10
That is a sharp looking desk, man! Nice work.
Nice job, as always.
Now, tell us about the L box ;)
11 out of 12 isn't bad. I'm vaguely amazed I didn't make that mistake more than once. But I made others...
I tried to make an object lesson out of it for my son, by telling him that we overcome our mistakes and do the best we can, and are proud of our work not in spite of them, but because of them; the imperfections show the soul of the thing in a way perfect mass production does not.
He immediately asked me to point out all the mistakes so he could decide if they were acceptable or not.
JohnnyEgo
10-10-2020, 08:57
I ordered some drawer pulls from China off of Amazon back in March. I'm not sure if they came preloaded with Coronavirus or not, but I am still alive. I was pleasantly surprised that they are well made and the finish layer is pretty thick, especially since they were inexpensive.
At the same time I bought the drawer pulls, I bought a cheap Chinese positioning jig that is a $20 knock-off of a $200 alignment system. And you can tell. Hard to get it to hold a measure, and I've already stripped out one of the locking pins.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/hardwaremount07.JPG
But I managed to get it locked up tight enough for using a pin punch to mark the screw holes consistently across all the boxes.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/hardwaremount01.JPG
For these fiddly little bits that need to be drilled with some precision, I love my 1930s egg beater Yankee drill I bought for $20 off a guy who finds them at yard sales and rehabs them. Love this thing.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/hardwaremount02.JPG
I also rubbed the screw threads in wax to ease them in with a Phillips screwdriver.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/hardwaremount04.JPG
Not bad at all.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/hardwaremount08.JPG
The pile of unfinished work.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/hardwaremount05.JPG
encorehunter
10-10-2020, 13:31
Thank you. I just ordered one of the drawer pulls jigs. That will save me a lot more than $20 in time.
I built one of the two barn doors today. I have to go get more rough 2x6s to build the other door.83358
JohnnyEgo
10-10-2020, 19:02
Very nice looking door! My son keeps asking me when I am going to build a picnic table, and my answer is when PT lumber pricing returns to sanity.
JohnnyEgo
10-11-2020, 18:25
Getting there:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/finishedboxes01.JPG
Time to rebuild my two f-up boxes. Box L needs two replacement sides, because I routed the template upside down. Box A has a giant gouge on the face where the dado stack hit a small knot and tore out a chunk while cutting the box joint fingers.
I spent about six hours over two days to recreate these three parts, the vast majority of that time in machine setup and take-down. I probably could have built 12 more of these boxes in very little additional time.
Saturday: Wood Prep
Unfortunately, while I have a pile of cherry scraps in assorted sizes and thickness, I didn't have anything with sufficient length, width, and thickness to cut the sides. So that meant cutting into another cherry plank.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes01.JPG
Then on to the jointer to be made straight and square along one face and edge.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes02.JPG
Tablesaw squares up the opposite side.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes05.JPG
Through the planer to clean up the remaining face.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes06.JPG
Split it into three 1/2 inch planks on the bandsaw.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes09.JPG
Let it sit stickered overnight to allow for release of any tension and equalize moisture content.
JohnnyEgo
10-11-2020, 18:27
Sunday: Wood Work
Marked out a couple of spaces that were at least reasonably close in terms of grain match to the A face piece. I am glad I marked out more than one, for reasons to follow.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes08.JPG
I had very little warp from these, which was a really pleasant surprise. They started out at 1/2 an inch, and the jointer really only took a few hundredths off the highs and lows. Planer then made both sides flat and parallel to one another, down to 3/8 (.3750)
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes12.JPG
Trimmed up the excess and got all the pieces very close to the dimensions of the parts they were replacing.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes13.JPG
The first set of box joints I cut was a disaster. The jig I originally used had sat in my shop since March, and while it hadn't been dropped or adjusted, wood movement had shifted position of the key. As a result, the spacing was off after the first two fingers were cut, and got progressively worse further down until the gaps were just too big to fill. Fortunately, I had marked a couple of potential grain matches, so I had some spares. In the intervening months, I had also built my new table saw sled junior, specifically for use with my dado blade. It let me clamp and easily adjust a sub-fence that I was able to dial right in with the part I was replacing.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes15.JPG
The result was joints that actually fit better than most of the ones I made previously. I was very proud of myself, until I considered the fact that when you've done this same set of operations 15 previous times, you ought to get better just through repetition.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes17.JPG
BladesNBarrels
10-12-2020, 15:24
Thanks again for posting.
I get inspired with your explanations.
After all, Woodworking is the art of correcting your mistakes!
JohnnyEgo
10-26-2020, 23:05
Sunday: Wood Work, continued
Little quick hand-planing to trim up the replacements to exact dimension.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes16.JPG
I didn't take any pictures of cutting the bottom groove in the two replacement sides on the router table, but it happened. Box looking good at this point.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes18.JPG
Routed the drawer sides to the template in the appropriate orientation this time. I checked this about six times before I brought them to the router.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes19.JPG
Interior finished and boxes glued.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes20.JPG
Exterior sand and fill.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes21.JPG
Ready for exterior finish.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/replaceboxes23.JPG
JohnnyEgo
10-26-2020, 23:39
Time to put some consideration into the cabinet carcass. Stacked some stuff up to start getting a better idea of dimensions:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass01.JPG
I had glued up some panel boards a few weeks back with bookmatched grain, but despite being in cauls, they warped, and the shared direction of the grain on the panels made that warp even worse.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass02.JPG
Cutting to actual width took out about half the warp, but I ended up having to cut down the joint line, and even then, I still had some warp on each individual board that needed to be planed out. I lost a lot of thickness in the process. Started at 3/4", ended at 5/8".
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass03.JPG
Fortunately, the bead profile still looked pretty good at that reduced thickness, so I went with it for the rest of the boards.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass04.JPG
Used my miter jig to cut the initial 45 degree miters, then cleaned them up with my miter plane on my shooting board and donkey's ear (the 45 degree platform)
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass07.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass13.JPG
Then stack, fit, and adjust. Two playing cards is about .25 mm, and I think an acceptable gap for seasonal expansion and wood movement.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass06.JPG
I can fit, space, or adjust a lot of things, but the width of this first drawer is fixed, and critical. Needed to remove about 2mm of space. Removed three, and had to discard that side and recut a whole new set of panels.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass08.JPG
Close. So close. Just a bunch of spacers, tape, and gravity.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass10.JPG
BladesNBarrels
10-27-2020, 07:44
You are a perfectionist and the results are great!
That is really nice work! I am sure your son will appreciate it, and enjoys the time spent with you in the shop!
JohnnyEgo
10-27-2020, 19:03
You are a perfectionist and the results are great!
That made me chuckle, because there is a serious lack of perfection in most of my work.
The combination of Covid 19 and the busiest work year I've had in decades has changed my cadence a lot. Previously, I'd come home from a long assignment, and have three dedicated days to knock out whatever I was going to do before I was back out the door. Now, I am mostly working from home, but it's very hard to get concentrated shop time. An hour here, an hour there. The upside when I only have a short amount of time to spend on any given thing is that I don't get super-bored with the really tedious stuff. So that forced patience has leveled up my game a bit this time around. But I still do a lot of stupid stuff that I either have to re-do or make-do, so perfection is in very short supply.
Great-Kazoo
10-27-2020, 19:45
That made me chuckle, because there is a serious lack of perfection in most of my work.
The combination of Covid 19 and the busiest work year I've had in decades has changed my cadence a lot. Previously, I'd come home from a long assignment, and have three dedicated days to knock out whatever I was going to do before I was back out the door. Now, I am mostly working from home, but it's very hard to get concentrated shop time. An hour here, an hour there. The upside when I only have a short amount of time to spend on any given thing is that I don't get super-bored with the really tedious stuff. So that forced patience has leveled up my game a bit this time around. But I still do a lot of stupid stuff that I either have to re-do or make-do, so perfection is in very short supply.
If you get bored. There's always some range time.
buffalobo
10-27-2020, 20:07
That made me chuckle, because there is a serious lack of perfection in most of my work.
The combination of Covid 19 and the busiest work year I've had in decades has changed my cadence a lot. Previously, I'd come home from a long assignment, and have three dedicated days to knock out whatever I was going to do before I was back out the door. Now, I am mostly working from home, but it's very hard to get concentrated shop time. An hour here, an hour there. The upside when I only have a short amount of time to spend on any given thing is that I don't get super-bored with the really tedious stuff. So that forced patience has leveled up my game a bit this time around. But I still do a lot of stupid stuff that I either have to re-do or make-do, so perfection is in very short supply.If half the "craftsmen" who write periodicals, produce TV, Youtube, instructional video were to honestly document their projects as you do yours, they would all be watching your videos.
JohnnyEgo
11-01-2020, 20:19
So the next day after I cut a new bottom panel, started fitting again with much more care. Started out with four cards worth of space, and worked my way very slowly down to two.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass12.JPG
Next, I decided I probably needed something more substantial than tape in the dry-fit, so I used a machine called a Festool Domino to route out some loose tenons.
I hate the Domino. That is heresy in my circles, with other hobby furniture builders swearing that it bends time and space and adds 10 skill levels to craftsmanship. And indeed, the large version of this tool, which I use to make outdoor furniture, was a game changer for me. But I hate it's little brother.
I think it is fiddly and does a crap job of alignment unless you are really careful throughout the whole process. These are also very expensive tools for what they do. The big one was $1700 and worth every penny to me. The little one was something like $1200, and I don't think it does a significantly better job then the much cheaper pocket-hole system like the Kreg jig, at a small fraction of the cost. It's real advantage is that it is strong and conceals pretty well, but I think I could have spent my life being very happy with other jointery methods for furniture.
Anyways, once you have carefully aligned everything, it makes these neat little holes.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass17.JPG
Then you stick the loose tenons in (also called dominos), and if you have done everything perfectly and lived a pure and blessed life, everything aligns.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass18.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass19.JPG
Although, more commonly, what ends up happening for me is that I spend the next 20 minutes planing or chiselling dominos to get everything aligned.
The mitered joints were even more of a pain in the butt. The tool has an adjustable angle fence, but it referenced off the inside surface, and I didn't like that, as one of my panels is a small fraction thinner than the others. Additionally, it wasn't lining the holes up where I wanted them, and blowing out the back of the boards. I solved it with a shim cut at a 45 degree angle and screwed into the fence.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass16.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass15.JPG
Next up, cut the grooves for the backer board on my tablesaw.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass20.JPG
The tablesaw blade I had in there didn't produce a perfectly flat bottom in the groove, and it didn't really need to either, as the final fit of the panel won't touch the bottom of the gap, and will allow some room for wood movement. But it only takes a pass or two with the router plane to have a flat bottom anyways, so that is what I did.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass25.JPG
That's a nice-fitting panel
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass26.JPG
With the dominos and the backer board installed, the dry-fit of the carcass itself is complete.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass31.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcass29.JPG
BladesNBarrels
11-02-2020, 10:02
Always look forward to your posts.
Thank you for the review of the Festool Domino.
I will stick with the Kreg tool for the projects I do.
JohnnyEgo
11-03-2020, 17:31
If you ever want to take the Domino for a spin, let me know. I seem to be the only one who dislikes it. I've got a lot of years and a lot of furniture held together with Kreg screws. It's a fast, inexpensive, and effective system. Give me a circular saw, a drill, and a Kreg jig, and I can knock together nearly any sort of cabinet in a Home Depot parking lot.
JohnnyEgo
11-16-2020, 00:52
There is the easy way to mount the dust panels, and the way I wanted to do it. The 'easy' way would be to use the Domino tool to stick loose tenons in, but it is not without it's challenges and I'd prefer to avoid them. I want to do a traditional dado, or cut channel, for the cross pieces to ride in. But I also want the decorative beads to be mitered. I had this all worked out for doing it with the Domino previously, and I will probably still do it for the less critical uprights. But there had to be another way.
It might not be readily apparent, but I am not much for planning things out. It is probably why no two pieces of furniture I've built have ever been at the same height. To date, the entirety of my plans for the individual drawers and the cabinet carcass have been as follows:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/plans15.JPG
It is also the same scrap of paper where I wrote my shopping list. But to mess with the carcass, I put in a little more effort. In fact, quite possibly more effort than I have planned for anything in my life, including weddings and children.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/plans16.JPG
Now that I had a plan, I spent the next day avoiding it. I sharpened all my chisels.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/chisels01.JPG
I mean all of my chisels.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/chisels02.JPG
On Sunday, I spent a day practicing with said chisels on a piece of scrap, until I came up with a way to have both dadoed shelves and mitered edge beading on the same board.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/chiselpractice01.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/chiselpractice02.JPG
No more putting it off, I suppose. Made a story stick so that my lines would be the same height with respect to the base. More consistent than measuring with tape. I wondered how I was going to accurately going to measure to .2mm, which is about the thickness of two playing cards. Then I realized my mechanical pencil lead was .2mm, so all I had to do was route to the outside of the line.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassdado01.JPG
Set up my fancy router on a rail, and then slowly and cautiously crept up on my bottom line. Stopped when I had two playing cards worth of clearance.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassdado03.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassdado04.JPG
Clean up pass to the width of the panel. This was very scary for me. Now I got to do it again on the other one.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassdado08.JPG
JohnnyEgo
11-16-2020, 00:55
Next came mitering the beads on the rail. Sharp chisel makes fairly short and clean work of this.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassdado13.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassdado14.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassdado15.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassdado16.JPG
Chisel and this weird contraption seemed like the best way to carve out the miters on the case itself.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassdado17.JPG
Next up, layout and mark-up of the dust panels.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dustpanel02.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dustpanel03.JPG
Cut the grooves for the panels on the tablesaw.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dustpanel04.JPG
Cut the tenons on my shorty sled on the tablesaw. These don't have to be pretty, just reasonably even and tight.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dustpanel05.JPG
JohnnyEgo
11-16-2020, 00:57
Tenon fit came out decent.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dustpanel06.JPG
I love it when a plan comes together.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dustpanel07.JPG
Cut some panels out of my cherry veneer ply.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dustpanel08.JPG
The grooves were a little tight in some places. I marked out where things got snug, and hit that spot with my much beloved rabbet edge plane.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dustpanel09.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dustpanel10.JPG
Dry-fit went decent. There will be some trimming and adjusting, but no complaints.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dustpanel11.JPG
Not a bad weekend's work.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dustpanel12.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dustpanel13.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dustpanel14.JPG
leightoncash
11-16-2020, 11:10
I completely reframed and finished my deck with materials bought with my stimulus check. So my deck will be paid for by my future grandkids [and your too]. The railing is a mix of electrical superstrut, angle iron and cattle panel. Lots of welding and time but I'm really happy with the end result and that the top rails are one piece continuous from corner to corner. https://uploads.tapatalk-cdn.com/20201116/7c7157f3a25e9647cdbd1fb35ad526c6.jpghttps://uploads.tapatalk-cdn.com/20201116/32e12cb6b2d9edb14cced284cbfca661.jpghttps://uploads.tapatalk-cdn.com/20201116/db35f0adfc139b900bd072057c71f083.jpg
Sent from my SM-N960U using Tapatalk
That looks great. Very nicely done. An actually hail proof deck railing.
leightoncash
11-16-2020, 11:17
I also just finished building new pantry cabinets. I might have $300 in materials here,, max. Just plywood, alder and lacquer. Free appliance from a client, cabinet hardware I cannibalized from another clients old cabinets (all soft close and undermount). I did the rest of the kitchen years ago and just recently got around to this last part. This is the last interior project for my house, I've now remodeled every square inch. I'm now mulling over building a master suite addition. https://uploads.tapatalk-cdn.com/20201116/189202cb4bafbc7ac17f583d74f5da3d.jpg
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Have you ever Christmas'd so hard that you never want to Christmas again?
