A Project for May, 2024

[steven newman]

Looking around for ideas, found this one sitting in the dinning room window sill...

Along with a writing desk...figured IF I change a couple details...like make the drawers 4" deep...and the sides into Frame & Raised Panel...hmmmm..

 

There is a Mystery board in the latest stash..

Is the 1 x 8...Ash..or...White Oak?   Them be Ray Flecks...

 

Have a few defects to work around...

At least in the 1 x 6 shorts...and one end will need trimmed up.

Yep, THAT one..

 

Next, decide which to use..

As either raised panels, or, the 4" deep drawer fronts...either way, both will be 4" wide...have to decide how LONG to cut them...

 

Will need 4 stiles, just have to figure out how TALL this case will be...and then how long to make the rails...

 

Starting tomorrow, when I haul a couple 1 x 6s to the shop...and the "Timer" set at 90 minutes...we'll see how much cussing will be needed..

Stay tuned...

[lew]

Following along!!

[Grandpadave52]

I'm here for the month. So you know, I'll be taking Memorial Day off though as a personal day.

[John Morris]

15 minutes ago, Grandpadave52 said:

I'm here for the month. So you know, I'll be taking Memorial Day off though as a personal day.

Heck, I'm here for a decade or more, I'm game!

[steven newman]

3 planks have been sent to the shop..for now..

Back 2 were from the same 10' long plank..front one was a close match...except for..

This little area..which will be headed for the Fire Pit later..rest of the grain?

Straight grained...

Quarter sawn Ash...

 

Single Brain Cell Sketch Up has put to work at the Drawing Board..

The Plan..as far as I can get, today...

That Plane Iron also made a decent straight edge and square to draw with,,then the hard part..

Doing the Math for a cutting list...just for the 2 sides...will be a lot of 1/2" tenons, and a lot of 1/4" deep grooves...not doing mitered connections between the stiles and rails, this time around...

 

Well, it is a start, at least..stay tuned..

[steven newman]

Regardless of how great a Plan is...it will change right after the 1st Shot..

First Cross cuts, already there be "issues", because of stuff like this..

I managed to get 4 stiles to rough (VERY) length..

But..some of the stuff for the rails wasn't working out..

The 2 beside the Stiles?   1-3/8", instead of 1-1/2"

Split ends?  In order to make this one work...had to cut back a bit...18" was a bit too long, anyway...now 15-3/8" will make use of a couple other planks

10 out of the 14 that I need... cut those 2 long ones, and I had a few more..only need 2 more.

The 2 top and bottom rails were still 2" wide, but were cut down to match the other rails.   Stiles are 2" wide, but need to be trimmed a wee bit..

maybe not quite THAT much...will know more once a do a bit more layout work.

 

Laundry is done, toes are resting up...Pop delivered to the Boss..legs have lost their "get up & go"..

 

Try again tomorrow, eh?

[steven newman]

Last night, tried the shop for an hour (not a good idea) and hauled that short, knot infested plank to the shop..

Yep, that one...and after removing the knotty parts...

Ripped the "remains" into 4 new, Narrow Rails....and replace 2 of the not so nice rails..

The narrow rails meant I couldn't quite use this..

As the fence would be in the way when I'd clamp a rail to the bench....so,  we have ways

This might give you an idea..14 narrow rails, each needing 2 grooves, plus 4 wider rails that need a single groove like these..

To house the raised panels in....used the one "Bad" rail to set the fence and blade on the tablesaw...

 

Things were going pretty good, until the last of the 2" wide rails...

Started flopping around in the cut...

All the way through, stem to stern...

 

 

Will remake another 2" wide rail...without that crack...and cut a few raised panel blanks.  

 

Once the stiles have been trimmed to final length..I can run the grooves in them as well...will leave the #45 set up...

 

Once the rails are ready, I can mill tenons on each end..stay tuned...

[lew]

37 minutes ago, steven newman said:

All the way through, stem to stern

Well that's a kick in the pants

[steven newman]

Rail work:

Cut a replacement for the Split one..Thought about using the 45 to plough the groove...could not keep it centered...cut a new one on the tablesaw...

The Narrow Rails..had a problem...

This stuff..and the wide rails as well...we have ways..

Got out the Cordless Router, set the depth..and..

Cleaned out 32 grooves, altogether...Rails need to all be the exact same length...so..

Pick out the shortest rail..line it up to the saw...gang a bunch onto the miter gauge..

Now they all match...repeat as needed, keeping that one short rail as a pattern..

Reset the saw a little bit..

We now have a tenon machine..because..

A few passes, with the fence as a stop..and..

Man that was a LOT of saw work..no wonder my feet started to cramp up..34 tenons.

 

Still have to cut haunches  on the wide rails..

 

Didn't even try to haul the 1 x 4 to the shop, too tired, right now...maybe tomorrow, eh?

[steven newman]

Hauled these 2 planks to the shop @1000hrs..

Did not figure on having to haul 2 more to the shop ( at least those second 2 were a bit shorter)

 

Not a whole lot of room..

When I need to cross cut these down a bit..and deal with ends like this..

Had marked one of the rails to show how long the Panels needed to be..

Only need 15 more...

Along with a 5' long 1 x 4...still came up 3 short...a decent 1 x 6 was cut up..

Figured I can rip these 3 for width...once I find out WHAT that will be...because..

Hmm...pick out the narrowest end, set the rip fence for that...

Run the straightest of the edges against the fence..

Until I had 16 blanks all about the same size.

