Popular Post steven newman Posted September 28, 2022 Popular Post Report Share Posted September 28, 2022 Lumber Run the other day...one of the boards was a1 x 6 x 6'5" plank of Maple....the other Maple was even longer...decided to see about a Project for October.. Sides are curved.. Fancy stuff.. However...sides needed to be 9/16" thick, not the 3/4" that the Maple was...lid panels are at 5/8" thick...need to do some resaw, it looks like. Hauled that plank to the shop, once the bench had been cleaned off.. IF I can hit me head on the way down the steps...imagine what this was like...had a few spots to work around, too.. Usual knotty stuff.. Even a "split end" Went to the cutting list...and started to lay out what needed to be cross cut.. Board was a wee bit too long to be cutting on the tablesaw, so.. we have ways..Disston D-100, just need a cut line to follow.. And work my way along until.. Left-overs? Will provide a 9/16" x 4" x 6" piece for the end of the box, to go with these.. Includes a "spare" side...but, these are all too thick...need to set up a kerf cutter, again.. Best face against the fence, run all 4 edges through...fence set at just over 9/16" for some cuts. and 5/8" for two others..blade does not reach high enough.. But, this will...just follow that kerf.. Until... "POP"...Repeat for the rest of the sides.. Will work on the other 3 parts later...will need to plane these smooth.. Before any joinery can start in.. Stay tuned.. forty_caliber, FrederickH, 4DThinker and 5 others 8 Quote Link to comment Share on other sites More sharing options...
Grandpadave52 Posted September 29, 2022 Report Share Posted September 29, 2022 18 hours ago, steven newman said: Stay tuned.. Sign me up! Cal and steven newman 1 1 Quote Link to comment Share on other sites More sharing options...
steven newman Posted September 29, 2022 Author Report Share Posted September 29, 2022 Took a while, and made a mess on the floor.. But, the 4 sides of the box are now flat, and the ends squared up...had to joint one edge a hair.. Then a bit of lay out, once I figured out which was the inside face.. 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... 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.. Was only supposed to be 3/16" deep, too....by the time I get things about done.. I might be closer to 1/4" deep...then do the other end piece to match. Next..lay out a few dovetails.. Yes, that Baseline in NOT straight across....has a slight curve to it. Chisels to remove the waste.. Note to self: ALWAYS have a piece under these dovetails..otherwise there will be a break-out on the inside.. Used the coping saw to clean things up..about like a rasp...then use this to trace out the matching parts.. Then some saw work... 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.. Dry fit, once the chisels were done..I thought.. 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... back was telling me that I was DONE for the day..right between the shoulder blades. 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.. Stay tuned... Cal, Harry Brink and Grandpadave52 3 Quote Link to comment Share on other sites More sharing options...
steven newman Posted October 2, 2022 Author Report Share Posted October 2, 2022 Up-date: all 4 corners are now fitted... 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... Cardio Workout, late Saturday night... And, they both needed planed flat...then another plane needed to be set up... Because I have 16 grooves to mill...some like this.. Some like this...and.. Gauge line was marked, to prevent any blow-outs to the outside.. Test fits along the way.. The ends also needed grooves...but they were too short for the 45..so.. A little safer, this way....and can fine tune for fit...enough that a partial dry fit could be done.. Can't do a full dry fit...would be no way to get it back apart...BTW.. 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.. Back said I was done...swept the Krunchies up.. Busy day? Detail look at the inside of the box.. Lots of interlocking joints...have 2 stopped dados to do...THEN I can start to plane things round... Stay tuned.. Harry Brink, Cal, Grandpadave52 and 1 other 4 Quote Link to comment Share on other sites More sharing options...
Popular Post Grandpadave52 Posted October 3, 2022 Popular Post Report Share Posted October 3, 2022 Looking good to this point which BTW is ONLY October 2nd. Cal, steven newman, Gerald and 2 others 4 1 Quote Link to comment Share on other sites More sharing options...
steven newman Posted October 3, 2022 Author Report Share Posted October 3, 2022 hey, I still have almost 24bft of quarter sawn Ash to build with...and about 5 bft of Spalted Maple left... Artie, Grandpadave52, Gene Howe and 1 other 1 3 Quote Link to comment Share on other sites More sharing options...
steven newman Posted October 4, 2022 Author Report Share Posted October 4, 2022 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.. 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!"... Not a good sound...time for clamps and glue...and cussing... Grrrr...Problem?.... 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 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.. 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.. Messy...we have ways.. Then try the divider for fit... 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... Got to about here, called it a night...waiting on glue to cure. 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? Harry Brink, Cal, Artie and 1 other 4 Quote Link to comment Share on other sites More sharing options...
steven newman Posted October 4, 2022 Author Report Share Posted October 4, 2022 Roh-kay...clamps on that repair came off, today....need to get the second dado..done Do a bit of lay out.. Then clamp #2 in pace, so it doesn't run away.. The a couple chisels, to remove most of the waste.. The a bit of clean up, with the router...plane.. That will do nicely. Set the combo square to 3/16"...and draw a stop line along the edges...coming down from the outside face.. Goal here is to plane down to that line, in a gentle curve from the center... Still needs a little more..got both of the end parts done...almost.. This was just from those 2 ends...set them aside.. Next, the same thing gets done to the long sides....can't use the vise, so a jig was cobbled up.. Same stop line. Can only do one edge at a time with this set up... got almost done with the first edge...when Uncle Charles showed up Had to quit for the day..while I could still climb the steps to get back upstairs.. Stay tuned.. Gerald, Grandpadave52, Cal and 1 other 4 Quote Link to comment Share on other sites More sharing options...