Big thanks for JohnnyEgo for some important tips up front on how to get this project completed. I've been hanging Christmas lights for a friend that started a Christmas light hanging company last year. I thought I was just going to be one of the guys with ladders throwing stuff up onto the roofs while the ground crews decorated trees and bushes and stuff. Well, a few of the projects were pretty big and I spent a whole week in a man lift putting lights in trees down at Cherry Hills Community Church. After that, I ended up doing a more specialized project for the biggest residential job.
My instructions were more or less "We want four 5'x5'x5' boxes to look like wrapped Christmas gifts with one side clear so you can see inside the gift, and each box will have a different scene inside. Also, if you can have a train visiting each box, and if you could build a rickety looking train bridge. Oh yeah, we need eight 8-10' tall candy canes!" Well, I had to massage the idea and get it realistic, especially since the job was sold back in October, and I was now looking at something like 3 weeks to finish it. I took some video tonight of the mostly completed decorations and will post that once it finishes uploading.
I settled on two 4'x4' boxes and one that was 30"wx30"dx42"h.
https://lh3.googleusercontent.com/pw/ACtC-3fb6O80Ck_aCEbk7Dq_wnFHwgTufaXrtjw-49lKrsaslwIpi7XgMdX9U5kj_hoZaOCnlDb8ofHdRzMqAZqh2N Wkyks7ze5KbXcqfd4GeGWl0XQQD15Lpj7JIESibyE8xGqh7QlA EuEkicjs3_FuHxJNkQ=w834-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3dVTleln6Lxu87LCI02dqnE81V0Dc31EoQQ2MPX_3NUbUBBZQS z_bMQr9rTqLJ7apjj_oZ2rP9kzZzPRB4vDzZvvr2GjsNFZzcTP gRYjLp66AtaP0ZN0SZ1XxQbp6UMqJmGtSGZeV6c0ioLq0_KiWy r4Q=w469-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3dv-ILGCWj0E6SXrYJRZDHRkc_hXvXum_4kVe14FMLoufFQs2hYYtJ 4jti1lfvJogTBx1vGMV75Ra9nl_ivzmfOx_O0xgXPzIl53cXSy 9rTOl-yOCpYkEFB8jSjtn6SPknu-NBRCWER7dGfKnw-7M5FMw=w469-h625-no?authuser=0
Once I heard that the client signed a multi-year contract, and realized that this stuff was going to have to be stored, I was faced with the added complexity of having to build it so it could be repeatedly taken apart and broken down for storage/transport. I used these threaded inserts I got from Amazon. These were great. Home Depot sells a version of this that is MUCH more expensive and is complete garbage. Once they get close to being tight, instead of sinking in they just explode. Avoid the brass crap from Depot.
https://lh3.googleusercontent.com/pw/ACtC-3e_G5H3Ud9CjadYWonipkdBOJ0oxoQK3SO_fJPAn0FwjCcx4Bq nzPOfGeAQzvjDn2mjxpBclIzSQTOKu3ug04TO-FCITR1XzEtKg4np26SSmWxmOYNQUdecio0wQ_6EFJta8eNmTz7 mIermrUt1QcC6CA=w834-h625-no?authuser=0
Here is the crap from Home Depot. Over $3.50 for each bag of two.
https://lh3.googleusercontent.com/pw/ACtC-3fu3Ogd7l24xAVTAkU2PhR4sTr7lqhoP-GWNFIUNq_xlq_wsh-IqIMxpxccKEp2J1MU-TNCfGaCyp7p_Ldb9wvixGEQn67maF6s1FsJN_E2B8eDjIu73w1 wI2JLtrpkhx6yb01UZD5a5cO0NluuPzAIkw=w834-h625-no?authuser=0
And here they've failed before they are even flush with the wood.
https://lh3.googleusercontent.com/pw/ACtC-3clU5LKlNZAmm6pgYPPrs7wq5h5rE4_r1SE01OZrLML18QJd3x XBDokKhhSCQoGn8MUKKbjPrhCXW_92e9fiNoo_hZfGb9FHVUY2 2TfGD_n6DeBt-slnXJ_rA2dVBYEnpNmIn9tCA2_vh3nuFk0KRTojQ=w834-h625-no?authuser=0
The painting was tedious. The spray paint wasn't laying down like I expected, but I still made it work. Each box has two coats of primer, at least one coat of spray paint (barely), and at least three coats of water based Urethane with a UV blocker so it won't yellow in the sun. Thanks to the awesome paint guy at my local Home Depot for the help.
https://lh3.googleusercontent.com/pw/ACtC-3f8-U49CfZTn1gQX5ytS8yqHlpAMQ9_my1RNweouLQSryYSWrFSb0o DbfrDPH9K1Z1y4rw_uCDIg_MW4ChZ0SrmV6NyE9zwccOQaZIkv kg2VJoTjJ-zGaWKacXh-Wst96G4Ou6paHSI-rNI08piKcnN8w=w469-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3ctcDGDDZfwsW14I45F3LmNhDruc9m3q0iel3-VySJViBFG1eMb-Y2B63NqT5QmnTSVp8JX7qD8OLbway_W2J4dA9xhHUet6YiqTk6 XA2yApwIHlvLJKInX7lcGB3IZ8JGwWVFfRmT1nkoWMp7-phLg0w=w834-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3eCzwb5n6UeGMqhrFFBfO6WVR6yToL2P7xMpeDZJ7pbwyPqaQN MTak9ZV4FA8iQloY5iYnPCde-OjzeQuPHQZGdlQFpeIEeK2H1lJ7GPcIkGWCBcQO4WMtUoYQlYn L0b9IZFMDTcBXHmToBNHleOiImVg=w469-h625-no?authuser=0
My original paint idea for the small box wasn't going to work out so I settled for some Christmas stars. Half way through taping the first one I considered scraping the whole idea, but it turned out to be worth it in the end.
https://lh3.googleusercontent.com/pw/ACtC-3fCXy-tlsHKgBITr5nvxfKsC8qh3eYV25_XC_lz-yI7GSwbuzIJ9NqvSXlZ7Kp3p5xDd5HwaLmArELOWDg7yKUP0pQ W-zAS5zqA6-JjZOrFDKh9JJvnxyg6NFrLmpAEkVtjdnUVRHCltuKVD_EopKm4 Gw=w469-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3cpj2Wcr_BCKL-42LS1vufdce5bAOnN9Yxcf0WVM7p_U5U80kq_lBGO6qDetpuVT GbG5tiAUF2eKdYWEYCaSpA8WYJhrM-h2Lhmb7pDlWf5ktSmidYPgECU5U7xhd3Gl4uBKYH8WX0EnhpQG Nq1b1U1zA=w469-h625-no?authuser=0
The theme of the small box was Rudolph and his girlfriend on a date. I was given the painted template and a general idea of the final, and I made it happen.
https://lh3.googleusercontent.com/pw/ACtC-3eBgYOyKn56MnlCNGyMLMtSc60mg07PPV3Tz7giT8k17KbeH_c 25Yol1CKXtRZNopN2sPHwUCBoPI0ws5iuO1A3XSlqcOxcujVH-GAtgfuuAL3e-lhDXUdjs5CneMpUzk40OkHBB-DeklKO950bLLf6ig=w469-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3cxFHMzK7QePVbsYVln8Z3mmhqR8XN60MmrwLPjWOYH5dhHU0U KGJh-kyHDGMSoFQQEtL5g3vgWuFe6nzPqwvpySCzhHIVlQy2_0DGgoU Y1xIa_uH4t6Dm7k_BhUlBhguGre0hpNyGe8OmnGpdB1L4l8w=w 469-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3f-BwBt_-noupzpIEf6M4BmuQfVxc2y2v19X8IY_z8lk9zQK8XvAGSYZv5I ettJXGipfSBzbSHiz_Ha1ZUlu7Z4vSI8L1m5SNs5kPrhzq8Zb1 h2oHeudC2KRxfL7uZw8uhJkccy16fV0pwA_nra1pljFg=w469-h625-no?authuser=0
The theme of the second box was some gnomes having a poker party. This was my favorite box to do as I got to be the most creative. I was given this photo to go off of along with, "maybe one of the gnomes can be hanging from the light!" I really liked the idea and worked hard to make it happen.
https://lh3.googleusercontent.com/pw/ACtC-3eg9hQdWvz_oSzy9LtGoXCf3OAXfhK58R5v0VnRm5cFwI68Trb 7_prda7In-mtshe2NkyhAibttpKgO0PG9t0vcfKq4neclnKt-UGjyOn4vAyxE9TCNdiMXksR1dlfDQ-LM4yQIxB5p4y0sMRB1fDbVLw=w469-h625-no?authuser=0
I was excited to make a chandelier. A few years ago I removed my front storm door (pretty sure it has been around since the '80's, if not the '50's when the house was built), and kept the panel because it felt like I could use it for something. After failed use as a tomato support in my garden for a few years, I eventually broke all the pieces down and it's been sitting around my house in one spot or another since. Earlier this year I decided that I needed to learn to weld aluminum when one of my ladders broke. For this project I got the spool gun back out and went to town. I didn't use any of the bends on the door as those pieces were too short, but I replicated them out of two of the long flat sections.
https://lh3.googleusercontent.com/pw/ACtC-3fIt78QH3fROvIFziJsMuXvDdYK3y98c7zIYsm5FWFc_Xz_94R elmjnsq4O3_35zrISehIjGnmoXEXhaImtWzFHfZJUbTejatDI2 CKpj33DzKS-E_KGrx5tmren70eRF9z8_QJ0L_9nz5DJ_QWxgvwmrg=w469-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3dGiqP2tiG1VizjyaWu0Rpr_y6s_aQIn0H_MUhOa2Pbpn41Y04 R--4AqNoxi02hwZBiXAJof5ucfmPdooJEM3hUBQ0XyWuXNNMdF9Dd iVTPut-ufyQA_yjCNDc6d9yDqVgoEaucsKVylRzt9PhMrXtPgw=w804-h625-no?authuser=0
After blasting apart each of the rings I made as the support base, each several times, I remembered that you always have to push when you use a spool gun. Things went way better after that point.
