Jump to content

A Paul Sellers Curved Sided Box build


steven newman

Recommended Posts

Took a while, and made a mess on the floor..:rolleyes:

289774746_Thurs.Journalmessyfloor.JPG.7a987adef4caabc6228d9b92691db26d.JPG

But, the 4 sides of the box are now flat, and the ends squared up...had to joint one edge a hair..

495407148_ThursJournalplaned.JPG.f4c3c23470c11040d0cfef438bde5f38.JPG

Then a bit of lay out, once I figured out which was the inside face..:WonderScratch:

850018774_Thurs.Journalsidesandends.JPG.640276513dad8d8e86a801f9ecbdd851.JPG

And marked things up..Then looked over the Plan..and went and watch Paul Sellers for a bit...to see how he worked on this...:ChinScratch:

582735850_Thurs.JournalTodaystasks.JPG.3f0f62bc5296f5613d52482d76100dd1.JPG

fancy stuff?    Step #1 is to mill a recess on the ends of the End pieces...

 

Sellers used a hand saw, and a chisel...first I need to lay things out..:OldManSmiley:

1348562751_Thurs.Journalchecklayout.JPG.c0c2c97adc456118fdaaa2c5b83ea728.JPG

Was only supposed to be 3/16" deep, too....by the time I get things about done..:ChinScratch:

124196569_Thurs.Journal2done.JPG.ab3b0844973144f85c5c489a75e3f655.JPG

I might be closer to 1/4" deep...then do the other end piece to match. :OldManSmiley: 

 

Next..lay out a few dovetails..:ChinScratch:

1757781672_Thurs.Journalsawcuts.JPG.866d8f4cb0a57df57335160ac0563c09.JPG

Yes, that Baseline in NOT straight across....has a slight curve to it.   Chisels to remove the waste..

1026363718_Thurs.Journalchiseled.JPG.5e42875bda9706f7cda57587e39f6c8d.JPG

Note to self:  ALWAYS have a piece under these dovetails..otherwise there will be a break-out on the inside..:ArguingSmileys:

Used the coping saw to clean things up..about like a rasp...then use this to trace out the matching parts..

1783990436_Thurs.Journaltranfermarkings.JPG.0c3ffd3e78878eba942ca828067548c9.JPG

Then some saw work...:SaluteandRun:

421719562_Thurs.Journalcheckingthecuts.JPG.cc54605e74db2a7a483236a7d1151b06.JPG

Where the curve goes along the end of the long side...that too has to be chopped out.   I was sawing on the waste side, again...can always pare a bit off if things are too tight..:OldManSmiley:

Dry fit, once the chisels were done..I thought..:Tapping:

1225658079_Thurs.Journalfirstdryfit.JPG.e08fe0b0653423ac230ba9e62a1e6250.JPG

This being about the second or third try...has a gap at the bottom....but once the sides are planed into the curved profile...gap will go away...:OldManSmiley:

 

back was telling me that I was DONE for the day..right between the shoulder blades. :BangingHead:  Sitting with a heating pad, at the moment..there is always tomorrow.

 

Will see how many corners I get done, then.  2hours total time in the shop, today....might have got a wee bit done..:ChinScratch:

Stay tuned...:cowboy:

Link to comment
Share on other sites

Up-date:  all 4 corners are now fitted...:TwoThumbsUp:

1831191478_Sat.Journallastcornerdone.JPG.905d477441a574a4e0ceea787b5b5fa1.JPG

Was finally starting to get the hang of doing tails first....ran out of corners to do....hate when that happens...also, I needed the last 2 boards resawn...

938957043_WorkingLatetimetoflip.JPG.3b85327d37e6a6bbade3fe038b959d32.JPG

Cardio Workout, late Saturday night...:Cheer:

371622412_WorkingLateflattening.JPG.d48892d14050d0977301944a192a3be5.JPG

And, they both needed planed flat...then another plane needed to be set up...:ChinScratch:

671762027_WorkingLatefirstgroove.JPG.1b9e92c70299781983b4e3860cdc1b43.JPG

Because I have 16 grooves to mill...some like this..

