Well, last night after Supper...I was just going to take a couple boards to the shop....that WAS the Plan.....Measured how much room I need for the insert..

This thing. Flanges on the sides will be on the outside of the face frame...May cover with chair rail molding..Bottom the the front of the fixed shelf needs to be 18", top edge needs to be at least 2-3" above that...needs air flow into the fan on the top of the heater.   Front of the fixed shelf, and the shelf itself will be out of these scraps of flooring...

With that long one as the front edge.   The rest will sit just like this, when looking  into the shelf. 

Grooves were done..

Dados marked out.  Mitre box to make the wall cuts..

Could have done this with the 45...but that means changing all the setups on it...we have ways

Hammer, Japanese mortise chisel to hog out the waste.  Stanley  39 to level and clean up.   I also face planed both drawer sides, to get them flat

About a minute per face.   A corded planer would have just pushed the board flat, without removing the cup and bow..

Back was cut from that 1 x 6 x 6' Pine board, jointed for width.   Usual pilot and countersink drills to make three holes in each dado, as I use screws and glue to hold the back in the drawer.  Lots of glue was getting spread around, six screws installed, and three clamps.   Checked things for square...squared up.  Then add a line of screws to attach the drawer bottom to the back's bottom.   Even marked a center point for the knob, and installed it.   Didn't feel like leaving this thing on my bench, but where else to sit it?

Hey, it works!  That spot where I miss-cut a dovetail...lower right corner.   When this comes out of the clamps, and I am cleaning things up, I replace that square.

Thanks to the kicker in the top frame, the drawer does not tip down, I can pull the drawer out even further, and no tip.  Them clamps ain't light.

The other board was brought to the shop, thought I could cut it to length, and maybe remove either the tongue, or the groove...yeah, Riiight.

This is after the bandsaw squealed it's way through....planes were just as noisey....it wouldn't fit on the mitre box.

Removed the tongue, and tried to plane it smooth.....planes are not supposed to squeak, are they?

The Boss does like the grainy look, though..

Just not sure what this "thing" is....doubt if any stain will affect it....any ideas what this is?  

Waiting around on the furnace guy to show up, today...maybe he can get the pilot to light? 

Stay  tuned....I may get the drawer cleaned up.   Whether to work on fixed (5) shelves, or start on that other door...remains to be seen...

This sure is gonna long nice with that insert in place!

Mystery wood MIGHT be Brazilian Teak ?   May just clear coat it, and use as an accent above the heater?

 

Need to buy a new bandsaw blade...

Loaded that Bandsaw blade fom the Wapak gathering into the bandsaw....runs great.   Football game wasn't going to well..visitors were getting "Homered", decided to take it out on a few boards...

Fixed shelf is installed...front was narrowed down quite a bit...shelf boards are just sitting loose.   Clamps on the drawer  are for a little block of Ash, that is being glued in place, to repair the piece that broke off...

Back of the shelf sits on a Ash rail...I used a "L" bracket on each end to attach the rail.    Gap is for any cables to pass through, or power cords.  I'll close off the door compartments AFTER this thing is hauled upstairs....gives the "movers" something to grab onto...

A bottom shelf..well, most of it...will add the filler later, as I make the rest of the shelves, I should have just the piece for there...

 

As for what is on my bench?

Actually...a bloody mess...is what i have...big chisel?   A Stanley Defiance chisel.

 

Maybe tomorrow I can clean things up a bit?    Stay tuned..

 

15 hours ago, steven newman said:

Football game wasn't going to well..visitors were getting "Homered", decided to take it out on a few boards

Good call on your part...last 8 minutes of the 4th quarter was all I saw of it AND all that needed to be seen...proof was in the pudding...well you know what I mean...great college football game!

Glad to hear the BS is up & cutting again.

The cabinet is coming along quite nicely...I'm enjoying the progression. 

That's going to be a great looking fire place surround, Steve. 

With AZ playing so miserably, I've had to rely on Ohio and Alabama for my football fix. Neither have let me down....yet.

Drawer got cleaned up, can't even tell where the repair was..

Lower right corner.  Sanded to 80 grit, for now...

Finally was able to square this end, and cut the curved part.....had to pull the sabre saw towards me...

If the edges look rounded over?

Is because this thing went on a ride all around the top..

Ran this bit around the flight deck...

16" wide, by 57" long.  Sanded at 80 grit, for now...

Top is done, for now, drawer is too.    Decided to work on plugging some holes, dug up this bit..

Bought this when Veritas first started selling them.   Cuts a 3/8" tapered plug in face grain.  Runs best in the drill press...