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https://lh3.googleusercontent.com/pw/ACtC-3crzqu0X-LlXdlItJ6c3JmbUl665B6s3ogGInWS2zLGvI06bzw8pgWpU0NC sz68f3ES3Cg5e-Scjeioba3SesJq2Jc4FMRL0-3_2DJNZbiy2qKLSJh2616qHuVuvKYgSGF7lsPY3fEfEQoRXett BCgqlQ=w469-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3crs3HCxmKAd4s476SEM7njOJLzign2YmdA0aVxlMrZb_UKo1t DSEXyAhCamb4dY7gCqk_4wHATsRpIWqBI1e-xhvIKL_IosqirLenLIr1ktRFiLwkGEgfFjlSgfnnz2um3Xi0Mi 4WZ6xsbzL-F4cCgJA=w834-h625-no?authuser=0
Some parts of this are pretty rough and I'm glad this is just decoration.
https://lh3.googleusercontent.com/pw/ACtC-3crTOjy6HC1TKMRCKUGu2E4ro6OI_5fmJBM81-ik0JRdNYzmsNkdAIZn-SzjsSWLtrOYDBjeR6cMUe62RrwMIZ44G39ksbO2abcZlFyxEGp Tx-ABSxh0wWyCSnxZ1RzaK6XkPruZECBfscT_DG3doAeFg=w469-h625-no?authuser=0
All my time spent watching MyMechanics on YouTube and other restoration videos kicked in and I rounded every sharp corner off with a file, and started sanding with 220 grit sand paper.
https://lh3.googleusercontent.com/pw/ACtC-3eZK_nycpeJqPmVZuPTlavYFhNZZeGmmfO2BJvyA9keC5oPdcv aW3hfcJa_6Z6FCsU_H7-DRoCXFQ1e7kB3e-TSj4oLdcDRj31xQiQLLvoX7q4ZnwRv40hBCnEzL0Lmcqt80UqQ SVlFzduyoyl4oh96tA=w469-h625-no?authuser=0
It was really cleaning up nice when I realized that 1) no one was going to notice, or care that I spent something like 8 hours building this from scratch, and 2) I still needed to paint it anyway to match the lights I was going to build for it. Oh well. I decided to paint only half so I could still have some shiny parts.
https://lh3.googleusercontent.com/pw/ACtC-3eTHdrxUJdT1OWYh4IA1MEb3yCc2CQeBrvBfQjZ_nPs93DNEUr i_tb-dImi9PKiZNbRgVNk3G1lBT3mPfKoDuk9yPktXakLj0ennznNWQ Bj2gakK5dW0b1ZvH8evVWZS1T8dma-15Py4HZQFkVJq0VSdg=w834-h625-no?authuser=0
Looking pretty good, but pretty bare, I'd have to come up with something more.
https://lh3.googleusercontent.com/pw/ACtC-3dOGlRwR9vw16Hc_3O9P-9B0IJ9gSpSNuD6Rs8ietoCRKhRjA2NSzVTOOqBxIaEJ3bFzOMN whfO39dkdF5Qv4TewGBOOw39ijH_NOzq3daFjc9H25GDDne9Z_ JxBO78g6RgligoG99U_Ww3mOx1NMD4RA=w469-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3cf4f8YQs13wtTOGpEj_4pD8fg2DSDcdAlH8EPfMgdCejTDFd_ 7KGIgFkVEgHeu9P_My0pmuxtvsIHxaslsQRWfoBTEtTKNqW3w4 A-SO4tMWDm6uvun-TNkhPG4YgmNu-R4F6GzVUVK7k-Dfhav1ERZOg=w734-h625-no?authuser=0
I had this broken hammer floating around in my tool box for years. I used a sawzall to chop the handle down and make it fit back on the hammer. I sanded down some parts of the steel, and all of the wood, then stained the handle with motor oil. I probably could have just left the original finish on the handle, but it only took me a few minutes. One gnome hammer.
https://lh3.googleusercontent.com/pw/ACtC-3duVLJ8bGyjRY6NgZgG0Jpg2OLnt8Mn_G7LosUei_2uWcr0fME RJyoKzLz80ELhiesGdqSr1LefaHW77BVAg5ouvcS-38yRfFG-pvHWePcEVbvu6wgt8eE1naHsvd9_GeaJoc2j-dpYka1f6dX1EGHrrQ=w834-h625-no?authuser=0
Skip ahead to the finished room. Using a sponge to create the fireplace worked out fantastic. I didn't have the time or confidence to try and paint the roaring fire that I wanted. I sketched out a door on the wall and was going to paint it, when I realized I could throw together a "real" door in half the time. I glued the door on and was using brackets to hold it to the wall. Those have since been removed, and the actual keys to that door knob are now hanging on the stud next to it. I really love how well this turned out.
https://lh3.googleusercontent.com/pw/ACtC-3dkfmhdTEbZcYYyidtnCiBVFao66l-V_TmfwGB4PU3TOa4FboR11nwdXcBh21JRsou5wfAA5wAzOSekE 2Sp18SX0ccG8kG-05kN5h6fiMQ0RIWjrlUJZELmM1c3Yzx9mC4aIB4EfoALLbfA44 hN5SMpcQ=w834-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3eXrLgxxZqlEHmLz4bCWpHpua4o3FWWsff0ZLoOtb9digyHKs7 jWUd5_aMyKso4ztqYLrs-0Pf2r8Z6opkee48NN1LTSQLt5U6hgWdzXuaXSvLVKYZed8Mp-x6l0EzcMS0LzvicMUAx0wPGfJB5V1GcMA=w834-h625-no?authuser=0
Here is everything taking over my entire garage.
https://lh3.googleusercontent.com/pw/ACtC-3ddzjuBcxcz85YeHsIacjaFCb8cLQFzylBaEwrzz1kchfLoXXf qssknKg7um6-1aOACX-qwVdgGrdqsYkXf-xHjQ8wVDL0Kq8tXIhWMTdxvWwcK-_rnYJpV5Kbrba0-IKi8rlZMu0ehddbuPGpj-J_rLw=w469-h625-no?authuser=0
The theme of the gold box was a Christmas town and several hundred dollars worth of stuff from Michaels was dropped off at my house. My wife mocked this up on our kitchen table for me.
https://lh3.googleusercontent.com/pw/ACtC-3e2_BQA-2mAlmTswOPakXGxLBRkW47IEPbhwIkUcCtpPxgC8uPlMdtC-3xCtLikGsE_u-nyXnt7XKtCAxXBcd6N2d46uMrBt6wgvn7N1-SsS4aoDVvyKQrIrdSIwLo1JgNsF79tT1wlcPI4wFAVpLn1Gg=w 469-h625-no?authuser=0
I moved everything to the garage and tweaked the mock up. With a 4' tall box, it doesn't make sense to have everything flat, so I was trying to get some elevation. I was running short on time, and creativity by this point. Frankly, the store bought stuff doesn't excite me as much and I was getting burned out. This was as far as I mocked up before I packed everything up to be delivered. I don't even have a final picture of how the town turned out, but it will be in the video later.
https://lh3.googleusercontent.com/pw/ACtC-3fpCV2LzEceV6Y8bmvmWM7feiFPl8NsI_CumCMKrf5I84yB-p6c5EU0ebeRhd8trDu8Lizvm68TGeez00xZeO1ws2-tiXKCf-kfTwVOEtCBc1L3X9jnEY8kpRQIRqRcx0zoW7JEYkMKTTRzLNR5 J-yuSw=w834-h625-no?authuser=0
I delivered the boxes, and as I alluded to in the Post Whore Thread, thought I'd have a little laugh since I was driving down I-25 during morning traffic.
https://lh3.googleusercontent.com/pw/ACtC-3cxy_H8RzgkRYZIpOF1zRd39cwDajQeM26_x-FukWp-OUFi077F_zJr4YUC0B7oJTEwJQ59NPX3gQ6PZkJ0RyPtzu_S3d 96GWBb5M697StR25l9Ud9YBLQpJLdo9KMH4yFu03BGPz9O3zWl zYf7stfOAQ=w834-h625-no?authuser=0
Here they are more or less in place.
https://lh3.googleusercontent.com/pw/ACtC-3dKCjXuuTFUVl1tdKHfZxGj4gSKFeQC39ndiriK_u6PxNNo-87o6apF2MbXTZBFirKyqKUHYRvqHmryLjdC37jPVIAxr2idjhD FeYHoMduJ_JOUZms_PN7mDqWS74qo6IOzZ7PqMqBs6bb_pnb5v Gnlfg=w834-h625-no?authuser=0
I had one day (that turned into two) left to start and finish the candy canes. A few days before I had called around to the guys at DBC to get some sewer pipe. They have helped me in the past when I built my chicken coop. Sewer pipe is generally larger in diameter, and WAY cheaper than schedule 40, 80, whatever PVC. I sent a runner and had the stuff dropped off at my house.
Once I got the design down, I was able to knock out each piece is just over 2.5 minutes, including sanding the letters off. A much needed relief to have something actually go smoothly.
https://lh3.googleusercontent.com/pw/ACtC-3dhDrA-jml2M9Bo9XVpGaUSAqgDj57BVQraiDusEBl3ZFnP6tK61rZC4p jdQPmTAcLHIXsE_sZ4Vk2lbGG7rWssrzP_rAy0AKwtspuUYISr ign-s27l9HGzLSJOR86YLcf0L6vZGc0H8qdBoNG_atY07w=w469-h625-no?authuser=0
I struggled with the shape because they are so tall. I tried to make the "hoop" match the diameter of the pipe, rather than the height. They look a little square, but I didn't have time to bend each piece myself. They look better with lights.
https://lh3.googleusercontent.com/pw/ACtC-3dhFWkwSufMHSamRFNN-mtjt2wvl-iEqBOGhVUSGRJG5qk36SRCtchfqUI4QCmjGHoKtQR3LHWQ3n-ud2bmIPCur0IgyuKTLCq8LUVXdzbbkGTWkxAmPvluJZ66ubXeE 85wfpvFqsA5JfP-OItz1nbX6w=w469-h625-no?authuser=0
I ran to K&K Surplus and picked up some T-posts to make stands. I got to use my new portaband, but broke my vise and couldn't handle the portaband bouncing around without the guard installed. It was back to the angle grinder. I also forgot to tighten the hose when I switched back from the spool gun so I did the first two or three with no gas, swearing the whole time because I didn't know what was wrong.
https://lh3.googleusercontent.com/pw/ACtC-3fqhBanCBd0bKSBlvPb6n0vVTtQ2HJhs4IWwGMQjeUn19VNCu4 _s6XvK_mH0KHJv377npNvksKfp9Qtcy0d3EPaGxrxyL4nvwI9t kHsN3R-GcSNAXUHIrg2nQiAUcXWMLkVPOcecNoeEyvLQeXDJeMo5A=w46 9-h625-no?authuser=0
I have no idea where any sprinklers were, so I only had the end protrude about 5-6" below grade. I also lobbed off the lugs so they'd be easier to pound in. The idea was to use the holes in the legs to stake down, but we didn't bother in the end.
https://lh3.googleusercontent.com/pw/ACtC-3duacrAhexu1gl13p9ozkX0Lr13kVColjnvcaVRyNKsXyodYUw vF5kRdK6Gi1Ddplf9aK2ftq8G392xXGPzulMCSJIP26PbeL31q jh3EnmXJB0lbaZID9H7uz1wJQZs4RjDh9c5AZQws0340Ci83w4 AkA=w469-h625-no?authuser=0
Making sure the bases worked in my front yard.
https://lh3.googleusercontent.com/pw/ACtC-3e_7jlQmW6SqsqXtl14EeY26FFZkS41lzmSV1mQZYmd79LjF1V yXZDe0WogDux0mmtRhRtqkT-4naDb_tdtspXBcngToKovBHYYZC0mp0ldGHGs76I19hPd1Uoxo w71-iyxhVis1952NXbptalmNVLGYA=w469-h625-no?authuser=0
I handed my daughter my drill with a 4" hole saw and the glue gun and had her make these guides so everything would be centered and the canes wouldn't be flopping around on the poles.
https://lh3.googleusercontent.com/pw/ACtC-3cGIv136hxmcuQpN1Nx8e_9YdooxDu6NbRL5VceB9OZq1qejjb HlNbpvl3LsaULRkFR16NrzcOdQltk4CSMaDhoHUp7qVpQedEM1 kvK10pNQuj1c85CB2B2-HKRdqKC86dMPZ-HknvOgtC_w3_JVbUgDA=w469-h625-no?authuser=0
Speaking of my daughter, I was also instructed to make a 20' tall ladder that could be strung with lights. One of my first ideas for the boxes was to make them out of 3/4" pvc and sew sil-nylon covers (tent material) so they'd look like presents. I quickly abandoned that idea, but still had all the pvc left over. I made my daughter create the ladder out of that PVC. Now she has something like 55 chop saw cuts under her belt. I delivered the ladder as requested, but it got cut down to two 7' tall ladders.
https://lh3.googleusercontent.com/pw/ACtC-3fehBbspYaN4xsmGcjIh2HKBXW_E8dMGTSmtzRi4RjmdOqhfUc Q5fukP5bLZoNE0oD1FCf8KGrvIIff6J56R3BEmhlDeh52rs4VR RwxGCGFh-lZlqeh3MhPM4k1agBbmhJWZdo2YYJH0DXbZ_5E3iUtqg=w469-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3eq2U6ivGl0XxyUuJLbbFHJt1hYpz7hzJycFH9PBP55KGZJV3E Eo58hiDLq3_fdoYpydNNZ5Zhn5zk7lebkQY3CV2rZZbNV__xtY 317608up-8HnLHeyVU3IjWbjL_3qDvmd4Sw6smcfN4kGRJuHRHVLA=w469-h625-no?authuser=0
I spent about 10-14 hours a day for 14 days straight making this project. A true wood worker could have done it way better, and quicker, but in the end I got it done. I have to thank my wife and daughter for all the help they gave me, which mostly consisted of doing what I told them for as long as they could until I yelled at them enough that they'd cry and run away. It's been a rough two weeks at our house.
Here's a video I took tonight while everyone was trying to finish everything up. I can't tell you the exact cost, but if you guess I can tell you if you're low or high.
https://www.youtube.com/watch?v=NlM_bBgIikE&ab_channel=StuA
jhood001
11-22-2020, 01:06
Jeez, Stu. Impressive.
Hey thanks. Nice to see you around Justin.
Great-Kazoo
11-22-2020, 09:07
VERY NICE.
As to the inserts from HD being crap, they are. However the ones you got on line. Ace and other hardware stores carry the good ones. .
Curious how much of a hit the one who bid it took. Based on the ever increasing price of wood.
BladesNBarrels
11-22-2020, 09:41
Great creativity! Thanks for posting.
What kind of electrical power do you need for all the lights?
Is there a supplemental panel?
One thing I can tell you was expensive was the plexiglass at $118 per 4'x8' sheet. I had to buy that twice.
As far as power, LEDs use so little power that most jobs require one outlet for the roof, and another one or two for trees and bushes. Most jobs are way smaller of course. That roof for example is probably all one outlet. This one has a lot going on and I was spared any of the set up except for wrapping the candy canes and setting up boxes. When it all came on with the timers last night, it only came in 4 or 5 stages though.
Irving... very impressive. Beautiful display, thank you for sharing.
After the holidays, are you on the hook for removal and storage for next year?
Yes to the company. I'm not personally storing anything. Last year I dodged removal, but I'll probably do some this year.