40546561_Sundayworkendgrain.JPG.01091f17e427059f43f3728e04034def.JPG

Some like this...and..

10935107_Sundayworkgaugelines.JPG.f27276a843d87d443c03ddd89bece20b.JPG

Gauge line was marked, to prevent any blow-outs to the outside..:OldManSmiley:

 

Test fits along the way..:ChinScratch:

221221834_Sundayworktestfit.JPG.928085c4c076b412c38ee02679416f61.JPG

The ends also needed grooves...but they were too short for the 45..so..:TwoThumbsUp:

1862795901_Sundayworkgroovingtheends.JPG.b81b52e1e01b043caa3120796d3019e2.JPG

A little safer, this way....and can fine tune for fit...enough that a partial dry fit could be done..:ChinScratch:

1942439146_Sundayworkbigdryfit.JPG.8cc7de2f736e6df1e883a1fc60d91836.JPG

Can't do a full dry fit...would be no way to get it back apart...BTW..

920449734_Sundayworkbottompanel.JPG.7a43a16f4375b3751f868d7d981bc662.JPG

The reason the panels do not reach all the way to the edges?    Because, I will be planing a round profile to the sides, and they will come back to the edges of the lid and bottom panels..:OldManSmiley:

 

Back said I was done..:OldManSmiley:.swept the Krunchies up..:SaluteandRun:

1314638278_SundayworkKrunchies.JPG.c1d92c2d431bc3d328712033ce4796e7.JPG

Busy day?   :JawDrop: Detail look at the inside of the box..:ChinScratch:

1454563201_Sundayworkinsidedetails.JPG.56aa0894b50427ceaaef7f4fb7a83a6d.JPG

Lots of interlocking joints...have 2 stopped dados to do...THEN I can start to plane things round...:TwoThumbsUp:

Stay tuned..:cowboy:

Link to comment
Share on other sites

Got bored,yesterday...and despite it being a Monday....decided to try my "luck" at chopping stopped dados....once I took the dry fit apart....that WAS the plan.

 

Started out ok, something simple, like this..

Boston.JPG.21cbadb19a278f7d4f3a719fc67725af.JPG

Addition to the shop.  other side says Boston.  As the little battery powered one wasn't getting a sharp enough point..

 

While tapping the dry fit apart...."Crack!"...:ArguingSmileys:  Not a good sound...time for clamps and glue...and cussing...1291302560_workedMondayrepaired.JPG.806e08455b77ea323bfde05c66b8341d.JPG

Grrrr...Problem?....:WonderScratch:

1977622225_workedMondayThePlanpage2.JPG.64417bcd76cf0bee37bb05a47bd0ff22.JPG

Involved the groove in the panels...panels are not glued in place, they have to float...turned out the groove was too tight..spent about half of the 90 minute shop time fixing THAT :BangingHead:

 

Looked around for a scrap to use as a divider, so I could size the dados ...the one I did find was...too long, too wide, needed planed flat...THEN I could lay out a dado....just one..as the other one will have to wait a day...then instead of just one chisel to do the chopping out..:OldManSmiley:

2088389781_workedMondaydadotools.JPG.0630be364570cd4237ec68315147b44b.JPG

Needed these 3...Middle one did most of the chopping, the other 2 tried their hand at cleaning the dado out.   Used a clamp on the vise's jaw to hold things still...had to add that screw to help out.    Finally was able to move the part to the vise...as the clamp was in the way of the router...plane..:PullingHair:

922983075_workedMondaystoppeddado.JPG.78a1614bc2900d2c2eac417df3660937.JPG

Messy...we have ways..:ph34r:

1504004157_workedMondayrouterplane.JPG.5a793f39c35cc602dfac2353ac14535c.JPG

Then try the divider for fit...:SaluteandRun:

791860900_workedMondayremovalabledivider.JPG.50bfd412b778f41dbee8b7c4d2266785.JPG

Right above the divider is a cut line...as the lid will get sawn off after the box has been glued up..design calls for the divider to be removable if needed, so the dados will be a tad loose...:ChinScratch:

 

Got to about here, called it a night...waiting on glue to cure.:BlackCloud:

 

Later today, since it is NOW Tuesday and Murphy has been evicted, that second dado might get done?    Then start in with the hand planes, and round all 4 sides in to shape.....might be more cussing involved?:ChinScratch:

Link to comment
Share on other sites

Roh-kay...clamps on that repair came off, today....need to get the second dado..done   Do a bit of lay out..:WonderScratch:

1510360195_Tues.Chopslayout.JPG.f5a2e7a8fff72b987ac1dc9a5725aec0.JPG

Then clamp #2 in pace, so it doesn't run away..

750535527_Tues.Chopsclampeddown.JPG.0628e14db775555f2a0d3fe9244c949e.JPG

The a couple chisels, to remove most of the waste..

711588658_Tues.Chopschiselwork.JPG.24c3c63d7f37f2050ecbc4ef5b359be5.JPG

The a bit of clean up, with the router...plane..

1133921419_Tues.Chopscleanedup.JPG.2b9b4e3f15c5cf6ba045d3b5dd6f6597.JPG

That will do nicely. :TwoThumbsUp:  Set the combo square to 3/16"...and draw a stop line along the edges...coming down from the outside face..:OldManSmiley:

804704346_Tues.RoundsStopline.JPG.1b44e3f688e1cc8e38fab311519ff82f.JPG

Goal here is to plane down to that line, in a gentle curve from the center...

1035190830_Tues.Roundsalmostdone.JPG.2d2d7338e7fdbbdea512279aee9b129a.JPG

Still needs a little more..got both of the end parts done...almost..

1245808201_Tues.Roundssofar...JPG.3aae8624766bb5139d9f8637e87cde1a.JPG

This was just from those 2 ends.:JawDrop:..set them aside..

 

Next, the same thing gets done to the long sides....can't use the vise, so a jig was cobbled up..:ChinScratch:1943439378_Tues.Roundsjiggedup.JPG.43f6f601de1706e17d37e8b42a465403.JPG

Same stop line.   Can only do one edge at a time with this set up...:OldManSmiley:

1782380274_Tues.Roundsafewmore.JPG.c8b56bcc0486bb6d489a6a34059f4dd7.JPG

got almost done with the first edge...when Uncle Charles showed up:BlackCloud:

 

Had to quit for the day..while I could still climb the steps to get back upstairs..

Stay tuned..:cowboy:

Link to comment
Share on other sites

The result of planing the 2 long sides last night ( Laundry Detail..) to get them to shape..

1514716984_Wed.Follies.lastnightsmess.JPG.a9fa7b44f761939cf3a8e21cadad5b85.JPG

And, this pile was even bigger than the one for the 2 ends...so, this morning, did a dry fit of the 4 sides..

912422138_Wed.FolliesNeedssawn.JPG.528b5f44dc1e2850b483f2c939463630.JPG

Hmmm...

65706818_Wed.Folliesneedstrimmed.JPG.ecce1793458d61853cfc0d64059f7c55.JPG

Needs a bit of a trim?...

2134264325_Wed.FolliesFinesaw.JPG.9ee669523150164cb060d6fbc0d2da2f.JPG

Then sand the saw cuts smooth.   Next step was to level the top and bottom edges..

1147297382_Wed.FolliesLevelingup.JPG.0eae07f6652b252c34e9f3abc3d41b2c.JPG

had a couple high spots to level out..until..

858648829_Wed.Folliesaboutready.JPG.78f85fa620208472b39d023c8ec77ac0.JPG

Close enough, because next....things getting glued up...even had to make curved cauls...:JawDrop:

1121650337_Wed.Folliesforestofclamps.JPG.7bb18f14d72920017ad8e3d3a41bde47.JPG

So..now I let this sit a day, before I clean things up, plug a few holes...and then saw the lid off..then clean up after that.   and maybe some hinges?

 

I'm about 1/2 way through Episode #3 ....

