Careful what you ask for....

Just when I thought I had all the mortises DONE...dry fit show things way way off..

Ooops..Instead of 23-1/4" between the top and both rail  it was dang near 30"...also, about those slats...14 need to be a hair shorter..to match the shortest of the bunch...Once those are all the same...I'll re-lay out the top rail mortises (2)...Might even trim the height down a bit?

 

Router bit:  Old one was LOOSE in the Collet!  Basically a FUBAR bit...tossed it into the trash...This one..

Carbide, with a bearing..doesn't burn...Along with the top of the Crest rail and the 2 frames...have these 9 to round over...

Once I get done with those ends...

 

BTW...we now have fresh DNA on the Project..

2 drips...seems a splinter was sticking up from a mortise I was working on....poke the end of me right index finger...ouch!

 

Decided that was quite enough, for today....although, while I was busy taking these photos...tried to bandsaw the armrest pattern....and promptly broke the blade.   New one is about $9 at Lowes....

 

Been THAT kind of a week...

Stay tuned..

New Bandsaw  Blade..

There was too much scrap in the shop....this is about half of it...

The other half?

Along with about every empty cardboard box it the house...

 

Finger is hurting, everything else wants to cramp up...didn't even install the new blade.    Blade was also the LAST one they had in stock at Lowes...1/4" x 80".....They did have a1/2" wide blade...never had much luck with the wider one...usually way too much set...

Calling it a day...

Norm would be proud of the progress!

Working way too hard, for a Friday..

Issues needed fixed.

.

All marked out to match the shortest slat...

This is with the other end set flush with each other...fixed that issue, and tried a dry fit...

Something don't quite add up...why is #15 slat still on the bench?

Yet all the mortises are filled?

 

Ok...Used both rails and 1 slat..to lay out where the NEW  mortises will be for the Crest rail...and set up to do some chopping..

Then set the frame back on the bench...Mortise chisel came from Okinawa a few years ago

Was a bit rough getting this clamped down to the bench...

Finally was able to dry fit the Crest rail ..

Then brought the bottom rail and one slat over to this thing..

As for the "patch" in the old Mortise?

Something like is called a "Dutchman"  ...they can disappear like this, or be another colour wood and be made to stand out...

Have since laid out and chopped the matching mortise, and cleaned up the other "Dutchman".   

 

Tried a dry fit of both rails and all 14 slats..and a clamp or 2.....not going very well...walked away before I started throwing things...

 

Going to NEED a few extra hands to glue the seat's back together...

 

Stay tuned...

Test fits...

Looks can fool a person..

As to HOW to get 28 tenons into 28 mortises, with glue...and NOT have things fall apart?

And..this is barely sitting ON top of the tablesaw, too boot...

I don't think 2 hands will be enough for this glue up....hmmm...

Am sure a LOT of cussing will be involved...

Stay tuned...

OK....Plan for today?    Try to glue and clamp that thing together...cussing WILL be involved...

 

Both frames need a round-over done on all edges....

 

Front Rail needs 1 mortise chopped, for a Center Seat support ( going with just  a middle one)...And try to saw out the seat support to fit.  

 

We'll see how this goes, today....

Looking awesome Bandit.

 

Are you sure you can get this out of the Dungeon once it's fully assembled? Hate to see you have to move the tablesaw out on the porch so you can sit on the bench in the basement.

Getting slow in me Dotage...took over 30 minutes, from start to finish....beginning with hauling 2 planks to the shop to sit on the top of the tablesaw....to this...

All glued up.  Pulled diagonals a few times...until both read 56-3/8"  Had to re-locate one clamp...

As it was pulling the bottom rail up...removed and moved UNDER the assembly.

 

Used a BIG flat-bladed screwdriver to 'coax" the last 4 slats into their new homes...

Cussing?   Paris Island Drill Instructor Level.....enough to make even R. Lee Ermy blush.....