Also props to my wife, who recently epoxied a counter top at her rental house all by herself after watching a ton of videos on Youtube. This was just basic white laminated countertop before.
https://lh3.googleusercontent.com/pw/ACtC-3csHBy1mThWJh97pqMa1KTyCq2yGF-27u4Zqg5Mf7QIKFDHse5g3-tlvfKecLFLH0j2ouUWlDeascTg_iweNZtRmOWG9BEOgTdvYgtR p98GDTgzyNWY5orLPCkMXHPitOX_qdyp34twVJc2Fs5P9bzc3g =w1288-h625-no?authuser=0
I wasn't involved in this at all and still don't understand how she got the marble looking detail in there.
https://lh3.googleusercontent.com/pw/ACtC-3cmdxF9bK2mtAT663rATlB8eFOjjHhN1-keN1xpcSQHD7KhXVfGMku0BPrsUJm7b6UeVm11btAI8vne2t7e mh6Pp3QQvzDw0sEVtQaZNpZ-aFu_3Pls1ORdzLQqJsXSBvC-Y5lDAMi-GDNvw4efgtY8uw=w1288-h625-no?authuser=0
JohnnyEgo
11-22-2020, 18:46
Those came out fantastic! You, sir, are a very creative and crafty guy. Make sure you charge appropriately for it; nothing will have you earning less than minimum wage faster than having all your friends see your work and then demand something similar, but with 87 small personalizations for half the cost.
I'm still working on the billing, but I'll end up doing better than I originally thought. I don't want to make a habit out of tearing my hair out for weeks at a time for next to nothing. Thanks for your guidance in the beginning!
StagLefty
11-23-2020, 16:27
Finally decided to re-purpose my old desktop hutch into a woodcarving station. Lotta gifts to carve !!!
https://photos.google.com/search/_tra_/photo/AF1QipNoGVkTHDgmzijCqmV6ZmTbJlGM7-3ivW0PhFl4
BladesNBarrels
11-23-2020, 16:43
Finally decided to re-purpose my old desktop hutch into a woodcarving station. Lotta gifts to carve !!!
https://photos.google.com/search/_tra_/photo/AF1QipNoGVkTHDgmzijCqmV6ZmTbJlGM7-3ivW0PhFl4
https://i.imgur.com/iK6rLnY.png
JohnnyDrama
12-11-2020, 11:46
I finally found enough time sitting still to cut up a few of my favorite shirts that I've worn until there wasn't enough left of them to be considered clothing. I'm discovering how much little stuff I can get done during a 45 minute Zoom meeting.
I will probably be set for a very long time when it comes to cleaning patches.
While I was making the Christmas boxes, I broke my vise. The threaded lock for the swivel base decided it didn't want to hold tight anymore. I finally got around to fixing that. Basically, both the inside and outside threads had flattened out over time and under pressure they would just slip.
You can see here that when I tried to clean up the threads, there wasn't enough material, or I was using the wrong die, or whatever, but it didn't work. I found this extra bolt with the same thread pattern and it worked inside the female portion.
https://lh3.googleusercontent.com/pw/ACtC-3esr-keG2lTxhCdNHYsciRYrY9zsA740SqCWuNWlfMxYbfYBkFkd71S M1lMgDAYKARH07Q-l0eTu-tbxQNKtnFjuBX7DkZdY8f9DsoMIfVaND9VmsgcId5BZ95CoJQV LfdmjArFBU1MC10090cjreRNXw=w1366-h616-no?authuser=0
So I used my new to me portaband and cut each one and joined the good base to the good threads.
https://lh3.googleusercontent.com/pw/ACtC-3f-WQbBdUO6dPzDpvc0Q9zEvyt9WGSyJUfRXEfWHgpRT2X-pr2Clgz0C15PYolym7M025ppqMWLxVsVqxLNp2thpjvcDUU7zt QzTRlkqXBgRiaWdAdLyEp61sOuZQXkesgugZkY3aqOUmguL2vm GI1lqw=w1366-h616-no?authuser=0
I tacked it a bunch of times and cut my wife loose on the bench grinder to flatten everything back down.
https://lh3.googleusercontent.com/pw/ACtC-3dHxxlIS84EZ8Cbyy9raLmVRzR7nyDGDn4ocibKxZSQ5MKCu5b OvTnuztIhMCR9zFHR_oK0WxWZrQtvy8tayuCMA-O0drdeB2wX1rPqsqtTFAtAR42fU_UVZ1q_78ys-0318JPOJ6xmP8H6T_CwmviAgg=w1366-h616-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3dwjaCb6lgOcf9hxOVkz0BnIQplINAEMeqs0MSvdq0_4yc0Rel twX-Azv8uORD7YDD4qWfPZNIzKuHnSFoMaGm5BPsLhDh3W0PFzYlim 2NINMJ0PRqDlbpwMgzJeejPMBW2GO9Ex0pL4Pyc9P5h0DtQ0w= w1366-h616-no?authuser=0
At the beginning, I cut the dowel out of the tightening shaft thing so I could asses the threads, knowing I could weld it back together again.
https://lh3.googleusercontent.com/pw/ACtC-3c4ll8wla-L2Jy1n3MHo4Y2MTRF-qAhBro15natY79SScdZTnQjBdQ2hI9mgV--Vm0Twh-CTOhpejQhO8pjr7F_5ZwfvsWVFnzS3fSO2UgYgccvvdyf9h3Wj ENOLCBLoC5pt-UEygOllNxbdYpI4ASuhA=w1366-h616-no?authuser=0
I took the time to bevel the edges to create a space for the weld bead to lay, tacked it back together, ground it down, then realized I got excited to weld and welded it back together without actually running it through the barrel first. Whoops.
https://lh3.googleusercontent.com/pw/ACtC-3dyMJCyKhk9cyw1dK1rOchUHYDPiVbQGD6vlYsQ_MZPgAGcVc7 Ys9U_3fUULVBXK9x6xcK8sRLIxZFtd3doAdbJjnZjbEBne-yLcLd5xrPyXmOdF4elXA58bQbRvDHhaoTDTs94ePSe5pCHJyMr P1CjDg=w1366-h616-no?authuser=0
So then I just ground down the flare at the end and let my wife try a couple of tack welds around the perimeter once I ran it through the barrel.
Here it is all finished up and now it works again.
https://lh3.googleusercontent.com/pw/ACtC-3cyDgxYWSYRhyB7kzh2a2tmUWU5nVP5qlgoKmmbvM72VG-rtEiysrRIVHkeEW4ndXziNhHWKYrDET_fyc1coReC2upO4CM8o yzxNlfRuxu_L1EhEZC0FUY3jAouMyD2lkwwYas0yRrBoEhDux8 FzpWKtg=w1366-h616-no?authuser=0
Hey, Irving. Nice work! I remember when you started getting into welding. Did you end up taking any classes?
No sir, just watching You Tube videos. A class would be nice since It'd force me to actually practice. I'm bad at just sitting down and practicing for fun. I usually end up just doing a project.
No sir, just watching You Tube videos. A class would be nice since It'd force me to actually practice. I'm bad at just sitting down and practicing for fun. I usually end up just doing a project.
Some skills are learned for the skill, some skills are project driven.
JohnnyEgo
12-18-2020, 21:55
The last few weeks, my free time has been consumed by getting my son through 5th grade math with a C this quarter, which has taken a crowbar, dynamite, and the grace of god. But he C-minused his way through the mixed fraction addition today, which helped him maintain the razor-thin lead on a 70.9%. Never have I worked so hard or been so happy for any grade of my own as for this C.
But I digress. Progress has been limited, and also distracted by some other things, but the project has at least progressed. What is left is a lot of chisel work. Most of it is easy but tedious. However, notching the carcass for the dust panels was actually tedious but critical, and a mistake here would waste a substantial amount of wood and effort.
Well, nothing to it but to do it. Out came a couple chisels:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/morechiselwork01.JPG
Had to carefully square up the router-made dado slot with the bead, which was fairly delicate with this much carved out of it.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/morechiselwork02.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/morechiselwork03.JPG
Then came slowly carving away at the bead with my little jig until I had clean-ish 45 degree miters without blowing out the case.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/morechiselwork06.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/morechiselwork07.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/morechiselwork08.JPG
Test fit looked good. Nothing glue and sawdust wouldn't conceal.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/morechiselwork09.JPG
JohnnyEgo
12-18-2020, 21:59
Got a pile of parts sitting here.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/morechiselwork10.JPG
Had to do a little tuning of the dust panels to make sure they end up relatively flush with the front and back panels.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/morechiselwork11.JPG
Dry-fit the panels:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/morechiselwork12.JPG
Carcass is now about 60% complete.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/morechiselwork14.JPG
What remains is fitting the dividers for each box, and the chisel work associated with the vertical beading. It isn't hard, and if I screw it up bad, it's easy to replace. But it will be very tedious to do 18 times, and each piece has to be fitted to allow the drawers to slide freely while still appearing vertically aligned and with reasonably decent panel gaps.
I want to smoke a pie. I ran my smoker, in the sun, today at full blast and could only get it to 275. Every recipe I see calls for between 350 to 375 (I feel like one was even 450!). I need to do something. The short of it is that I just cut a plate to fit on one of the racks so I can cut my space in half.
Here is my Master Forge smoker that I picked up at a garage sale for $75.
https://lh3.googleusercontent.com/pw/ACtC-3eRXU2KkPylz_UQdvH9t4NpnhtPM83rdFOBI_n8x61tDZUndk9 ADYlJfbsjeJaUcZBZ_AXqfUdjCH9yibgRAxKDMv5ToLCVK2BXu 48N1rloGyWAsf5u1S7fR3V41FPqC8V7FXFIzMWZuf1fWLU8IC_ jWw=w834-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3d2b8oF6qGX6MsGotWTdYNHxmMTrfm4dxTMMrIyrO0UppT6TZ1 jVA8Tcys_x6vw8Urv0v6wk0YpSdhfcSORMMtiQBt71CozcvJVW WM--hOppGW3u7B2BoQMqfoBwmCH_JXOnNSm_YYl3RuOsCe8neyacw= w834-h625-no?authuser=0
At least a year ago, maybe two, I ordered another thermometer. My plan was to install it on the side, about half way up.
https://lh3.googleusercontent.com/pw/ACtC-3dbeLY59Vz3-ZZAHwZUa-SZkWyuW7BmBV9tCRUSbS4ozD937bMH9tYDrjm9kYKs9jLc0Q5A q2ZMn65mZJYm1qtiLgUleghQVhoQIGvyCnsGE1bXGYRcGZm8-giWym0vbqdEwqjITKXgpMwlS5-58tHKYA=w834-h625-no?authuser=0
As usual, I forget that when welding very thin metal (22ga), especially to thicker metal (1/4"), you can't just run a bead. So of course I blew right through. You have to spot weld. Maybe someone can do it, but I can't. Pictured is after I blasted through on the right side, then patched it back up.
https://lh3.googleusercontent.com/pw/ACtC-3cqsMxeGdLqd72uCbpkDQgMc0t1RMXpxPOsHtaHADAs5s603fw Aq9E48WctfZxV8SHbDurCH6vbB43BysislPnzbb0XHjCkJZD9y BeTuoLo1K-PgO5PzoirjgSpkEMfCHqSTQ5wW97TkGzdhkBdHiu7ew=w834-h625-no?authuser=0
I ground it down, then welded a tiny plate on the back just to plug the hole.
https://lh3.googleusercontent.com/pw/ACtC-3ccprzZLF1SycG4ODE3EslbgpVo7cV_5FR605WegPJciJ75QY8 NZm38HXhGG8Fsxl6vb27EJ-B7wdCo1moYGw4thpVL2mRcQq46grCJjo53371JzIx18D99wx1L 2HS7R9aYGG1cFcG4dYniiLrgW7edDA=w834-h625-no?authuser=0
The plate isn't anything special. Just a 1/8" sheet of diamond plate that has about 1/2" on the sides, and a full 1" on the back of a gap between the plate and the wall.
https://lh3.googleusercontent.com/pw/ACtC-3ft23W7bLL3jwwfRj4W-mtzvh5K9gLxXvoTguwW_6Spcz6wGRDT15onN1vbQ5MeQ3xnBi7 611WU3V-PPDRWHEvMza-xXZPh95S6cCD8gHyhSK8zgGZ8f4tn_2a8O1Wa6Nwf241p2odot jvz9inPnx6x2Q=w834-h625-no?authuser=0
It's working though. With just the lower temp gauge, I was able to get the gauges to read 265 on top, and 340 in the middle after only about 10 minutes.
When I put the plate in and opened the door for the picture, the top gauge dropped to 200, and the bottom dropped to 325. I've been measuring the temp every 5 minutes and got as follows.
Time -- Top -- Middle
7:00 -- 200 -- 325
7:05 -- 200 -- 380
7:11 -- 210 -- 386
7:15 -- 210 -- 386
Now I closed one side vent
7:20 -- 215 -- 396
7:25 -- 220 -- 396
Then I closed the other side vent
7:31 -- 225 -- 405
7:38 -- 230 -- 410
It's a success.
After messing around the drilling through this 1/4" plate, I realized that I could have just used the step bit and drilled out the side of the smoker and been done in 5 minutes. I like welding and practicing though, so now it's welded on there. At least I didn't weld the nut onto the stove like I originally planned. I thawed the pie, then read the directions that said you should cook it at 350 from frozen. So now I'm refreezing the pie to cook it in about 15 minutes. I'm sure it's going to be a big mess, but oh well. Can't wait!
You can see in my second photo that I made a rack for the wood chips out of a garden trellis I had laying around. If I don't at least double up my aluminum boat, it burns through and dumps all the wood chips directly onto the burner. I have an oval piece of 1/4" from a wood stove I got on here that fits right into the holder. I don't know if that is too thick to start the wood smoking or not though. I guess that will be my next experiment. I'd kind of like to weld up a little box out of something like 18 gauge, but I don't have anything like that on hand at the moment. Anyone have any input on that part?
JohnnyEgo
12-31-2020, 21:36
Little side-trip the week before Christmas. Small box time once again. Pumped out one for my son's teacher, two for the nephews, one for the niece, one for the neighbor.
https://www.johnnyego.com/wood/2020Projects/teacherbox/2020teacherbox02.JPG
https://www.johnnyego.com/wood/2020Projects/teacherbox/2020teacherbox07.JPG
One of the aforementioned upsides about cutting box joints for 13 different boxes for my son's card catalog is that you get pretty good at a thing after 14 times. Box joint set up went quick, tear out was minimal, and the joints were tight with nearly no fill.
https://www.johnnyego.com/wood/2020Projects/teacherbox/xmasbox14.JPG
https://www.johnnyego.com/wood/2020Projects/teacherbox/xmasbox15.JPG
While I was messing around in the shop avoiding the tedious work to come, I decided to rebuild my rail quiver, which has seen better days. It was built out of MDF and lasted almost a decade, so I can't complain too much. But it wasn't terribly space efficient, and now I have more rails.
