Pirate Chest Build - Part 4 done (lots of pics)

[Mike Allen1010]

Earlier parts of this build are described in previous, separate posts.

This is the last part of the build; making the sliding trays that go inside the chest and carving a shell for the front of the chest.

Here are the runners screwed to the inside of the chest that the trays will slide on.


https://farm5.staticflickr.com/4580/38981713312_74f899a1ae_z.jpg (https://flic.kr/p/22oFtgo)1 (https://flic.kr/p/22oFtgo) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr


Sawing the tray components to size at the bench hook and shooting the ends. I don’t always take the time to use the shooting board for all furniture parts, but these will be dovetailed so nice clean, square ends makes it easier for DT layout.

https://farm5.staticflickr.com/4730/38131134585_86947d1b5b_z.jpg (https://flic.kr/p/216w2QV)2 (https://flic.kr/p/216w2QV) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr

https://farm5.staticflickr.com/4521/39017286771_f7a18ac8d4_z.jpg (https://flic.kr/p/22rPN1T)3 (https://flic.kr/p/22rPN1T) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr

https://farm5.staticflickr.com/4535/39017286801_e5e012474c_z.jpg (https://flic.kr/p/22rPN2p)4 (https://flic.kr/p/22rPN2p) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr


Here are the components for 3 rectangular trays: mahogany, cherry and some cool flame figured Maple.

https://farm5.staticflickr.com/4679/25147071128_d14848744f_z.jpg (https://flic.kr/p/Ejaj8S)6 (https://flic.kr/p/Ejaj8S) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr


Apparently the LOML thanks the shop is a perfect place for flower arrangements – I’m not so sure.

https://farm5.staticflickr.com/4692/39017283801_56f2e57692_z.jpg (https://flic.kr/p/22rPM8F)7 (https://flic.kr/p/22rPM8F) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr

I’m a tails first guy – I like to use a tiny rabbit to help align the boards when describing the pins from the tails (sometimes called the 140 trick after the Stanley model fenced rabbit plane). I also like to pare inside corners of the tails to help the joint go together that glue up.

https://farm5.staticflickr.com/4633/38981712702_a9fc5698ab_z.jpg (https://flic.kr/p/22oFt5S)8 (https://flic.kr/p/22oFt5S) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr

[Mike Allen1010]

Here’s my set up for planing joints flush after assembly – in my twin screw, face vice with a supporting board. Every time I try and shortcut this step by not using a backing board I always gets spelching/chip out, so for me it’s worth the time to clamp up the backing board.

https://farm5.staticflickr.com/4571/38301726524_c7a5df2fc9_z.jpg (https://flic.kr/p/21mAmTf)10 (https://flic.kr/p/21mAmTf) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr


Here are the completed sliding trays. Finish is same as the rest of the chest; Watco oil/varnish followed by shellac and paste wax.

https://farm5.staticflickr.com/4544/24153769567_f5d9391311_z.jpg (https://flic.kr/p/CNoobT)11 (https://flic.kr/p/CNoobT) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr


https://farm5.staticflickr.com/4526/38131130295_bd4be5a2eb_z.jpg (https://flic.kr/p/216w1yX)11 (2) (https://flic.kr/p/216w1yX) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr

https://farm5.staticflickr.com/4637/24153768477_4602c74007_z.jpg (https://flic.kr/p/CNonS6)13 (https://flic.kr/p/CNonS6) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr


https://farm5.staticflickr.com/4516/38131127915_22acd08dcb_z.jpg (https://flic.kr/p/216vZRV)14 (https://flic.kr/p/216vZRV) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr



Here are the carved shells (described in a previous post), that serve as the handles for the chest installed.

https://farm5.staticflickr.com/4638/38131126475_20989ce25b_z.jpg (https://flic.kr/p/216vZr6)16 (https://flic.kr/p/216vZr6) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr


Here’s some pictures of the different style carved shell that will go on the front of the chest;

Tracing the design onto the carving blank with graphite paper and sawing out the rough shape.

https://farm5.staticflickr.com/4529/27240242829_91a1faa672_z.jpg (https://flic.kr/p/Hv8na8)17 (https://flic.kr/p/Hv8na8) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr



https://farm5.staticflickr.com/4586/25147062468_08ed26c4d7_z.jpg (https://flic.kr/p/Ejagyy)18 (https://flic.kr/p/Ejagyy) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr


Layout for shaping the upper surface – it’s slopes from the high spot where dot/circle is down to the limit line 1/8" from the bottom of the blank. I do most of the shaping with rasps, files and sandpaper.

https://farm5.staticflickr.com/4522/38131126065_441fbf2dfe_z.jpg (https://flic.kr/p/216vZj2)19 (https://flic.kr/p/216vZj2) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr

With shaping completed I redraw the layout lines and incise the lines that divide the convex and concave shape lobes. V- Tool establishes the line on the outer perimeter and a sharp knife for the narrower lines at the back of the shell.