 

Change the saw over a bit..Zero Clearance Overlay...tilt the blade to 15 degrees..

Run all 4 edges through...times 16..

 

Then reset the saw to mill a rebate on the back side...

Which left a kerf all the way around...reset one more time..and finish the rebates..

They will need a bit of fine tuning...but

Outside view...that lip will have to go away, though..

16 raised panels...awaiting final fitting up/out...

Quitting time? 1200hrs....

Discovered one other problem.....there is not one cold Guinness in the house!  Will have to correct that ..today..

Stay tuned..Stiles will be next..

 

[lew]

2 hours!!!!  Takes me almost that long just to make a trip up and down the stairs!!

[Larry Buskirk]

18 minutes ago, lew said:

2 hours!!!!  Takes me almost that long just to make a trip up and down the stairs!!

 

Might take me that long just to think about it. 

[Grandpadave52]

I made my breakfast and coffee during that time and watched some Frasier reruns. Oh, and cleaned the cat litter box.

[steven newman]

Well..75 minutes IN the shop, before I had to stop.....bad form to be dripping sweat on the work pieces..

 

Goal was to get the 4 stiles cut for length..and get a couple grooves done...THAT was the goal

Checked the far end...seemed to be square enough...guess I can line up all 4 (hammer assist, of course) Then plop a 2" wide rail down, and mark where the tenon stops..

which is where the top-most raised panel will start..

Then another line where the panel stops..this is for the tenon on the narrow rails..

Have to watch the defects,,when the groove gets made...continue along with the panel and rail..

 

8 panels later..another 2" wide rail is marked out..the "F" is for a 3" foot..which I have a pattern for..

And. anything below the bottom of the foot ( Soles?)

Will get sawn off.   While I only used the 2 kinds of rails and one Raised Panel for the layouts, decided to try to dry fit all the parts..

8 raised panels, and 9 rails...

 

 

Ok..clear the deck, er...Bench top..

Need to set up one Stile to get it's groove thing going..

Other end is in the Leg vise...and under the center of the Stile..

There is a stock rest...as for the "far end"..there is a clamp going across the top of the bench..one end is in the tool well, but, I had to allow space for the Stanley #45's fence to slide through, and have it low enough that  the clamp doesn't hit anything..

Plenty of room...so now?

This thing is just an old, plain candle...after a couple passes, it gets rubbed down into the Groove-to-be...

As it can be a tight fit down in there...about every 3rd pass, add a bit of wax...plane does slide a bit better..

I did use one of the raised panels to check the depth..

Trying for no gaps..had to adjust the depth stop on the 45 twice, to get it correct...

That almost clean area? That was where my feet were...

 

Got 2 Stiles done...was dripping onto the woodwork...( no shop fan, yet), decided to stop, lay out a few of these..

Which is where I need to chop a mortise..

As part of this tenon will be in that mortise. 

 

Scrap Report...

I do have use for that plywood panel...the rest will be heading upstairs to the Fire Pit...

About 2-3 days to get this deep...as soon as I can load it into the Trash can..Fire Pit..

 

Stay tuned

[lew]

Your work flow is amazing

[Gerald]

What has happen to Igor? has he passed? Not having a shop helper is a bummer.

[Grandpadave52]

Wow, getting caught up on this build has got me really motivated to do something. Starting out slow though...just in the initial thinking about it stage now.

[Larry Buskirk]

1 hour ago, Grandpadave52 said:

Wow, getting caught up on this build has got me really motivated to do something. Starting out slow though...just in the initial thinking about it stage now.

 

Right there with you Dave. 

 

 

 

 

[steven newman]

Hauled this out of the shop, this evening..

Topped it off with the shavings from yesterday...and..

"Fire in the hole!"

 

I also got Stile #3 set up and ready for tomorrow..

And THAT was it for Shop time, today..

[steven newman]

Worked in the shop..on a Monday?So....issues were bound to shop up

Issue with the cutter in the Stanley #45,,,was shaped like a  )   I could center the cutter to make a cut..but, the pin to adjust the depth would not be in the notch in the cutter...replaced that with a straight cutter of the same size...Plane worked a lot better..

Then #3 Stile decided to join in the fun...

Was trying to avoid hitting that spot,,,it split off anyway..finish the rest of the groove, then..

Glue and 5 c clamps to repair it..then sit this over with the first 2 stiles...

And, let them sit a day, or 2...was able to groove #4 stile without any issues,,

And decided to sweep up all the crunchy "Noodles"..

Hand a profile for the bandsaw to cut..

So.....

Case now has a foot to stand on...

Cleaned the bench a bit...and got out the Mortise Jig ( and..I get to sit down, finally!)

The Visegrips clamp a part in place..

And..I can chop 2 mortises before I have to move the stile...Need a couple tools..

Plus a couple others to pry out the chips this chisel leaves behind..

first 2 mortises are done, and a dry fit with a raised panel between the 2 rails..

Top and bottom wide rails have a Haunched Tenon..the rest have a simple tenon..haunched?

This is called a Haunched Tenon...the short section fills the groove, the LONG section goes into a mortise...

Also means I have to leave the area with the red "X" intact..another dry fit,,

Last 2 mortises are done.  Things were getting crampy, decided this was enough for a Monday..

Down to the last mortise...out of 9 total,,get about halfway down the stile, rotate the stile, and finish the last 4..

 

Stay tuned..goal is to have one side all fitted and in the clamps by Wednesday night...