 

Right now, I am soaked...someone forgot to turn on the shop fan

Think I will just sit a-spell, and cool back down....can't do a whole lot more IN the shop, today, anyway..

 

Stay tuned  

Today...was a Dry Fit Day...

Wanted to see IF I had enough clamps...and to lay-out and cut out a seat support for right in the center

That plank is just over 5' long, BTW.   Might be able to get 2 slats for the seat out of it

 

This is the only clamp I have that is long enough (barely)  the only other one wasn't even close?

"Missed it by THAT much, Chief.." So, Wednesday being PayDay..I go out and buy 2 black iron pipes...both 6' long, one @ 1/2" the other @ 3/4"...

 

Seat support ?

Gets screwed to the bottom of the back rail in a notch..

While in the front rail, it goes into a notch at the top of the rail..

Also with a bit of glue and a counter sunk screw.

 

Frames needed a router run...

Once I had cleared off the bench..

Router was having "issues"

Bit wanted to slip a bit...kept going deeper....figured as long I will be sanding this smooth to get rid of the ridges...might as well pin the joints, as well...

 

Fancy joints =Fancy saw.   Once things were smoothed down..even the feet were rounded over...

A Plastic nailed in pad will go here, later.  Soon had both frames done...

 

Next trip to the shop?   Slats for the seat..and a pair of arm rests...

 

Clamps? will need to be at least 50" between clamp faces....gluing this thing up will be something else...

And, this ain't the New Yankee Workshop...

 

Stay tuned..

 

 

Whew!!!

Good progress but I am disappointed  in your inventiveness. Create a bench hook the proper length and those new pipes will not be needed, especially at the price pipe has probably gone up to.

 

or here are two other ways without buying that much pipe:

 

Edited May 14, 20233 yr by Gerald

Amazing work!!! Don't forget a connector between the parts sitting on the ground so it doesn't sink in to dirt. Might give some strength to the legs too. Just a thought!!

Will be sitting on a concrete Patio, inside a gazebo...

Just could not stay away from the shop, today...Monday or no Monday...so..

Lay out and bandsaw one arm rest...then trace around it...

Then bandsaw the send one out...these have to be mirror images of each other...

Angled notch is to match the tilt back of the back...beltsander to even things out.. (1/4" bandsaw blade is lousy at following any line)

And, by the time I get to the big curve..

I also had an idea where to chop a hole at....

Whichever of these 2 work the best...will soon get put to work...

As these will go all the way through....may have to dig out my corner chisel, too?

 

Got maybe 1/4" deep, decided to double check locations...

Once the tenon comes all the way through, it will get a wedge...back at the back will be a counter sunk screw...maybe a plug to cover...

Stay tuned..

Had to dig out this ...

To clean up a square hole...

So..I can lay out the one for the other arm rest...

Test fit of the first one.

.

Stay tuned...

Making great progress. Gonna be a relaxing seat come Memorial Day.

Now have both arm rests fitted...

Along with 5 slats for the seat...there is also a 6th slat...but, it is a bit shorter...as it is the front of the seat, and sits on top of the front rail..

This is what you would see, if you were under the bench...Mid seat support sitting in a mortise in the Front Rail...both are laying on top of the front of the seat slat

 

Arm rests and the front seat slat have also been rounded over..

Both faces done...

IF an edge on the front slat will be seen, it got a round-over...was safer to use the router table, rather than a hand held router...

Still..I made a mess of the floor, again...

Trying for a Thursday glue-up...anyone want to stop by and help out?

 

Stay tuned..

 

14 hours ago, steven newman said:

Trying for a Thursday glue-up...anyone want to stop by and help out?

Just a thought, will it fit up the basement stairs once assembled....

Yep...

Replacement iron pipe bought..will install after Lunch....Time to spread some glue?

 

 

Film @ 2300 hrs...names changed to protect the guilty, of course. Cussing maybe involved.....Guinness Draught Stout is IN the fridge...when I get done...

 

Stay tuned..