https://farm5.staticflickr.com/4516/38301721474_8a8b518ee4_z.jpg (https://flic.kr/p/21mAkob)20 (https://flic.kr/p/21mAkob) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr

https://farm5.staticflickr.com/4642/38131125415_d85f005d0f_z.jpg (https://flic.kr/p/216vZ7P)21 (https://flic.kr/p/216vZ7P) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr


With the lobes divided, next step is shaping the upper surface of the convex lobes with a 3 – 5 sweep gouge held upside down.

https://farm5.staticflickr.com/4532/38981712272_bf77431f08_z.jpg (https://flic.kr/p/22oFsXs)22 (https://flic.kr/p/22oFsXs) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr

Here’s a picture with every other, convex shape lobes completed, before starting on the shaping for the concave lobes.

https://farm5.staticflickr.com/4551/27240241519_1b790e5014_z.jpg (https://flic.kr/p/Hv8mLx)23 (https://flic.kr/p/Hv8mLx) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr

Here’s the completed shell; for me the concave lobes are fairly straightforward and easy to shape. Getting the convex lobes a little more delicate. Finally, the toughest part IMHO is keeping the narrow dividing lines at the back of the shell, which are closely spaced together, from chipping out.

https://farm5.staticflickr.com/4539/27240237329_da6295f4c9_z.jpg (https://flic.kr/p/Hv8kwi)24 (https://flic.kr/p/Hv8kwi) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr

I’m not very good picture of the finished shell screwed to the front of the chest.

https://farm5.staticflickr.com/4533/38131120725_8f756e10cc_z.jpg (https://flic.kr/p/216vXHX)25 (https://flic.kr/p/216vXHX) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr

[Mike Allen1010]

And some also not very good pictures of the completed chest.

https://farm5.staticflickr.com/4736/38131119835_e365b988c8.jpg (https://flic.kr/p/216vXsB)28 (2) (https://flic.kr/p/216vXsB) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr


https://farm5.staticflickr.com/4636/25147063628_d5cf49cc05_z.jpg (https://flic.kr/p/EjagUy)29 (https://flic.kr/p/EjagUy) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr


https://farm5.staticflickr.com/4573/38131117735_f1d64560aa_z.jpg (https://flic.kr/p/216vWQp)31 (https://flic.kr/p/216vWQp) by Mike Allen (https://www.flickr.com/photos/157847244@N02/), on Flickr

This is the 3rd time I built this design in different sizes and I’m not sure I would do it again – the Coopered, curved top is time-consuming to glue up and shape/surface because you can’t hold it securely on the benchtop without jigs. Also getting the dovetail top and bottom rails that surround the chest lined up so the simple but joint joining the vertical Stiles of the slides to the front/back all coordinated so everything goes together so that it fits, is also difficult for me to visualize in my mind’s eye and therefore problematic. A simpler, more traditional sort of chest construction is for me a lot easier and more fun to build.

Thanks for looking,

All the best, Mike

[Bill McNiel]

Holy expletive, Mike! Very nicely done; design, materials, finish, craftsmanship and attention to detail. Impressive piece without being overbearing.
BTW-Great build presentation.

Thanks for sharing.

[Travis Porter]

Gorgeous! Love all the details in the chest and the details you included with your posts.

[Mel Fulks]

Looks more like a retirement gift for an admiral who saved Western civilization ! But the design might get pirated.

[Ron Bontz]

Now that's just plain cool. Beautiful work as always, Mike.

[Brian Holcombe]

Beautifully done Mike!

[Christopher Charles]

Fabulous work Mike! (And the flowers were a nice touch!)

How did you capture the bottoms of the trays? Were they grooved or simply rabbeted? I'm making some small trays for a jewelry box and will almost certainly just rabbet them.

Best,
Chris

[ken hatch]

Mike,
Beautiful!
ken

[Chet R Parks]

Mike,
Your having way to much fun. The coopered top, carvings, inlays and design are truly inspirational. Thanks for taking the time to share your build. BTW the flower arrangements look great and your tenon saw in the second picture did not go unnoticed, beautiful saw. Hope you and your neighbors are staying safe from the fires.
Chet

[Jeff Ranck]

Absolutely amazing. Your skill always impresses. What a wonderful present.

[Malcolm Schweizer]

Amazing work! I love that miter saw, by the way. Also the shells are well done, and I will tell you in advance I am going to pirate that shell handle idea.

Overall, I give this two thumbs... arrrr... make that one thumb and one hook up!

[Mark Stutz]

Absolutely stunning work, Mike. I would say I would pirate it as well, but truth be told, there are just too many firsts- coopered top, carvings, marquetry, string inlay- for me to do in just one project. Maybe someday!

[Mike Allen1010]

Fabulous work Mike! (And the flowers were a nice touch!)

How did you capture the bottoms of the trays? Were they grooved or simply rabbeted? I'm making some small trays for a jewelry box and will almost certainly just rabbet them.