Works great on Pine.....Ash, on the other hand.................................do you smell something burning?

Even brok a couple off in the bit.  rather toasty?  Got a tad smokey in the shop....stuff stinks, too...may have to look into a sharpening, soon?

Ok, here is how these work.  Screwdriver to "pop" a plug out.  grab the fat end between the thumb and index finger lined up with the grain.   Dab of glue around the narrow end, stuff that into the counter-bored hole.   A few hits with the hammer.   Block of wood for the hard to hit plugs....ran out, about halfway through...need to "bake" another batch...

Just about done.   Shelves need made, and that other door needs built...

All them holes need plugged....got most of them today...may need another dozen, yet...

Stay tuned

Great progress Steve.  We've had fun on this build so far!

What speed are you running that plug cutter at?  A chart I have by my drill press says about 500 rpm for hardwood.

A little 5 speed drill press....I usually use 5th gear....tried it done in 4th...stall out.

 

Will see what I can get done today...Monday, or no Monday...need to get this thing done.

Was an Odds & Ends sort of Monday.....spent as much time sharpening things, as building things...

 

8 cleats needed ripped, crosscut and pre-drilled.    Shelf parts needed cut to size....had one cupped..

Will sand that flat, next trip to the shop.  Clamps?     Didn't like the gap at the top of the drawer...

Added a thin, tapered strip of Ash..tapered to match the gap. Glue, a couple clamps, and a caul..let this sit awhile.

Used the frame saw to cut a 1 x 6 into shelf parts....bandsaw to rip the last section to width....saw seemed a bit dull..

Got out the saw vise, scrounged up a file..and sharpened the saw up...added the black tape as a grip, and to let me know where to grab the saw at..

Oil stone, because a chisel needed some work.  Old No.3c was even put to work, today...shelf parts needed fine tuning. 

Chisel was to trim plugs with..

There are two plugs in this picture...Chisel pops most of the extra off, then pares things flat...plugs?

Cleaned, sharpened and try again with this thing..

Cutter did have a few burrs.    first four still wanted to burn....down-shifted from 5th to 1st, and try again...was a bit hard to get things started..wanted to walk around

Second set of 4 looks a lot better.  Only needed 8 plugs...

Took the clamps off.  The Boss is complaining, though...seems one of those hinges squeals when you open the door...like a hinge in a horror movie...

Anyway,  wasn't getting too involved..Monday.   IF I can find my bench in the morning..

Maybe I can get that last door built?   That bit of Pine in the vise?   Was doing a test drive  of the sharpened saw..

Both as a rip cut, and..

Seemed to work ok...

Stay tuned....have to get back to work..tomorrow..

Drawer looks good.

Not ready to see leaves like that.....

So...6 hours IN the shop, today....paying the price of that now....bench was cleared off, tool well cleaned out...

Jig pieces will get re-arranged a bit...

That 1/4" plywood has a notched corner, now...pine 1 x 1 has some help holding things in place..

A washer, and a screw...set to just clear the fence on the Stanley 45...

Got the stiles grooved...used the far jig for the smaller stuff, like the wide rails...

And then the two narrow rails..

Rails needed a bit of plane work.   Boards were just skip planed, I had to plane off the "skips"....narrow rails weren't quite as narrow at one end, as the other...Jack plane took care of the tapered end.   Took a Gatorade break.   Came back, wide chisel to "flush" the plugs that are installed....couple hits to knock them down flush.

 

Door #1 had squeak issues, bottom hinge needed "adjusted" a bit.....loosen the screws, adjust the door a bit ( size 11 shoe..) and tighten back up.   Added a strip to the top of the door, like on the drawer.....glue and a clamp, and a caul...let sit the rest of the day.    Tenons needed milled...

Laid them out, used a tenoning jig...on the bandsaw..

Maybe a game of Dominoes, later? 

All the parts for the frame...needs mortises chopped.   Mortise jig is set up..used door #1 to lay out locations...chopped away...

Test fitting as I went....and marking which part went where..or tried to...Got this stile all chopped, laid it beside the other stile..

Used it to transfer marks for the mortises to the other stile...Got those 5 done....then a dry fit...

Took a bit, to get all the parts to line up square...center one was really bad....hammer to adjust a few items...all square, now...used this to size the panels

These were already roughly cut to size....needed squared up,  and cut to final length...the plank behind had "issues" , you  can see one of them here...