Grandpadave52 Posted October 5, 2022 Report Share Posted October 5, 2022 2 hours ago, steven newman said: Had to quit for the day.. You best get cracking on this Project for October...times a'wastin'...already the 4th...only 27 days left Cal, Artie, Gene Howe and 1 other 1 3 Quote Link to comment Share on other sites More sharing options...
steven newman Posted October 5, 2022 Author Report Share Posted October 5, 2022 The result of planing the 2 long sides last night ( Laundry Detail..) to get them to shape.. And, this pile was even bigger than the one for the 2 ends...so, this morning, did a dry fit of the 4 sides.. Hmmm... Needs a bit of a trim?... Then sand the saw cuts smooth. Next step was to level the top and bottom edges.. had a couple high spots to level out..until.. Close enough, because next....things getting glued up...even had to make curved cauls... 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... 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... Grandpadave52, Gerald and Cal 3 Quote Link to comment Share on other sites More sharing options...
Grandpadave52 Posted October 6, 2022 Report Share Posted October 6, 2022 Really beginning to take shape; no pun intended. Interesting design moving away from a conventional type box. Cal and steven newman 1 1 Quote Link to comment Share on other sites More sharing options...
steven newman Posted October 6, 2022 Author Report Share Posted October 6, 2022 And, here we go..clamps came off today... 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.. 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.. Sand and plane and sand some more...lid panel edges get a slight round over. Time to draw a line.. All the way around, centered on that one pin....Then stand the box up, at an angle.. Saw this corner, then the other corner on this end of the box... connect the 2 corners on this end,,,repeat for the other end of the box.....Breaktime! 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.. 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? A bit rough...9ppi rip saws tend to be that way. close the lid, for now.. Tomorrow, I can plane things level, for a closer joint line..thinking this just might be the front of this box... Hinges, and some sort of feet? Stay tuned.. Cal and Gerald 2 Quote Link to comment Share on other sites More sharing options...
Grandpadave52 Posted October 7, 2022 Report Share Posted October 7, 2022 2 hours ago, steven newman said: Hinges, and some sort of feet? Stay tuned Whew...cutting it close for a Project for October. First week is about to come to a close. BTW, really cool and unique. Cal and steven newman 1 1 Quote Link to comment Share on other sites More sharing options...
BillyJack Posted October 7, 2022 Report Share Posted October 7, 2022 Looking good… Cal, steven newman and Grandpadave52 2 1 Quote Link to comment Share on other sites More sharing options...
steven newman Posted October 8, 2022 Author Report Share Posted October 8, 2022 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.. And, had a gap. Flattened the hinges a bit, with a "Lineman's Pair of Pliers" Worked on the lid first...lay out and chop.. A few simple tools were needed.. That IS a Phillips screwdriver. still needed to wax the threads..but.. 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.. While trying to keep the 2 halves lined up....about like herding cats....did not take too much digging, and soon made a "connection" Then close the lid... And check to see how things line up...had to squeeze the hinge side a tad... More of a shadow line..we have ways.. Scrape all four sides with the No.80 scraper...until the shadow lines go away... What lines? 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.... Stay tuned.. Gerald and Cal 2 Quote Link to comment Share on other sites More sharing options...
Gene Howe Posted October 8, 2022 Report Share Posted October 8, 2022 Great job, Bandit. steven newman and Cal 1 1 Quote Link to comment Share on other sites More sharing options...
Cal Posted October 8, 2022 Report Share Posted October 8, 2022 That looks real good Steven. What will it be used for? steven newman 1 Quote Link to comment Share on other sites More sharing options...
Gerald Posted October 8, 2022 Report Share Posted October 8, 2022 Looking like a done job already. Surely only a couple more days to finish and then what is on tap for the rest of the month? steven newman and Cal 1 1 Quote Link to comment Share on other sites More sharing options...
steven newman Posted October 9, 2022 Author Report Share Posted October 9, 2022 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 Found a scroll blade for the bandsaw the other day...AFTER I had bought a new blade.....and put it to good use... 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.. 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.. Cal 1 Quote Link to comment Share on other sites More sharing options...
steven newman Posted October 9, 2022 Author Report Share Posted October 9, 2022 Razor saw to start...chisel to rough things out...Dremel sanding drum to smooth it out.. . Then dig up a couple screws, drill a couple pilot holes for them...cut a black chain for length.. Was tired of the lid flopping around...then the can of Witch's Brew Stain..while the lid was open.. Then shut the lid, and do the outsides of the box.. The bottom was down first..then the rest... Ends were done, and the back.. With the lid being the last to be stained.. Will let this sit a day or 2...then a coat (or 2?) of Clear Gloss Poly...and a buffing out... Almost done... Single Brain Cell Sketch Up is already hard at work...something a tad bit bigger is a-coming. 24bft of quarter sawn Ash has a job to do... Stay tuned... Grandpadave52 and Cal 2 Quote Link to comment Share on other sites More sharing options...
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