Something to build for June...

[steven c newman]

All the rehabs are done...cleared off the bench, for now..Road Trip to spend a bit of Mad Money....
479676
3/4" x 5-3/4"x 5' mostly....and a weird looking 4 footer...9 boards total. Long boards are from 4 planks that were 117" long...not going to fit in the back of my Chevy....cut somewhere near the middle, one end was 59" long, the other was a bit shorter. Total cost for the 9 boards? $17.00

He talked me out of buying more Ash, as he wanted to get rid of the Maple, instead..
479678
This might be interesting..a bit of Spalt going on?

Let it sit there for a bit....there IS a spot that needs something done....
479679
Not the best look, is it? So....How about a Hobbit sized Tool Chest....?

Area I have to work with, and stay out of the way of my kneecap going by: 32" for a length...I can go up to 17" high, COUNTING a lid...and I can only come out from the wall 16".....and, NO, that floor jack WILL be heading outside to the shed....

Figure a Frame & Panel Chest will work...21 bft of Maple. May have to go back and buy a couple more planks, for the lid. Hauled 2 planks to the shop...idea was to glue up a long panel, then cut it into smaller panels for the front and back of the chest....
479683
Yep, I would pick the 2 planks that were 59" long...and one has a live edge, to boot. Matched up the grain along the non-live ( dead?) edge with the other plank's grain/spalt....edges needed jointed before any glue up..so..
479684
Takes a BIG board to make a Stanley No. 8c look like a jack plane...Maple Flavoured shavings, anyone?
479686
So..once the edges matched up...then the glue, cauls and clamps arrived...
479687
Which about shut down the shop..almost...had one other item ...
479688
The Dungeon Creek...usually runs right where I am standing....

waiting on glue to cure, and a floor to dry.....stay tuned.:D

[steven c newman]

Clamps came off, today...spent one hour IN the shop....BOTH knees are acting up, now.
479803
That one edge looked close to straight (it wasn't) decided to joint that edge to give me something to do layouts from...so..
479807
Then the ends needed squared off, too....
479808
Once both ends were squared off, according to the jointed edge...
479809
I could start to lay out for 4 panels....length of the plank was 59" strong.....divide by 4....=...14-3/4"

Made a few cuts, until..
479810
Panel #4 was left on the "Saw Bench"...
479811

Was I done with these 4 panels? Not quite...but...the non-jointed edge was tapered....and had bark....figured the max I could use was 10-3/4" width...set that on the Tablesaw/Rip fence....buzzed all 4 through...so all are now the same size. and that was about it for today....according to my knees.....


maybe tomorrow, I can get a start on the Stiles & Rails....figure out what size panels I'll need on the ends....And MAYBE start milling a few parts?

Stay tuned...

[steven c newman]

1/2 an hour in the shop yesterday....2 planks milled down into "parts"....
479874
all 8 stiles roughed out, rails for the front and back frames, and the 2 dividers.....Didn't have the time to bring a third plank to the shop....
479875
These will be the rails for one of the ends...And that was all the lumber I had IN the shop. Still have 4 more planks upstairs to bring to the shop....

made a nice pile of sawdust...
479876


Stay tuned...

[steven c newman]

There are now 2 panels sitting in clamps....both 11" long...for the 2 ends of the chest. Let these sit a day or 2


Next step would be to turn these panels into Raised Panels....and mill a few grooves for the panels to call home.

Might just use hand planes for both?

[steven c newman]

Thinking about doing the grooves first, then see how well the panels will fit into the frames....BEFORE the panel raising can begin.:confused:

As for the end panels...
479941
and
479942
Need these out of the way....so the Stanley 45 can be set up and used.....

Stay tuned..:D

[steven c newman]

Decided the edges needed a bit of prep work, before the grooves are done.....needed a jig to hold things steady..
.479966
One end of a rail fits into a notch...then locked in place...
479967
One on each side, one at the rear pivots to tighten the jig....
479968
Edge prep...was still rough sawn, Stanley No.8c...
479969
Does a decent enough job....then on to the Stanley No.45..
479970
Combo square set at 1/4" deep....just as a check for any high spots..
479971
So...how many passes does it take, to go 1/4" deep?
479972
Maple Flavoured Noodles, anyone?