Old guy:
https://www.johnnyego.com/wood/2016Projects/Slatwall/slatwall03.JPG
https://www.johnnyego.com/wood/2020Projects/railquiver/railquiver01.JPG
New guy:
It's built out of Baltic Birch scrap, which should be a little tougher. Made the rail slots much narrower, and made the whole thing a little deeper so I could stick some of the accessories that go with the rails on the side.
https://www.johnnyego.com/wood/2020Projects/railquiver/railquiver04.JPG
https://www.johnnyego.com/wood/2020Projects/railquiver/railquiver06.JPG
https://www.johnnyego.com/wood/2020Projects/railquiver/railquiver07.JPG
JohnnyEgo
12-31-2020, 21:47
My wife mentioned she'd like to park her car back in the garage for Christmas, so I went into full shop compactification and clean-up. It will be nice to start the new year with a clean-ish shop.
https://www.johnnyego.com/wood/garage/2020shopclean01.JPG
New rail quiver doing it's thing.
https://www.johnnyego.com/wood/garage/2020shopclean02.JPG
The upside of office closures is that I unbolted these cabinets from my office and reattached them to my garage wall, where I find them much more useful. Corporate didn't see this coming when they said we could get anything we needed from the office.
https://www.johnnyego.com/wood/garage/2020shopclean05.JPG
So nice to see the top of my workbench again:
https://www.johnnyego.com/wood/garage/2020shopclean06.JPG
Going to start on a new fast project over the next two days; a simple shelf for my furnace room. Then plan to get back on the card catalog on Sunday.
https://www.johnnyego.com/wood/garage/2020shopclean01.JPG
https://www.johnnyego.com/wood/garage/2020shopclean01.JPG
JohnnyEgo
01-04-2021, 00:08
First completed project of 2021 is my new year's resolution. From 2018.
I have needed a shelf in my utility room for a while, since the current system is piles of stuff in cardboard boxes shoved up against the pilot light for the water heater. The bright thing to do would have been to go to Lowes or Home Depot and spend $99 on one of those metal utility shelves, and I would have been done in an hour. But how could I call myself a woodworker unless I procrastinated forever and then threw a thousand dollars worth of tools at it?
Since the forum software limits the number of photos I can cram into a post, I am going to chunk this out in rough units of 10. This is cheapish-quickish utility grade furniture, and not a master-work, but I hope my foibles with power tools will at least be entertaining for some.
On the plus side, this went together quick. A few hours Saturday, a few hours Sunday, no paint or finish, and minimal sanding. Start with a fairly simple plan and a few quick measurements to make sure it will fit in the space I have for it.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf05.JPG
Breaking down the sheet:
First step was to carve up the sheet goods. I have a track saw for these purposes, so I drug out some saw horses and my adjustable height table, slapped a piece of foam on it, and started cutting away.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf02.JPG
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf03.JPG
Made a reference cut along the long edge. I probably didn't need to, as the factory edge was straight and in good condition, but it's cheap insurance on things being square.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf04.JPG
Once I had the long reference cut, I cut the side at 90 degrees and checked for square.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf06.JPG
I have the TSO rail guides, which are great when you have to build ten of these things, and honestly pretty great even when you only have to build one. Set them to 12", and they made quick work of dicing up the sheet and having everything cut to the same width.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf07.JPG
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf08.JPG
Useful on cross-cuts as a positioning guide, as well.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf09.JPG
Sheet is all diced up!
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf10.JPG
JohnnyEgo
01-04-2021, 00:11
Joining all the parts
Next came time to poke some holes so I could join all these pieces together. I really like pocket holes for this purpose, and if I had used them alone, I would have been done with getting the shelves fixed much faster. However, I have decided that I am going to learn to love my Domino in 2021, whatever it takes. So I punched a bunch of Domino slots into pretty much everything. Used the TSO guides and the back side of my rail as a story stick so that everything ended up in the same place on both shelf sides.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf11.JPG
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf13.JPG
Used a Kreg 5mm shelf pin jig to give myself about two inches of adjustability on all the shelves that aren't fixed.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf12.JPG
So many poked holes.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf15.JPG
What rocks about the Festool system is that this is the dust that made it to the shop floor for all of these operations:
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf16.JPG
I put in a bunch of pocket holes anyways, because I trust them more than small Dominos in particle board.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf18.JPG
Screwed it all together. Bolstered the middle fixed shelf to support some extra weight.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf19.JPG
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf22.JPG
Cut up some Doug Fir strips to face frame it out on the compound miter. Face frame will give it some more strength and rigidity under load.:
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf23.JPG
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf24.JPG
JohnnyEgo
01-04-2021, 00:12
Iron-on Edge Banding
I had planned to trim out all the shelves the same, but it needlessly complicates the adjustable nature of the adjustable shelves, so I decided to edge-band them.
First step when working with iron-on edging is to wait until your wife is too distracted and then ask where the iron is, when she is unlikely to ask follow-up questions like 'why'. Also, a little pro-tip: using mineral spirits on a hot iron to clean up any hot-melt adhesive residue will result in a very unique smell, a discolored iron, and a wife who will guard the new iron carefully and vigorously interrogate you whenever you ask for it for the next 20+ years.
Anyways, the kit requirements for doing this are fairly simple. An iron, some scissors, a razor blade or something sharp to trim the excess, and a roller or block of wood to help smooth it out and make sure the glue makes good contact with the particle board.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf35.JPG
Slow and steady pass with the iron:
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf36.JPG
Hit it with the roller to make sure everything sticks:
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf37.JPG
Trim the excess with a flush plane or razor:
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf38.JPG
I don't know if this is a thing you should do, but it's a thing I've always done; burnish the corners by running a screwdriver along the edge at about 45 degrees, with moderate pressure. Breaks the edge a bit.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf40.JPG
Followed up by a quick hit of 220 grit sandpaper, and I get a nice-looking edge that won't cut you or catch on things dragged across it.:
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf41.JPG
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf42.JPG
JohnnyEgo
01-04-2021, 00:12
Edge routing and finishing:
Time to soften the edges. I used a 3/8 roundover bit in a handheld router for this. While the dust collection on the Festool tools is pretty good, it does have it's limits. And one of those is inside edge routing around corners. So I knew this part would be messy going in. And it was.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf43.JPG
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf44.JPG
Not much sanding necessary on this. My weapons of choice are 150 and 220 grit sand paper in some Preppin Weapon sanding blocks, and some adhesive-backed 220 in a rubber curved profile. For these long, narrow, and flat pieces, they were faster and more controlled than a power sander would have been.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf45.JPG
Knocking it all together for a test fit:
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf46.JPG
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf47.JPG
Once it was looking like it was in final form, I knocked it all apart again. I need to notch all the shelves for a stud that runs through my unsheathed utility room walls. Unfortunately, my dado stack didn't have the depth to knock it out in one operation, so I had to improvise a bit. Poked two holes with a half-inch drill bit.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf48.JPG
Then ganged them up and defined the edges of the notch with my table saw blade as high as it could go.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf49.JPG
Then carved out the rest at the bandsaw. Good enough for utility-grade shelving.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf50.JPG
Last thing I needed was some short legs, which I cut out of some 2x scrap:
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf51.JPG
JohnnyEgo
01-04-2021, 00:13
Installation:
Dragged all the knocked down parts to the basement. I screwed the shelf back together in the hallway, then fit my little platform in the utility room where it is going to live.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf52.JPG
Then I dropped the shelf in place between the studs, and secured it to the platform with pocket-screws from the underside of the base. It also has two screws driven through the studs towards the top to keep it from tipping.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf53.JPG
Fit like a glove. Well, a semi-tight glove, just in case the walls settle or shift. A little glue and the application of the face-frame finished the job.
https://www.johnnyego.com/wood/2021Projects/utilityshelf/utilityshelf54.JPG
This seems so much nicer and less likely to catch fire than the previous jumble we had. I am very content with it. And thus ends my first completed project for 2020!
Grant H.
01-04-2021, 00:25
Nice!
Seeing your posts makes me think wood working is a possibility for me, but then I try simple stuff, and it's way harder than I think it should be.
Somehow metal just cooperates better for me...
How do you make the initial reference cut if there is a concern the factory edge isn't square? Is it a simple as using a drywall square? I imagine better tools, but similar concept?
JohnnyEgo
01-04-2021, 02:12
Honestly yep, drywall square works fine. In my pre- disposable income days, I'd use a long melamine shelf board clamped to whatever I was cutting to use as a fence to establish one straight long edge. Then I would use a shorter shelf board with a framer's square against that straight reference edge. It's the $20 solution that does the exact same thing as the $2000 solution in terms of straight edges at 90 degrees to one another. It just doesn't clean up after itself.
BladesNBarrels
01-04-2021, 09:15
Great sequence.
You make a finished piece of furniture when most people would just tack up some 2 x 4's.
You are an inspiration.
Thanks for posting.
encorehunter
01-22-2021, 15:13
84692
We decided we needed to get busy on the home office. I have been using it as a store roo for the last few years. I am trying board and batton for over the sheetrock for something different. I cut a beetle kill try that was still standing, moved it to the mill, milled it and then took a torch to it. It is about 3/8" thick, so not very heavy.
encorehunter
01-24-2021, 14:12
84729
Some of the left over scraps from the sawmill. The wife mentioned she wanted a coffee table, so a hours worth of time, a torch and some screws. Hopefully it will keep the Mrs. happy for a few days.
BladesNBarrels
02-28-2021, 10:27
Been working in a storage garage with lights and heat, but no entertainment.
I looked around and found a Bluetooth Speaker Kit at Rocklers:
https://i.imgur.com/MCFNQZo.jpg
Looked at the plan in the speaker box for wood boxes and thought I would try something a little different.
How about a small Ammo Box?
https://i.imgur.com/ern64xy.jpg
https://i.imgur.com/otElupp.jpg
Used hole saws to drill the appropriate sized holes for the speakers on one side and the controls on the back
https://i.imgur.com/Xg1DEzx.jpg
https://i.imgur.com/dAhtvP4.jpg
Add the Speakers and Control Panel
https://i.imgur.com/lX0mgPT.jpg
https://i.imgur.com/wirdMxo.jpg
https://i.imgur.com/Hg3kwxA.jpg
And, with surprisingly good sound, I have a portable speaker unit that runs the music from my iPhone
https://i.imgur.com/atnenDp.jpg
Awesome! This thread delivers.
theGinsue
02-28-2021, 18:25
I like the Bluetooth unit; it's generations above what was available when I drew up plans to do this 15 years ago.
Does the Bluetooth unit have an integrated battery pack with USB charging?
Any plans to drill small holes (meshed on the inside) to include/ let out bass?
I've never had a hole saw give me such a clean cut... you've got talent.
The ammo can project is perfect timing, as I'm working on my own ammo can project. I'm not done yet, but I'm impatient so I'll share now. I've had this idea kicking around in my head for a bit, but I got an invite for a friend's birthday this weekend that said, "If you want to bring a gift, think of some SMALL thing that is representative of what you share in common with blah..." and I thought, "Oh, perfect." Of course I'm using the left over panels from the grill project.
It's about as rough going as I thought, since small stuff is difficult and I don't really have the tools, or skill set, but I'm pretty happy with the progress so far.
https://lh3.googleusercontent.com/pw/ACtC-3dNJuwUhrXyWw2V5zyINE6eHCfOZlpzKo4fIXyFx9DwCa3Cd8Q Ga-jgbfuQ4KHfDMrHMSVd_DNe06AWy38NpcqMcVX6GWtprwGlvVlv jW9-qg_zlgsp-ZBDO9tVlgmczthjzvwhNvR3QrqFyGM0YzUnwg=w1366-h616-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3ePUgmFWMUwkL718tjsMYcyT2OQlj3AitXZTuJGfeOhp2WrHUy 3v5OWQnhFPN1qEzRDXWncpGSKkYNjHFkc8E8vXyciqiX1zZqJG SQSkkwmuUjxCOh5Iew-qbl2gdbO7Lz9xNm5Y0sVzMvWYLWAbJVUiw=w1366-h616-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3fzMw3ZP__eFk-TRegZMPrd5HsOgcgA3tvh1E829JrNB2adjxfiskUwYsjmRqZWV aBcJBY67OSgNDB92RWo2icVY3TWrcHZ99BV5ngkZgV7rWI0MPd 50aEkBXqylivfYaujh_PlWHJSyplStcoS6aOhiA=w1366-h616-no?authuser=0
I realized I was going to have a problem trying to fold all four sides of a box, but I happened to have this scrap piece of tube that fit perfectly.
https://lh3.googleusercontent.com/pw/ACtC-3cnUU1J_kYgJ2C8wOjVFEw8e7zE9gNzfhXGf_AS13WZ8YOss3e aovmdgF6VbyxcIq40LAYB9otMCoVdETlJmCxHC_ti1F847Pl5p JZ4J5ugDnvg0RpqpTwOi-lkhvxpqLWOclM5qKPm4AyCFYpe6OqLaA=w1366-h616-no?authuser=0
Using the aluminum vise jaws I made during the last project so as not to indent my metal.
https://lh3.googleusercontent.com/pw/ACtC-3e7KMJg68r5emlFvX9Z5JFmM5-La9HTEY3-SS1AuRvBXykyY7QnQ0UBLsXAoXpi47OrB8Kmt1ZgWhzsUsHCmw zvArrseWaBCKC6jl-cqzRfWLY6p3yEtrE984OTnhqF8mEEh8Qe-Tsnpd7v4wm4gUicTQ=w1366-h616-no?authuser=0
Mocked up.