Big knot between two panels...knot down on the corner, plus one behind the two panels...Got things cut to about the right length...decided Gatorade Break #3 would be about it for the day...start time was 10:00am, quitting time was 4:00 pm....6 hours.  Took almost 30 photos, too....just skimmed through, for now..

 

Maybe tomorrow, I can get four panels raised, and maybe a glue up?    Picked up a couple boards today, to make the other three fixed shelves. 

May install the last 8 plugs, too?   We'll see..

Stay tuned...

Actually...had just over 7 hours in the shop....was just going to take a few pictures...hour later...came back up from the shop...

No gaposis to the top of the door....plugs were pared off, too....block plane to smooth them out...later..

Blanks for the raised panels...

Hmmm, could be better.....beltsander with the 80 grit belt..then one of these..

Even made a jig, to do the raising with...

End grain gets done first....then rebuild the jig for the edge grain.  Once they are all done, they can go into the frame...

And a glue up....maybe by tomorrow, I can hang the door?.....resting up, today. 

 

Cool...Gonna' be a two door coupe.

2 hours ago, Grandpadave52 said:

Cool...Gonna' be a two door coupe.

A "HOT" rod?

John

Today was SUPPOSED to be a day off from the shop....was even being lazy all day long.   This evening, decided to at least haul the two 1 x 12 x 48" planks to the shop

Each board is about 4 bf....Home depot wanted $8.96 + tax a piece....I was downstairs, to also bring a decent scrap of Ash back upstairs....going to do a sample board with the stain the Boss picked out......a load of clothes had to come out of the dryer, and another load started...multi-tasking?

 

Looked over at the bench..had that one panel just sitting in the jig.....decided to at least test the jig out....right?

Next thing I know..

This happened.   in fact, all four panels had this happen....then the jig got re-made..

And a test drive....about  then, I remembered to turn the fan up to HIGH ( a bit late?)   The usual suspects played a role..

No. 3c, a No. 4c, and a Millers falls No. 14 ( no c...) they also made quite a mess..

Well, maybe after a good night's sleep, I can get those panels done?  

 

I tried this the way Sellers does, with the boards held vertical in a vise....didn't really like it....went with the panels flat on the bench.   No.4c to rough the bevels in, No. 3c to fine tune it.    The Jack was to rough in the side bevel..then the No.3c cleaned things up....trying for that nice "Crisp" corner like Sellers likes..

Forms a nice straight 45 degree line down to the corner.  One side bevel done...7 more to do....then run a rabbet around the inside edges of the panels, to fit into the grooves better...and maybe center the panel into the door's thickness...

Stay tuned...

15 minutes ago, steven newman said:

Next thing I know..

This happened.   in fact, all four panels had this happen....then the jig got re-made..

Boy, I hope you fed those elves well for getting all this done. At least you could leave the fan on for them. 

Well, Grandson bought brunch this morning.....finally got to the shop about 1225 hrs.....came back from the shop about 1540 hrs.....and crampy.... 

Yep..one of those days....plugs have been installed...the final 8..

Will trim them down, tomorrow....big jack planes was a bit too big for doing bevels...tried a different "Jack Plane"..

Shavings?

Got all the bevels done....( have to custom re-fit a few, later)

 

Time for the rebates..redo the jig,,again..

Got a rebate plane set up, to go across the grain..

Even had a way to check for fit..

Got all the end grains done....redo the jig, set up a different plane...

As I didn't feel like messing with the spur on the 78.   Got all the side rebates done..

Then got the frame out of the clamps, and started to assemble.....three of the panels are too wide?   Custom fittted each one, until they all fit

 

Not sure what happened....all four panels WERE the same exact size....anyway....glue and clamps..

Floor slopes a bit, under the right corner....Cleaned up the mess..about the third time today..

Clothes in the dryer were also done...hauled them out of the shop....I'm done for the day....

Let things sit til tomorrow...and see about plugs, hang a door, and shelves....will need help to move this thing around, to where I can work on that end...

Stay tuned...

1 hour ago, steven newman said:

Clothes in the dryer were also done...hauled them out of the shop

That's one of my jobs, too.

2 hours ago, lew said:

4 hours ago, steven newman said:

Clothes in the dryer were also done...hauled them out of the shop

That's one of my jobs, too.

Mine too.

 

4 hours ago, steven newman said:

Even had a way to check for fit..

Glad the "jig" worked. Probably should paint it orange or yellow so it doesn't get misplaced.

4 hours ago, steven newman said:

will need help to move this thing around, to where I can work on that end...

you bet...weighs a tad more than that compressed fake wood knock-off at Big Lots. A lot classier looking too.