 

Stay tuned...:cowboy:

 

BTW: Already working on a plan, to use up most of that Ash Stash...but, yall have to wait to find out what that will be...

 

Link to comment
Share on other sites

And, here we go..clamps came off today...

668119610_Thurs.sawwork.cleaningup.JPG.a5cc49ee5239716eb7c3c43892cf08a4.JPG

Cleaned up the long sides, first.  Yes, that "gap" is supposed to be there...makes the lids appear to be floating.  Leveled and sanded smooth everything on the long sides, filled any gaps in the dovetails...then, onto the ends..:ChinScratch:

345382781_Thurs.sawworktrimsaw.JPG.e431f03c896610e36ef3aa6ade54d946.JPG

 

They all had holes and crack to fix...square holes got plugged, chisel to custom fit each plug to the holes..4 on each each.. Had a crack to fill.  Finally..:Praise:

1937584747_Thurs.sawworkallcleanedup.JPG.e3172bbb91b25e60c6ecc1fd21edb130.JPG

Sand and plane and sand some more...lid panel edges get a slight round over.

 

Time to draw a line..:ChinScratch:

1059719671_Thurs.sawworkallthewayaround.JPG.5270b8a0b22cd38b2da2e39bf75a3bcc.JPG

All the way around, centered on that one pin....Then stand the box up, at an angle..

1890731967_Thurs.sawworkcornersfirst.JPG.d474af4de90ee73389fab474b115ad09.JPG

Saw this corner, then the other corner on this end of the box...

589259129_Thurs.sawworkendsnext.JPG.8ea275189e55e979c5cb5c1862b64ad2.JPG

connect the 2 corners on this end,,,repeat for the other end of the box.....Breaktime!:SaluteandRun::SaluteandRun::SaluteandRun:

1516837494_Thurs.sawworksbreaktime.JPG.470c8277a9c3436cb0cc2f3facd1453b.JPG

Along with a "P-Call"..remembered to turn the shop fan ON when I got back to the shop..

Next..lay the box on a side..

1327180743_Thurs.sawworkthenfinishthelongsides.JPG.859748bedec7e91daf473599e91cd8d4.JPG

And connect the 2 ends..until you feel the saw is through this side...add a shim to this kerf ( like another saw blade) flip the box over, and saw again..

results?:ChinScratch:

124608920_Thurs.sawworkroughcut.JPG.1b2d507769de95211e7791c0b465b3ef.JPG

A bit rough...9ppi rip saws tend to be that way.   close the lid, for now..:SaluteandRun:

510859854_Thurs.sawworkdone.JPG.ab42d1bb2eff1061453aedc964be7bd8.JPG

Tomorrow, I can plane things level, for a closer joint line..thinking this just might be the front of this box...:WonderScratch:

 

Hinges, and some sort of feet?  Stay tuned..:cowboy:

 

Link to comment
Share on other sites

Hinge install, today....didn't want to press my luck too much...Got the lid to lay flat on the box, no gaps...only to lay out for 2 hinges..:ChinScratch:777835636_HingeInstalllaidout.JPG.535a4e8f3113dff078a6bcdc2d55d142.JPG

And, had a gap.   Flattened the hinges a bit, with a "Lineman's Pair of Pliers" :ArguingSmileys:

 

Worked on the lid first...lay out and chop..:OldManSmiley:

1810959935_HingeInstallfirstchops.JPG.7ca61513b5230085e45078e1263c4af7.JPG

A few simple tools were needed..:rolleyes:

686418220_HingeInstalltoolkit.JPG.e5fefc801a3be661cdd0589e36b2495e.JPG

That IS a Phillips screwdriver. :JawDrop: still needed to wax the threads..but..:ChinScratch:

582949230_HingeInstall1sthinge.JPG.7bd1df35fd5d83783b37bcc5d0963da8.JPG

This one was a bit too square...the rest were curved a little bit after this one.  When both hinges were on the lid, use that to lay out for the box..:OldManSmiley:

336475925_HingeInstalllaidoutbox.JPG.fccad2911b0ee89c54309e9f7d1da782.JPG

 