https://lh3.googleusercontent.com/pw/ACtC-3dUAjOdHoD3mDisFXjXkHX-KAhI-OoksmtX-8r6Hv-TNXgT9GFGrWmx9hiWgI9dnA1ckT6hdJpA6Y5jdxKDCgiIlsrwB LFONDuAJnMOIhpN4o3wEyiYVW5M3NeXkGpmGupD7nxwu9YLDv5 mJwBwLi_2_Q=w1366-h616-no?authuser=0
I tried to make the dimensions roughly the same as the full size box.
https://lh3.googleusercontent.com/pw/ACtC-3djBF8pPTNv3ni8edGXgxvEWxdPwYdOMvvIYTSnncez7rxER1I womL3Fjdz9_QBCz5vTIHLOCRKdzsrzGaCmYTEsZVpVnuzyk2Tz cWfC5ESt73E-ZkZC77KyagekMp4WQ5secMe-6GGcHsJ10UNBIi6iA=w1366-h616-no?authuser=0
The idea is that it will hold a single 10mm bullet, because "it's the only round that'll penetrate the skull of a bear and I wouldn't go into the woods carrying anything less!"
https://lh3.googleusercontent.com/pw/ACtC-3dsfXU_nlE8HBx8jzp6qQTdfuCKQ9pW5QYOTqEDdYIvhRHefIJ 2RlMeSWNuF8o3ihLvzMEUU2yUBu8ciO29Gbist2LNXqE-w3FMVSly63tx_0wDlOBB56WZmRSqVUUcwuFC-PgJAiyLpmwCqCN3rkmUlw=w1366-h616-no?authuser=0
Welded and cleaned up. It got pretty wonky as far as being square and the bends aren't real tight, but it's the thought that counts right?
https://lh3.googleusercontent.com/pw/ACtC-3dmf_tHdvNrQD05elC7YvZotySoToghqSW-2N_5HEE56q2PrOCCjifjtmkXyBgTbNIl67UGnzrNPTx9dlYrag Sqjo5s2mCZ79xO56y2QpJGMk_9MnIQR7KqbarNvXdnrFqkmF76-hlEMuVeME6BJzBz9g=w1366-h616-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3cOVQxp1ty6y9xS-Rw8qNRmiIKQLh-utJ2Y-DBPkvlj1Vsjv-D2ortHFDcVKNeDqYF3iv_vHFi67IDYYpslmUkLGlhxbDgEAlS8 fEq82qr1TTpUWbOAhYuPHf6ftUwy58TxAtdFrb8-154EZK1jgw-0Bg=w1366-h616-no?authuser=0
The hinge I used is way too big, but I'm short on time.
https://lh3.googleusercontent.com/pw/ACtC-3cca0m5EmOOPaD45abfoU9ZFyXp2Xnh_ux3EwgDC2utTjJOWfz HOsuk8NVUC7zQFDOvh6q0xHCwq8dF2EOynkSzjN6V43On673KG n1de_nBidZgBgyaRBdca_FhSoExkduZJueflwPwdjoL7FHHYwL dCw=w1366-h616-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3fNl1YkvTnRiios2yGKFg70UlQKVLkvWaXOw1x6eOYfL3xTsWx WePwUqF5qp669OYNiJJY1md6zIXbg0XUU1sMv-nh_h7WvODZReN6Qq_VT7vxRcNbeGrTiq0CVauTEVAqFSdctk5V bHazyWXatjQxKWQ=w1366-h616-no?authuser=0
I still have to make the handle and see if I can cobble together a locking mechanism. I want to line the lid with some conveyor belt material in an attempt to keep it water tight. I'm hoping to clean up the edges with a file when it's done. I'm sure the paint will gum stuff up, but I'm going to go for it. It'll look like I made it out of clay, but I think it's adorable.
theGinsue
03-01-2021, 01:16
Now you need to paint it OD
Oh that's coming. Might even try some lettering with a tooth pick, but we'll see.
I've never had a hole saw give me such a clean cut... you've got talent.
If you rename "hole saw" to "annular cutter" you might have better success :)
https://youtu.be/-5zSadDZMhA
BladesNBarrels
03-01-2021, 09:27
I've never had a hole saw give me such a clean cut... you've got talent.
New hole saws off Amazon, slowest speed on my 20 year old Delta drill press at 620 rpm.
3 clamps holding everything steady.
Very light pressure - touching the material and lifting every 4-5 seconds.
Also built up wood scrap inside the can to back up the metal for the side holes.
The back hole I had to clamp everything to the drill press table and did not back up with wood - I figured the short width in the back gave good support.
The spindle and chuck did not like staying together at first. I lightly sanded the spindle and tapped the chuck back on with a rubber mallet.
Just a few curses and everything finally came together.
It looks great. I had no idea building those was a thing, but last night I saw a ton of videos about it. Basically like a DIY version of my Harmon/Karden speaker, which I absolutely love.
BladesNBarrels
03-01-2021, 09:38
I like the Bluetooth unit; it's generations above what was available when I drew up plans to do this 15 years ago.
Does the Bluetooth unit have an integrated battery pack with USB charging?
Any plans to drill small holes (meshed on the inside) to include/ let out bass?
I was really impressed with the Bluetooth unit.
It has an internal battery that supposedly is good for around 11 hours.
It took less than an hour to fully charge.
I have an outlet with a USB plug in that handles the USB connector to the Control Panel for charging.
I thought I could just store the accessories in the Ammo Can.
I like the sound of the speakers as they are - I am in a 25' x 35' garage with a 22' ceiling and it I can hear the music very well.
https://i.imgur.com/BX3UvmN.jpg
BladesNBarrels
03-01-2021, 09:43
It looks great. I had no idea building those was a thing, but last night I saw a ton of videos about it. Basically like a DIY version of my Harmon/Karden speaker, which I absolutely love.
Right around Christmas, Rockler put the kits on sale and I bought a couple thinking I would find a use for them.
They actually work better than I expected.
I am glad you posted pictures of your mini Ammo Can - what a great gift idea.
It looks like you have a creative slant to your projects.
Makes this a great thread.
theGinsue
03-02-2021, 02:01
I was really impressed with the Bluetooth unit.
It has an internal battery that supposedly is good for around 11 hours.
It took less than an hour to fully charge.
I have an outlet with a USB plug in that handles the USB connector to the Control Panel for charging.
I thought I could just store the accessories in the Ammo Can.
I like the sound of the speakers as they are - I am in a 25' x 35' garage with a 22' ceiling and it I can hear the music very well.
https://i.imgur.com/BX3UvmN.jpg
Thanks for the info; it's most useful!
Um, that's NOT a garage, that's a freaking warehouse. Dang that place is huge.
BladesNBarrels
03-02-2021, 09:56
Thanks for the info; it's most useful!
Um, that's NOT a garage, that's a freaking warehouse. Dang that place is huge.
I have been looking at the Garage Condos since I first saw them at GarageTown at Highlands Ranch.
In 2008, with the recession, they were out of my price range, but I kept thinking about them.
I was finally able to manage one in Castle Rock this year, and it has been a great diversion from the corona virus restrictions.
By waiting, improvements to the design were made with each new development.
This is their latest and includes a sink with an on-demand water heater, a hose bib faucet by the door, an electric heater (commercial property, so the rates are pretty high), great lighting, 20-amp electric outlets all around, a 30-amp RV outlet, windows in the back wall and in the 14' door, a man door for access, an epoxy finished floor, and great insulation.
It has been my ultimate Corona Virus Project.
I am on the waiting list to get a mezzanine that will be about one fourth the square footage with a set of stairs. I can move the boat gear storage up to the mezzanine and have a work area below.
They are just finishing the build-out of their last units and should be done by mid to late March.
https://i.imgur.com/Gre5jSr.jpg
All finished up. I was really trying hard to put a correct handle and latch mechanism, but I had to give up and move on. Doing it out of a mig gun with 0.30 wire just wasn't going to happen. My plan was to use the mig wire as the handle and latch wire. The amount of work I tried to put into this just doesn't come through, but that's okay. I filed, sanded, used bondo, and primer, and more sanding on this. In the end, it just looks like I welded it and painted it at the same time. Oh well, I can learn those finishing skills on some other, preferably larger, project.
Original handle idea was way too big.
https://lh3.googleusercontent.com/pw/ACtC-3fgRgDyLWfAQ5YpbR6qBL7BsMC0MuPA-CIcoNGLxCseZ8VRkTVJ1D_so8WOkFy_ROJ9Q04nLqVYkDw3Amd RliQR7mixnp10Il043j2dDUUmGAqdno_P97HHP9QhRbIsUrYsW dMYk83_2FJzIKkldhus0w=w1099-h625-no?authuser=0
Had this idea, and I would just weld a top plate. That's as far as I got. I tried to build the handle the same way, but welding three tiny pieces of metal together turned out to be difficult because the weld pool was bigger than the part and would just melt everything together.
https://lh3.googleusercontent.com/pw/ACtC-3c3z0huh4CpEfO-vzQGtICzUxQJV4ZeS1N00zJzd2sBuDHWuQUmbm_c7G8Ynq5f8Z FKErFXGic8unBXke36tY2pyN0Rf5OVwPZRFDc4Ps8FFDuzhbms ybfXFh2MHU-4GhREVw1ALBSo2P26IBxuXyF6Pg=w948-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3cmmgv3kh13fyzdHOrGUmjE02DY4fyZjhY3yWCcjNpdJLiGd8H VyAlMGQ4IPDOSKsr6fLbb0t1FzQZBOQOfL-FLQjm-0mWnoT3s6AljuSpld1ksJEUEOsNPEp_B7vknuu505AHfaNRdqe 5iFZRuxsr-Rw=w1025-h625-no?authuser=0
Using bondo was fun, but I was mixing up such a small amount, that I couldn't avoid using way too much hardener and it set-up way too fast for me to do a good job.
https://lh3.googleusercontent.com/pw/ACtC-3ebpG4v1nApf31UN7yljhrbeZ3zabFqNtnq7SIfGhyW9vzl6E_ nObx8ts0O7c3t0OSIjpdOfeUGS4ZZZ8yz7onnqNFdBhXAKIRba KiIVIeGlL29GaRYQBl-zYvlGFy6M1z7sH1f_-VS6AFzFfxaQsABlA=w941-h625-no?authuser=0
I got excited when I sanded it because it all felt so smooth, but ultimately I sanded too much/poorly because not only did every scratch and dent I was trying to fill still show up, but the bondo created lines and high spots so it looked worse than if I had just sanded the metal.
https://lh3.googleusercontent.com/pw/ACtC-3e5ki_3Su5Q8tTRe4z6geRBzLeBEosZd6a-O7VYSzSCKcsHhLaUm88c9f1gm_AfFij8VYCQxqj8bUbfeIkYZa zvoomXo_ZOoO8xguUzJHOEN_qrl5V4DZ8ubwbUdwA9Wh5e8cnN RQ-FTkTZVugEBQOv4A=w1041-h625-no?authuser=0
Primed with whatever filler primer I already had.
https://lh3.googleusercontent.com/pw/ACtC-3dYe_MJ_wvCC1u4JCXvdM6_Mt9f26hLi6XjOjA9qY9QaUyIhcu 2nVio0ji8nRPfT15wzWJ-23jbp7EO7oWnboE1Q6ffvPB83Ux_vDdE3xEQK9C-hrm0jaNY_jaCQElYsXuhiXj6MHwa8CTs0eqxPJqtWQ=w1132-h625-no?authuser=0
All done. I tried so hard to get the spacing correct.
https://lh3.googleusercontent.com/pw/ACtC-3eLaQWE0VLGVGDSF3H0VZ-Stuvw9QGht687nK4b94qoPEBVghNEtgwUt3EOXMy0AFN420zWn Q7S-itwWxTlKT-EC4wyew1kWKzeyfKnVGFjcU2HVDAzMZIhwRhnbP_KHNs0cjxGh hARhuo3P8LX_sIwYw=w1122-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3cjXjmbyNNysROmkSvQ28QOWPTYE_Ic9HhiBMmv8QWCqJtTTqY 6n6DeSqtNc5ZygcOBZMEztmrcY5wFkgXdCmiqlOROA1788NZ4u Qco3MC_5K3FASNDNM97tNncPtEFnVcm2eJOeSJaSJh0-101cwRf7A=w1080-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3dhDqyQr_ln-o79XSYa-GTVafz1BIIaFBk6koZxdR8ORg2jctx1MCRW5f4p1PYvxmgXooo 8vEvvzGnh_iOKC9E1fVJQ4_EQtR3WAkDCfP47JwWrxx7LA0WHN b0Y3gTgBFqGg1EA2PDHFet_pbJbyqHj5g=w1111-h625-no?authuser=0
I used that folded up piece of paper as a straight edge, and I used the font size on the tag from my reloader covers to try and gauge the font size for this. I painted with with a BBQ skewer. I went looking for tooth picks, but found the wood skewer to be better anyway since you can hold onto it. Thanks for looking.
Great-Kazoo
03-06-2021, 18:32
All finished up. I was really trying hard to put a correct handle and latch mechanism, but I had to give up and move on. Doing it out of a mig gun with 0.30 wire just wasn't going to happen. My plan was to use the mig wire as the handle and latch wire. The amount of work I tried to put into this just doesn't come through, but that's okay. I filed, sanded, used bondo, and primer, and more sanding on this. In the end, it just looks like I welded it and painted it at the same time. Oh well, I can learn those finishing skills on some other, preferably larger, project.
