Thanks again for posting.
I get inspired with your explanations.
After all, Woodworking is the art of correcting your mistakes!
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Thanks again for posting.
I get inspired with your explanations.
After all, Woodworking is the art of correcting your mistakes!
Sunday: Wood Work, continued
Little quick hand-planing to trim up the replacements to exact dimension.
http://www.johnnyego.com/wood/2020Pr...aceboxes16.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/2020Pr...aceboxes18.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/2020Pr...aceboxes19.JPG
Interior finished and boxes glued.
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Exterior sand and fill.
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Ready for exterior finish.
http://www.johnnyego.com/wood/2020Pr...aceboxes23.JPG
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/2020Pr.../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/2020Pr.../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/2020Pr.../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/2020Pr.../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/2020Pr.../carcass07.JPG
http://www.johnnyego.com/wood/2020Pr.../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/2020Pr.../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/2020Pr.../carcass08.JPG
Close. So close. Just a bunch of spacers, tape, and gravity.
http://www.johnnyego.com/wood/2020Pr.../carcass10.JPG
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!
That made me chuckle, because there is a serious lack of perfection in most of my work.Quote:
Originally Posted by BladesNBarrels
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.Quote:
Originally Posted by JohnnyEgo
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.Quote:
Originally Posted by JohnnyEgo
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/2020Pr.../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/2020Pr.../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/2020Pr.../carcass18.JPG
http://www.johnnyego.com/wood/2020Pr.../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.
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http://www.johnnyego.com/wood/2020Pr.../carcass15.JPG
Next up, cut the grooves for the backer board on my tablesaw.
http://www.johnnyego.com/wood/2020Pr.../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/2020Pr.../carcass25.JPG
That's a nice-fitting panel
http://www.johnnyego.com/wood/2020Pr.../carcass26.JPG
With the dominos and the backer board installed, the dry-fit of the carcass itself is complete.
http://www.johnnyego.com/wood/2020Pr.../carcass31.JPG
http://www.johnnyego.com/wood/2020Pr.../carcass29.JPG
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.
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.
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/2020Pr...et/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/2020Pr...et/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/2020Pr.../chisels01.JPG
I mean all of my chisels.
http://www.johnnyego.com/wood/2020Pr.../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/2020Pr...practice01.JPG
http://www.johnnyego.com/wood/2020Pr...practice02.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/2020Pr...cassdado01.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/2020Pr...cassdado03.JPG
http://www.johnnyego.com/wood/2020Pr...cassdado04.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/2020Pr...cassdado08.JPG
Next came mitering the beads on the rail. Sharp chisel makes fairly short and clean work of this.
http://www.johnnyego.com/wood/2020Pr...cassdado13.JPG
http://www.johnnyego.com/wood/2020Pr...cassdado14.JPG
http://www.johnnyego.com/wood/2020Pr...cassdado15.JPG
http://www.johnnyego.com/wood/2020Pr...cassdado16.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/2020Pr...cassdado17.JPG
Next up, layout and mark-up of the dust panels.
http://www.johnnyego.com/wood/2020Pr...ustpanel02.JPG
http://www.johnnyego.com/wood/2020Pr...ustpanel03.JPG
Cut the grooves for the panels on the tablesaw.
http://www.johnnyego.com/wood/2020Pr...ustpanel04.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/2020Pr...ustpanel05.JPG
Tenon fit came out decent.
http://www.johnnyego.com/wood/2020Pr...ustpanel06.JPG
I love it when a plan comes together.
http://www.johnnyego.com/wood/2020Pr...ustpanel07.JPG
Cut some panels out of my cherry veneer ply.
http://www.johnnyego.com/wood/2020Pr...ustpanel08.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/2020Pr...ustpanel09.JPG
http://www.johnnyego.com/wood/2020Pr...ustpanel10.JPG
Dry-fit went decent. There will be some trimming and adjusting, but no complaints.
http://www.johnnyego.com/wood/2020Pr...ustpanel11.JPG
Not a bad weekend's work.
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http://www.johnnyego.com/wood/2020Pr...ustpanel14.JPG
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/202...b35ad526c6.jpghttps://uploads.tapatalk-cdn.com/202...84cbfca661.jpghttps://uploads.tapatalk-cdn.com/202...057c71f083.jpg
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That looks great. Very nicely done. An actually hail proof deck railing.
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/202...3d74f5da3d.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.
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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.
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Here is the crap from Home Depot. Over $3.50 for each bag of two.
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And here they've failed before they are even flush with the wood.
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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.
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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.
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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.
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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...-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.
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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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Some parts of this are pretty rough and I'm glad this is just decoration.
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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.
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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.
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Looking pretty good, but pretty bare, I'd have to come up with something more.
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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.
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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.
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Here is everything taking over my entire garage.
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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.
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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.
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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.
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Here they are more or less in place.
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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.
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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.
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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.
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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.
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Making sure the bases worked in my front yard.
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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.
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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.
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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_...b_channel=StuA
Jeez, Stu. Impressive.
Hey thanks. Nice to see you around Justin.
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.
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.
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I wasn't involved in this at all and still don't understand how she got the marble looking detail in there.
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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!
Finally decided to re-purpose my old desktop hutch into a woodcarving station. Lotta gifts to carve !!!
https://photos.google.com/search/_tr...GM7-3ivW0PhFl4
https://i.imgur.com/iK6rLnY.pngQuote:
Originally Posted by StagLefty
Durka-Durka !!
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.
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So I used my new to me portaband and cut each one and joined the good base to the good threads.
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I tacked it a bunch of times and cut my wife loose on the bench grinder to flatten everything back down.
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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.
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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...-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...-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.
Some skills are learned for the skill, some skills are project driven.Quote:
Originally Posted by Irving
Like parenting.