While trying to keep the 2 halves lined up....about like herding cats..:BangingHead:..did not take too much digging, and soon made a "connection":ChinScratch:

1576655665_HingeInstalltheywork.JPG.b65365320f729309b1f7661f88a43ef4.JPG

Then close the lid...:SaluteandRun:

1342639095_HingeInstallcheckalignments.JPG.20dd85f9f3c6e871db7a0f5980639c0e.JPG

And check to see how things line up...had to squeeze the hinge side a tad...:ChinScratch:

1072540877_HingeInstalldone.JPG.2023ff03621a9ed79d73265d12d9b2e5.JPG

More of a shadow line..we have ways..:ph34r:

864800319_HingeInstallcleanupalingment.JPG.3a91aab611b2ac0b60179458d31445e1.JPG

Scrape all four sides with the No.80 scraper...until the shadow lines go away...:OldManSmiley:

52800050_HingeInstallwhatcutline.JPG.5d9cc7c1508eb59a5a666b15d4f38ecb.JPG

What lines?   :WonderScratch:

 

Items left to do? 1) curve a finger lift, 2) add the feet, and 3) add some sort of finish....all the while rehabbing a plane, to get it ready to ship out on the 19th of this Month....:JawDrop:

 

Stay tuned..:cowboy:

Link to comment
Share on other sites

Camera issues yesterday...went to install the chip into the camera...PING!  Off to parts unknown...With almost a 100 photos I still needed to save to a file.

 

After 2+ hours of looking everywhere along it's "Flight path"..nada....had to go out and buy a new chip...grrrrrr:ArguingSmileys:

 

Found a scroll blade for the bandsaw the other day...AFTER I had bought a new blade.....and put it to good use...

1774102084_KeepsakeBoxdetails.JPG.69743d6165102d6c1d77276147fe4888.JPG

Made 8 parts, to build 4 feet....Small Mitre Box to miter the corners...and a bit of glue.

Let them sit over night...them sand the 4 smooth and flat...more glue to fix them in place..

285667391_KeepsakeBoxallthefeet.JPG.97e14c01b23bdcd90b109ea3b8128875.JPG

And let this sit a day....still haven't found that missing camera chip.....

 

Need a couple more things to do , today....film at 2300hrs

Stay tuned..

Link to comment
Share on other sites

Razor saw to start...chisel to rough things out...Dremel sanding drum to smooth it out..:TwoThumbsUp:

.1723464917_KeepsakeBoxthumbnail.JPG.8058dda3855e798603658f5dd914f3d0.JPG

Then dig up a couple screws, drill a couple pilot holes for them...cut a black chain for length..:ChinScratch:

1780598586_KeepsakeBoxchainedup.JPG.d2f483487cf5951b341dd9428d253d78.JPG

Was tired of the lid flopping around.:BangingHead:..then the can of Witch's Brew Stain..while the lid was open..

2129956919_Stainedinside.JPG.a391a3d106dcdfc36d3c31b86b2a9f75.JPG

Then shut the lid, and do the outsides of the box..

1448524027_Stainedfrontview.JPG.ba375fa6cad0063f2d36d06ba744dcba.JPG

The bottom was down first..then the rest...

2122040766_Stainedendview.JPG.dc2968bdda1d61aaff7494557209f8eb.JPG

Ends were done, and the back..

223101164_Stainedhingeside.JPG.db0a578f4d547c9779248593b2f810a4.JPG

With the lid being the last to be stained..

212732438_Stainedliview.JPG.7a1ff099a076887051c0a756fe44ba71.JPG

Will let this sit a day or 2...then a coat (or 2?) of Clear Gloss Poly...and a buffing out...:Tapping:

 

Almost done...:TwoThumbsUp:

 

Single Brain Cell Sketch Up is already hard at work.:OldManSmiley:..something a tad bit bigger is a-coming.   24bft of quarter sawn Ash has a job to do...:ChinScratch:

 

Stay tuned...:cowboy:

Link to comment
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Restore formatting

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

×
×
  • Create New...