Best,
Chris
__________________________________________________ __________________________________________________ ________________

Hi Chris,


Because the trays are relatively shallow I think around 3 inches tall, I wanted to keep the bottom to maintain as much of the vertical tray space as possible. I used a LV rabbit plane (one of my favorite tools) to plow quarter-inch rabbits on the bottom of all 4 sides. Unfortunately this results in a gap when the rabbit isn't completely covered by the half pin. I say the off cuts from the dovetails to glue in plugs to cover the gaps. Frankly, I'm sure there's a better way to do this that doesn't require a post glue up fix. Unfortunately despite all the dovetail boxes I've built over the years – I have no idea how to do that. I welcome any advice or suggestions?


Because these trays are relatively narrow (see I think probably 4 inches wide), I'm not as worried about the expansion of the solid wood bottom is I probably should be.


A lot of the trays/drawers I make are relatively small, which feeds my likely delusion that expansion of solid wood bottom should be catastrophic. Frankly, these issues are one of the reasons why building larger drawers, such as those for a full size dresser/chest are IMHO The a lot easier.


Best, Mike

[Mike Allen1010]

QUOTE=Chet R Parks;2754115]Mike,
Your having way to much fun. The coopered top, carvings, inlays and design are truly inspirational. Thanks for taking the time to share your build. BTW the flower arrangements look great and your tenon saw in the second picture did not go unnoticed, beautiful saw. Hope you and your neighbors are staying safe from the fires.
Chet[/QUOTE]

__________________________________________________ __________________________________________________ ____


Chet,


Thanks for your far too kind comments! My wife Sherrie is very "artistic" – she has some kind of weird knack I completely don't understand, for color/shapes/ textures. She's really good at photography, floral design and interior design; probably a big reason why for the first 10 years of our marriage most of my woodworking projects "somehow" never made it into the house, despite my best intentions.


Those early furniture projects always somehow seem to be gifted to friends/family who "you know it doesn't really work for our house, but so-and-so (fill in the blank) I think would really appreciate it". A large percentage of my "shop furniture" today are projects I thought of as "quality furniture" when I built them back in the day, but in reality have ended up in the shop as places to store finishing supplies, camping equipment, etc. In all honesty, I have to admit she's always been right about my projects. Even though I've occasionally submitted projects to juried shows etc. (with no results speak of), it's 100% true her approval to put one of my furniture projects in the house is the highest compliment I could hope for


The shop made backs saw in the picture you mentioned has a "Mexican Kingwood" tote. Probably one of the hardest woods I've ever worked. Although this saw turned out okay, I'm not planning to use that wood again. I'm at an age/physical condition where selecting "hand tool friendly" woods for my projects is the prime directive.


As a native Southern Californian, we've always had fire seasons - not surprising given we live in arid/desert like environment. Even though this past winter was one of the wettest on record, the brush always dries out (it was 76° in San Diego today), and I'm amazed how quickly these wildfires spring up.


I would think in this information age people couldn't be "surprised" by a fire in their area, but it happens all the time here. Couple years ago we were evacuated. Helicopters dropped fire retardant right in our house and 3 houses on our street were burned. I guess is as one of the reasons my boys are always nagging me to add some kind of "news alert" to my phone so we don't get caught by surprise. I guess my old school approach of just looking for the smoke on the horizon is not a very effective strategy.


I hope you've been enjoying a nice fall season up your way. Always great to hear from you.


Best, Mike

[Mike Allen1010]

Amazing work! I love that miter saw, by the way. Also the shells are well done, and I will tell you in advance I am going to pirate that shell handle idea.

Overall, I give this two thumbs... arrrr... make that one thumb and one hook up!

__________________________________________________ ______________________


Malcolm,


Thanks your kind, piratical comments (anytime you can work "arrrrh make that one thumb and one hook up" into a conversation you're definitely channeling Capt. Morgan!).


BTW, I really enjoyed your earlier pictures of you and an adorable young lady in pirate gear – nice! I always enjoy your posts and hope your recovery from the hurricane is progressing.


All the best, Mike

[Mike Allen1010]

Looks more like a retirement gift for an admiral who saved Western civilization ! But the design might get pirated.

__________________________________________________ __________________________________________________ _______________
Mel, I see what you're doing here – "design might get pirated..." – well played my friend, well played !:)


As to admirals who could be said to have saved Western civilization I nominate Chester W. Nimitz, Commander-In-Chief US Pacific Fleet 1941 – 1945 who led the successful battles Coral Sea, Midway, and the Island hopping campaign through the Solomons Islands cross Pacific towards Japan and ultimately signed for the United States during the Japanese surrender board US Missouri on December 2, 1945.


I'm no historian, but as a Navy veteran, I'd say he surely deserves better than this simple chest. Sorry if this is too political for SMC.


All the best, Mike

[Mike Allen1010]

Thanks everyone for your gracious comments. You're far too kind. I'm so grateful for the SMC community – I've learned far more than I've ever contributed. I am glad this post is of interest to my fellow Neanders.


Brian, Ron, Ken – I'm a big fan of your work and and avid reader of your websites. I'm still waiting for the 3 of you to work together to create my dream TV channel covering: Mexican food, flying, beautiful hand tools and Asian woodworking techniques. Come on boys I know you can do it!:D


Cheers, Mike

[steven c newman]

Chest looks GREAT! Sooooo, what is the next project?;)