Original handle idea was way too big.
https://lh3.googleusercontent.com/pw/ACtC-3fgRgDyLWfAQ5YpbR6qBL7BsMC0MuPA-CIcoNGLxCseZ8VRkTVJ1D_so8WOkFy_ROJ9Q04nLqVYkDw3Amd RliQR7mixnp10Il043j2dDUUmGAqdno_P97HHP9QhRbIsUrYsW dMYk83_2FJzIKkldhus0w=w1099-h625-no?authuser=0
Had this idea, and I would just weld a top plate. That's as far as I got. I tried to build the handle the same way, but welding three tiny pieces of metal together turned out to be difficult because the weld pool was bigger than the part and would just melt everything together.
https://lh3.googleusercontent.com/pw/ACtC-3c3z0huh4CpEfO-vzQGtICzUxQJV4ZeS1N00zJzd2sBuDHWuQUmbm_c7G8Ynq5f8Z FKErFXGic8unBXke36tY2pyN0Rf5OVwPZRFDc4Ps8FFDuzhbms ybfXFh2MHU-4GhREVw1ALBSo2P26IBxuXyF6Pg=w948-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3cmmgv3kh13fyzdHOrGUmjE02DY4fyZjhY3yWCcjNpdJLiGd8H VyAlMGQ4IPDOSKsr6fLbb0t1FzQZBOQOfL-FLQjm-0mWnoT3s6AljuSpld1ksJEUEOsNPEp_B7vknuu505AHfaNRdqe 5iFZRuxsr-Rw=w1025-h625-no?authuser=0
Using bondo was fun, but I was mixing up such a small amount, that I couldn't avoid using way too much hardener and it set-up way too fast for me to do a good job.
https://lh3.googleusercontent.com/pw/ACtC-3ebpG4v1nApf31UN7yljhrbeZ3zabFqNtnq7SIfGhyW9vzl6E_ nObx8ts0O7c3t0OSIjpdOfeUGS4ZZZ8yz7onnqNFdBhXAKIRba KiIVIeGlL29GaRYQBl-zYvlGFy6M1z7sH1f_-VS6AFzFfxaQsABlA=w941-h625-no?authuser=0
I got excited when I sanded it because it all felt so smooth, but ultimately I sanded too much/poorly because not only did every scratch and dent I was trying to fill still show up, but the bondo created lines and high spots so it looked worse than if I had just sanded the metal.
https://lh3.googleusercontent.com/pw/ACtC-3e5ki_3Su5Q8tTRe4z6geRBzLeBEosZd6a-O7VYSzSCKcsHhLaUm88c9f1gm_AfFij8VYCQxqj8bUbfeIkYZa zvoomXo_ZOoO8xguUzJHOEN_qrl5V4DZ8ubwbUdwA9Wh5e8cnN RQ-FTkTZVugEBQOv4A=w1041-h625-no?authuser=0
Primed with whatever filler primer I already had.
https://lh3.googleusercontent.com/pw/ACtC-3dYe_MJ_wvCC1u4JCXvdM6_Mt9f26hLi6XjOjA9qY9QaUyIhcu 2nVio0ji8nRPfT15wzWJ-23jbp7EO7oWnboE1Q6ffvPB83Ux_vDdE3xEQK9C-hrm0jaNY_jaCQElYsXuhiXj6MHwa8CTs0eqxPJqtWQ=w1132-h625-no?authuser=0
All done. I tried so hard to get the spacing correct.
https://lh3.googleusercontent.com/pw/ACtC-3eLaQWE0VLGVGDSF3H0VZ-Stuvw9QGht687nK4b94qoPEBVghNEtgwUt3EOXMy0AFN420zWn Q7S-itwWxTlKT-EC4wyew1kWKzeyfKnVGFjcU2HVDAzMZIhwRhnbP_KHNs0cjxGh hARhuo3P8LX_sIwYw=w1122-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3cjXjmbyNNysROmkSvQ28QOWPTYE_Ic9HhiBMmv8QWCqJtTTqY 6n6DeSqtNc5ZygcOBZMEztmrcY5wFkgXdCmiqlOROA1788NZ4u Qco3MC_5K3FASNDNM97tNncPtEFnVcm2eJOeSJaSJh0-101cwRf7A=w1080-h625-no?authuser=0
https://lh3.googleusercontent.com/pw/ACtC-3dhDqyQr_ln-o79XSYa-GTVafz1BIIaFBk6koZxdR8ORg2jctx1MCRW5f4p1PYvxmgXooo 8vEvvzGnh_iOKC9E1fVJQ4_EQtR3WAkDCfP47JwWrxx7LA0WHN b0Y3gTgBFqGg1EA2PDHFet_pbJbyqHj5g=w1111-h625-no?authuser=0
I used that folded up piece of paper as a straight edge, and I used the font size on the tag from my reloader covers to try and gauge the font size for this. I painted with with a BBQ skewer. I went looking for tooth picks, but found the wood skewer to be better anyway since you can hold onto it. Thanks for looking.
Very nice gift and job putting it together.
GJ Irving. Might be a producible novelty there, you know...
Or a really, really dark and expensive labeled pharmaceutical for Oregon (https://www.oregon.gov/oha/ph/providerpartnerresources/evaluationresearch/deathwithdignityact/pages/faqs.aspx).
Thanks guys.
GJ Irving. Might be a producible novelty there, you know...
Or a really, really dark and expensive labeled pharmaceutical for Oregon (https://www.oregon.gov/oha/ph/providerpartnerresources/evaluationresearch/deathwithdignityact/pages/faqs.aspx).
Gift went over pretty well. As far as a product, I thought it'd be a perfect Christmas ornament.
BladesNBarrels
03-07-2021, 09:18
A lot of work and rethinking, but the result is looking great.
JohnnyEgo
03-23-2021, 21:09
So this thing went on hold for a while during an epic period of work volume. I finally had to take a week off for my own sanity, so I had the opportunity to put some focused hours back into the card catalog. What is left is the 20% of construction that is dull and tedious and I have been avoiding. I managed to avoid it a little longer because my garage was so trashed out I don't think I had room to swing a hammer. Space is a tool, and one I was sorely lacking.
Chaos:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/garagemess01.JPG
Just plain chaos:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/garagemess04.JPG
All three of my workbenches were full of crap everywhere.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/garagemess05.JPG
At least good enough to get started:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/garagecleanish01.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/garagecleanish02.JPG
Mortising Domino (Floating Tenon) Holes
I'd been struggling with how I wanted to do the lattice. Struggling in the sense of not really wanting to use the Domino for the floating and through mortises, even though it was probably the best tool for the job. But very small errors in alignment across four separate boards turn into big differences in fit when everything is together. I used what I had, the parallel guide system, to try and make everything consistent when carving the holes. It was a mixed success.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/reardominos01.JPG
For the cross pieces, I found it easier to just flip the Domino upside down, clamp it to the table, and feed the work from the top.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/reardominos02.JPG
The tape over the knob is to remind me of which side I chose as a reference, and not fiddle with that adjustment
http://www.johnnyego.com/wood/2020Projects/cardcabinet/reardominos03.JPG
JohnnyEgo
03-23-2021, 21:11
Cutting Tenon Stock
I've got a box of 500 Domino tenons of various sizes, but the length of the tenons is fixed. I needed some short tenons for the top and bottom, and some longer ones that could join three pieces. So I found some scraps and started cutting some tenon stock.
Cutting to width first:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/makingtenons01.JPG
Cutting to thickness:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/makingtenons02.JPG
Rounding over at the router table:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/makingtenons03.JPG
It was actually about as fast to cut them to length by hand then to set up the bandsaw or tablesaw to do it for 12 tenons. Probably took about 5 minutes, tops.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/reardominos04.JPG
This also gave me the opportunity to fix a mistake I had made where I ended up placing a Domino incorrectly, and had to cut another one adjacent to it. This sort of plug is called a 'dutchman'. Stuck the tenon stock in:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dutchman01.JPG
Trim to length with a flush-cut saw.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dutchman02.JPG
Plane it smooth with a flush plane.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dutchman03.JPG
Had I been thinking about it, I probably could have flipped the plug so the grain orientation would be a better match. However, this is on the inside back of the panel, and it will never be seen. So good enough.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/dutchman04.JPG
JohnnyEgo
03-23-2021, 21:22
Stacking
I have all the parts I need to start stacking:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/stack04.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/stack01.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/stack02.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/stack03.JPG
The cross pieces needed to be trimmed to width so that they will be flush with the back piece. Quick visit to the tablesaw.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/stack05.JPG
Followed up with a block plane:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/stack07.JPG
Good enough!
http://www.johnnyego.com/wood/2020Projects/cardcabinet/stack06.JPG
Everything ready for fitting:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/stack08.JPG
Your ability to keep all of the components and order of operations straight makes me envious. Seems some of the steps are to fix an issue that you otherwise might not realize until 7-10 steps later in the process.
JohnnyEgo
03-24-2021, 13:19
A lot of it I bring on myself. If there is one thing I have become passably good at over the years, it is fixing unintended consequences. One of the dumber choices I made was the up-front choice to make the boxes first, then make the carcass. There are a lot of people who swear by that method, and it probably does work really well if you are making a desk or a dresser with a limited number of drawers, and where you are face framing and can easily make adjustments. But it has proven to be a nightmare with 13 drawers and no face framing to hide bad choices. Just have to figure out a way to make it work at this point.
JohnnyEgo
03-28-2021, 22:10
Fitting:
I had thought the back fitting would go quick, because it is way less complex than the front fitting. I was wrong. This ate up the entirety of the day, mostly in pulling everything apart, making a couple of adjustments, putting everything back together, and then repeating over and over again.
Five of the drawers fit as planned. Seven needed to be fitted, because of small but stacking variances between where I had intended to put the cross-pieces, and how they actually stacked up over five panels.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/backfitting01.JPG
Even though I planned and measured a bunch of times, I ended up with the farthest vertical row being spaced too close to the left panel. The other four boxes just needed trim here and there, mostly reflecting the box itself being less than perfectly square after glue-up
http://www.johnnyego.com/wood/2020Projects/cardcabinet/backfitting03.JPG
Did the best I could to make sure everything had at least a little bit of space for expansion. In theory, the way I ran the grain on the boxes, they should tend to expand vertically rather than horizontally.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/backfitting06.JPG
Took all day to get here. All day.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/backfitting08.JPG
Getting there.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/backfitting09.JPG
JohnnyEgo
03-28-2021, 22:11
Front Cross Piece Work
I got in some good practice with the back lattice, and I had a definite plan. Parts of this went surprisingly quick. First, I cut the cross pieces to 3/4" over the width of the openings:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece01.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece02.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece03.JPG
Marked them up carefully, labelled them well, and then wasted 3 of my 4 extra test pieces on getting the Domino aligned so that it would be perfectly centered. But once I had that locked into place, it took no time at all to route some extra deep Domino mortises in all of these.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece04.JPG
Very happy with how well the mortises and tenons align before any trimming
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece06.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece05.JPG
Next, I cut some rabbets into each end. These were spaced with the help of a 5/16" brass spacer to give me consistency across all pieces.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece07.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece08.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece09.JPG
JohnnyEgo
04-02-2021, 19:24
First fitting. These are super tight, but the first fitting is only about making sure they are consistent and aligned vertically. This turned out better than I expected.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece10.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece11.JPG
A very little bit of trimming just to make sure edges aligned where I wanted them to.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece12.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece13.JPG
Coming along nicely.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece14.JPG
Now to make the cross piece miters. I've mentioned before that I do everything possible to avoid taking my sawblade off of 90 degrees. So the 45 degree donkey's ear jig came out. I have a brand new blade in with a flat top profile. Even though it is a ripping blade (few, far spaced teeth), it is new and sharp and I figured it would be clean. It ended up cutting so clean that I didn't need to cut wide of the miter and trim the chip out away with a hand plane. Very happy with this.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece16.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece15.JPG
All the crosspieces mitered up.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/crosspiece17.JPG
BladesNBarrels
04-03-2021, 10:58
That really is impressive.
Thanks for posting all the steps.
JohnnyEgo
06-27-2021, 22:57
After about two months of putting it off, I grit my teeth and got back into the garage for some time dedicated to the really tedious task of mitering in all the cross pieces.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/miteredframe01.JPG
The first task was to break everything down and trim up cross pieces width-wise. To cover some spacing issues, the center pieces are slightly wider than the pieces on either end, and since I can't trim the case itself, the end pieces can only be trimmed on one side. Once everything is good enough here, all final fitting will be done to the boxes.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/miteredframe02.JPG
Took a little break about half way through to sharpen my block plane blade.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/miteredframe03.JPG
Because each vertical run of cross-pieces was a slightly different width to each-other, and a considerably different width to the carcass profile, none of my jigs would work to miter them in. I did it mostly free-hand with the chisel, and a 45 degree fence to keep the final cuts cleanish.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/miteredframe05.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/miteredframe10.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/miteredframe11.JPG
I definitely got better as I went along. The first three were pretty rough, and there will be a lot of sand and filler work in the near future. But once I got into the groove, I started fitting them better and better.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/miteredframe12.JPG
Finished the first and second rows, then called it a night.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/miteredframe13.JPG
JohnnyEgo
06-28-2021, 23:18
Sunday morning began with some more chisel sharpening. I resharpened after every 5-6 miters. Most of them, I just had to hone on the 12000 grit stone for a few swipes to tighten up a good working edge.
When they can cut a doubled-up shop towel cleanly across the grain with only the pressure of their own weight, I consider them workably sharp.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/miteredframe08.JPG
Nothing fancy. Just two cheap chisels, a moderately expensive small chisel, and some marking equipment.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/miteredframe09.JPG
Didn't take long to get the second rail complete.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/miteredframe13.JPG
Third followed shortly thereafter. Starting to get pretty good at this.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/miteredframe14.JPG
All finished. This is a milestone moment.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/miteredframe15.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/miteredframe16.JPG
Still a lot of work left to do. Got to fit some internal rails so the drawers don't wrack when pulled in and out. Then a lot of glue, sanding, and interior finish work before it can get final assembly and exterior finish. But the end is finally in sight. With any luck, I have about two weekend's worth of work to go.
A JohnnyEgo Dresser, circa 2021 :)
(Things that would be said on Antiques Roadshow.)
Very cool.
Are the drawers currently labeled just so you can keep track of them while you build?
JohnnyEgo
06-29-2021, 23:32
Mostly as a convenience. The drawers are numbered in permanent market on the drawer bottoms, but it is marginally quicker for me to keep track of them as labelled. In theory, when I do final fitting they should all fit in any opening, but they will have more even gaps if they go back to the one they were primarily fitted for. My son plans to label them with the different Pokemon types when we are finished.
I did a small thing today, but it let me scratch another line off the final punchlist, so that was good. I had previously milled some tenon stock for the floating tenons, and today I cut and fit all the forward tenons.
Nothing fancy, just mark to length and cut quickly with my $15 Zona saw. That thing is remarkably useful for the money.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/frontfloatingtenons01.JPG
Just in case someone tuning in doesn't want to look through nine pages of pictures, there are holes in the ends of each of the cross pieces to accept a tenon, and a hole in the rail itself.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/frontfloatingtenons02.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/frontfloatingtenons03.JPG
When I've done my part to perfectly center each mortise and align the mitered ends as best I can, everything fits where it is supposed to and looks reasonably aligned.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/frontfloatingtenons04.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/frontfloatingtenons05.JPG
With everything tenoned into place, the structure is very rigid and still reasonably square, which is good. At this point, there is still not a drop of glue in this project, but it is fairly stable.
http://www.johnnyego.com/wood/2020Projects/cardcabinet/frontfloatingtenons06.JPG
The only parts I have left to cut are the drawer guides, but it is going to take a while to taper them to the front and back supports. I might skip ahead a bit and start gluing the panels as I find free time in the next few nights.
No glue so far, impressive.
Brief contribution since I didn't take build pictures.
See this spider? She's sad.
https://lh3.googleusercontent.com/pw/AM-JKLUEaDR6eT3_iTszKD44qdaPEhBZ9Ls_MrLnc0H8OhIU0UfZx Xi9okybx9vxjawWrYw4VgLc4QmN2vxYK4m2zwfQtpF2v62ppqF rkgvLm9QMqETU5zxZbqx2nOnKMHkgt0N5LNYmC2l_-dfHg4mERtGawA=w834-h625-no?authuser=0
Just look at that sad, bored, I-haven't-eaten-in-six-months-because-I-don't-like-my-cage face.
https://lh3.googleusercontent.com/pw/AM-JKLVjOUScrK-IHoRaSzFV4W7kYTOmE_Y-GrpCUQvNMJzRMXyWjLkpxS3i0o5tsupqFWWWAQliGiq8pDqB72 mjnoSSQjBqmNuVa996MGnlzrASUc7tNVNI3ld5SFVd0GqytESf K3--ngww5_11Kizv1foaSg=w834-h625-no?authuser=0
It was time that I got to execute my life long dream of gluing plexiglass together to build a better prison for this spider.
Let's get started!
https://lh3.googleusercontent.com/pw/AM-JKLUYmI9LxsX8_VC25qeeiHgJc1vNNJxLcGpKQ52wZ62j3bBLf 64DREdY9i_AaJ5WvNWRN7TYm4ZJhvAgeBOvpYvs-pkM0TuWfu_UHyLYdFCYh9ZFKOb-7I6tEHExU29mddy8eMIkulluYXXEw1zrhdD_nA=w1366-h616-no?authuser=0
https://lh3.googleusercontent.com/pw/AM-JKLWOg4B-GFXAv-suf6LlP0n0iOt1OgThIfRovWG5NDg_tzHizAD0bX1o4DDIPXml TQMo6lrJ1oh5JSC3YdvJyfKFfiah16rQ6OZ7Q5MbDwqs2uWEx_ iydbqGJkAZwe9OZj5iH1YZ69e52mxECGwpQl4sEA=w1366-h616-no?authuser=0
Size comparison with current cage.
https://lh3.googleusercontent.com/pw/AM-JKLVK881ZlUVEOQejiKWTnony0u10RlvppW7RXmXZzkMZx32Vw pKDuO1AO_Hj7vz2z8VAuMJqYZi5MOTQgUZbo8ug8Xmej_Chl3O gfv3VN5wGqLCKS61UDAFefXDw-iKLmWDlfXlGiA0JZc4e_2vHQhHp2Q=w834-h625-no?authuser=0
And done.
https://lh3.googleusercontent.com/pw/AM-JKLVFMd1bq4MunNm93wB1Iy2zqgJ-KYIhWK70oy98Kd5Knz5VPRc7uVnHXEkbydzdXDvPA0Kef5wuc8 1FQSwj48pqTawORAL__G4_bBYdOjOWAfQTy1tOabgfJu6YtvoT sEg8vkslOL4IH3csI0wryLhaLQ=w469-h625-no?authuser=0
Metal, I mean plexi-glass. That spider has a good dad, lol. Looks like a Tarantula?
JohnnyEgo
07-03-2021, 11:37
Who lives in a pineapple under the sea (of plexi-glass)?
Ir-ving's Spi-der!
In all honesty, had you not told us that was your spider's face, I'd have thought I was looking at it's butt.
That is a nicely crafted terrarium! I have contemplated trying to weld acryllic a couple of times for different purposes, but never got around to actually doing it. How hard was it go apply and set?
Beautiful job!
Great-Kazoo
07-03-2021, 12:15
Nice project and tarantula. Is yours hand friendly? The ones we had were, and had no issue sitting on your shoulder.
What do you feed your tarantula? what's her name?
It's not mine, it's my daughters. My brother bought it for her birthday a few years ago. It eats crickets, when it eats, but we're going to try meal worms as well. Her name is Venture and she's a pink-toe'd tarantula. Named after Vin from Mistborn.
Welding the plexiglass is easy enough, but even with the little needle syringe it comes with, it's very easy to get the weld everywhere, then it ruins the finish on the panels. You basically hold the panel together for a minute or two, then it holds itself.
The hinges aren't installed in line with each other so there is some binding, but the wall flexes enough that it doesn't matter. The same wall flex allows the door to sag way too much as well. Were I to do it again, I think I'd put the hinges on top, OR just do a magnet in all four corners with no hinges at all. Both the hinges and magnet idea were experimental and worked okay enough.
The adults don't pay her much attention because she lives in the kid's room. However, I've seen my daughter pick her and move her around before. I didn't even know she ever handled her. I think she got cocky though because kid said the spider got snappy at her just before, and during the cage move.
My brother had the same spider growing up, and he thought it'd be a wonderful idea to buy my kid one. Thanks bro.
"Her name is Venture and she's a pink-toe'd tarantula." I was going to mention the pink toe-nail polish.....
Just like I feared, I rushed through the spider cage project and now the door won't stay shut. My daughter says she'll wake up to the door wide open and the spider just chilling inside. However, at least once so far...
https://lh3.googleusercontent.com/pw/AM-JKLUHTKF0pg8Wj_Th9qh_5HciGg1IvHQYnTnijTBM9iVdN3wpv krU4NZGXQERnZaVJXMcz2Q-FP3trqgwZaj35Impwuxu9vovKEse8r-t56tarVufUDBVllCw6ih_5KRRM-rQNX2mmUatzKE0qZ0e03Xl-w=w469-h625-no?authuser=0
I think you should get some magnets to keep that door closed.
I did, but the whole thing flexes enough that they weren't lining up. Eventually two of them fell off, as you see in the photo. I told the kids she can weld some tabs on to to door and glue velcro on instead.
Or you can just have a free-range tarantula.
She probably wouldn't go far. Especially once the dog or cat saw her.
JohnnyEgo
07-26-2021, 14:11
Some tedious stuff that needs to be done. Started out by finally gluing all the panels together. I used cauls, which are slightly curved pieces of 2x4, to help me get even clamping pressure across the glue joint.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/panelglue01.JPG
A little clean-up, then the interiors got pre-finished. I find it a lot easier to pre-finish than to try and get stain into a bunch of tight corners after assembly.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/panelstain01.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassglueup04.JPG
Did my last dry assembly, and cut up the drawer guides. These will be hit with wax to make the drawers go in smoothly.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassglueup01.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassglueup02.JPG
All the parts ready for glue.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassglueup05.JPG
I used Titebond III, which is a wood glue that dries clear(ish) and has about a 30 minute working time. I used every last second of it to get things in clamps.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassglueup07.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassglueup08.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/carcassglueup09.JPG
JohnnyEgo
07-26-2021, 14:18
It was an absolute bear to get this assembled within the glue's set time, and it fought me in every way possible. At one point, I had all but one corner aligned. I applied some force to the corner to get it to settle, and heard the dreaded 'CRAAACK'. Split the top panel at the groove for the backer, all the way through, and down 90% of the length.
Not much to do at this point but move on, so I broke out more glue, sawdust, and clamps, and pushed everything back to roughly where it was. Filled
https://www.johnnyego.com/wood/2020Projects/cardcabinet/carcasscleanup10.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/carcasscleanup11.JPG
Sanded it flush, filled any gaps with sawdust, and sanded it flush again. Then finished off with the card scraper. The crack runs vertically in this picture all the way across the top panel, and I can see it instantly still, but I think I did a pretty fair job blending it.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/carcasscleanup12.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/carcasscleanup13.JPG
Last thing to do was to apply Danish Oil to the exterior of the panels.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/carcasscleanup14.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/carcasscleanup15.JPG
It's getting there! Hearing a crack during final assembly has to be heart breaking for sure.
JohnnyEgo
08-01-2021, 20:53
Home Stretch:
Some final fitting courtesy of the sander, followed by hand-sand clean up.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/finalfit01.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/finalfit02.JPG
Some paste-wax on the runners:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/finalfit03.JPG
All lined up for final coat of Danish Oil:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/finalfit04.JPG
I used the actual pull itself to determine the position of the holes.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/pullmounts01.JPG
Quick tap to the marking punch to locate the holes.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/pullmounts02.JPG
Perfectly positioned and drilled.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/pullmounts03.JPG
Case is complete, all runners mounted, and the inside waxed and buffed.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/casecomplete01.JPG
Drawer fitted and in place
https://www.johnnyego.com/wood/2020Projects/cardcabinet/casecomplete02.JPG
As complete on the bench.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/casecomplete03.JPG
Final pictures of it in place, and commentary, coming soon.
Great-Kazoo
08-01-2021, 22:37
Home Stretch:
Some final fitting courtesy of the sander, followed by hand-sand clean up.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/finalfit01.JPG
https://www.johnnyego.com/wood/2020Projects/cardcabinet/finalfit02.JPG
Some paste-wax on the runners:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/finalfit03.JPG
All lined up for final coat of Danish Oil:
https://www.johnnyego.com/wood/2020Projects/cardcabinet/finalfit04.JPG
I used the actual pull itself to determine the position of the holes.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/pullmounts01.JPG
Quick tap to the marking punch to locate the holes.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/pullmounts02.JPG
Perfectly positioned and drilled.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/pullmounts03.JPG
Case is complete, all runners mounted, and the inside waxed and buffed.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/casecomplete01.JPG
Drawer fitted and in place
https://www.johnnyego.com/wood/2020Projects/cardcabinet/casecomplete02.JPG
As complete on the bench.
https://www.johnnyego.com/wood/2020Projects/cardcabinet/casecomplete03.JPG
Final pictures of it in place, and commentary, coming soon.
Looks like vacation gets you motivated ;)
BladesNBarrels
08-02-2021, 10:27
You have some of the coolest tools.
I had not seen the locator for the drawer pulls before, and I am a fan of the latest tool flyers.
Great project. Thanks for posting and the updates.
https://i.imgur.com/R6Jb9xx.jpg
SideShow Bob
08-02-2021, 19:19
Daym,
I learned to use the “Dewy Decimal System” in a cabinet very similar to that one except it was aged & worn way back then.
JohnnyEgo
08-03-2021, 14:17
Haha yes, two additional days of vacation and the incessant demands of my 11 year old certainly helped motivate me to finish. Just for a quick recap,
Before:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/pokechaos02.JPG
After:
http://www.johnnyego.com/wood/2020Projects/cardcabinet/cardcatalog01.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/cardcatalog04.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/cardcatalog05.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/cardcatalog07.JPG
http://www.johnnyego.com/wood/2020Projects/cardcabinet/cardcatalog06.JPG
So the after-action lessons are as follows:
At some point, I am going to need to build two replacement boxes for the two that hit the shop floor and dented their corners. In the future, I think if I have something critical to the appearance, I will budget the wood, time, and effort to make spares, even if they go in the scrap pile.
I don't think I got a whole lot out of making the drawers first. They were nice to have during the fitting process for the carcass, but I think I would have been better off to just build the carcass and fit each individual drawer. 10 of the 12 are interchangeable, which is nice, but I don't think it is all that critical.
I did some needlessly complicated things, such as integrating the beading into the carcass. Would have been easier and faster to just mill the beading and apply it to the carcass like a face frame. That would also have the advantage of being a lot less critical for a lot of things. There are a couple of face miters that I would have loved a do-over on, but had to grit my teeth and fill because I couldn't afford to remake the panel.
There are a few relatively inexpensive tools that make a tremendous difference in a project like this. The hardware alignment jig that BnB complimented me on was $27, and made for very consistent hardware mounting across 13 total drawers. My $13 Zona Razor Saw was very useful for cutting little shims, cleaning up rabbets, and doing minor precision trim cuts. The Veritas Side Rabbet is not nearly as inexpensive these post-Corona days as when I bought it, but even at $150, it is so useful for fitting drawer bottoms that I would fork over the money again without hesitation.
Lastly, hand-sharpening is not that hard and does not have to be tremendously expensive. I did spend a couple hundred bucks on my water stones, but there are cheaper options. And any time spent sharpening is 1/3 the time and frustration of using a not-quite-sharp-enough tool. I sharpened my chisels at the start and mid point of every day, and it was the right call to stop every time and do it. I am coming out of this project with a lot more knowledge and appreciation for my non-powered tools, although I am never going to give up my tablesaw or jointer.
Thanks all for joining me on the 16 month adventure!
You had beer left over?!?
JohnnyEgo
08-03-2021, 19:29
Look closer. Different beer.
Left over beer is left over beer...
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