One done...and LOT to do....

Stay tuned..

[Richard Hutchings]

Love watching you work. Staying tuned.

[steven c newman]

Was almost too hot in the shop, yesterday..but..
480000
The other 3 long rails now have their grooves done...

Reset the jig, as the stiles are quite a bit shorter..
480001
Even had to use a smaller plane to plane an edge....
480002
A front stile...
480003
have to figure out that "foot print". Once ALL the grooves are done, I can cut the tenons on the rails (1/2" ) chop the mortises, dry fit the sides and ends, and the size and raise 6 panels.....all panels were made a bit over-sized...better than being under-sized.

May need a bucket...
480004
These are starting to overflow the bench..
480005

have 7 more stiles to groove, and the 2 dividers.....plus make and groove 4 rails for the ends.....

This MIGHT take a while

Stay tuned...

[steven c newman]

All of these grooves are to house the raised panels in...
480021
Stiles and rails for the front and back of the chest..takes almost 30 passes per groove...get about 10, wax the groove, and go again...
480022
Spent one hour IN the shop, today....4 stiles for the ends of the chest...and 2 dividers for the middle of the front and back..About 8 grooves, plus changing the jig...plus jointing a few edges..
480023
Yes, I fit the size of plane to the size of the work...Stanley No. 60-1/2 seemed to be about right...

Had to stop for the day...need to clear this space off..
480024
As I need to mill the rails for the ends of the chest....
480025
Kind of rough, at the moment....still making a mess of the place..
480026
About as many ON the floor, too...softer than standing on concrete?

Stay tuned

[steven c newman]

Last four 1/4" x 1/4" grooves are done...as I managed to rip, cross cut and joint the 4 rails for the end frames..
480062

Set up some frame parts, to see how well the Raised Panel blanks will fit..
480063
They were about 1/4" TOO LONG...go back, and cut that off of each panel...and make sure the panels are square..
480064


Changed the Stanley #45 from a groove plane to a Tongue plane....after I had sharpened the cutter..
480065
The "Finicky" part was getting the fence set just right....but..
480066
1 done, 3 to go..3/16" cutter.

Stay tuned..:D

[steven c newman]

1 hour today, before the toes started to cramp up....got the other 3 tongues milled...
480104
Issue was the board edge was wider that the #6 tongue cutter.....3/4" wide cutter..vs a 13/16" wide edge...tongue was indeed centered...needed that block plane to peel off the ribbon left on the edges..

Switched to the 3/16" groove cutter...matches the tongue..
480105
Removed the sliding stock...for the narrow cutter.
480106
When the left hand wasn't operating the camera, it had to hold onto that front knob, to help balance the plane. I also had to re-arrange the jig quite a bit.....no longer on an edge...but doing the inside faces of the stiles....
480107
Have to keep these sorted out...test fit?
480108
This is the corner joint/glue joint....so that either "face" will look like the same 3" width..
480109

Then laid out some curves for the bandsaw to knaw its way through..
480110
Again, just a dry fit...have too much else needs done.

About this point, all the toes started to cramp up...:mad:

Stay tuned...:D

[steven c newman]

Spent a 1/2 hour in the shop, this evening....mainly laying out some more curves...
480174Trying
to keep track of which stile goes where..
480175
First 2 pairs...made things a little easier for the last 2..
480176

Cleared of the tablesaw..and gave the 2 dividers their 1/2" long tenons...
480177
They will sit in a 1/4" deep mortise, in the bottom of the groove....as soon as I find the exact center point of the long rails. These were the "easy" tenons...from now on, we be doing Haunched Tenons...Still need to set up and chop a few mortises. THEN start raising panels...

Shakers set their panels with the bevel to the insides of the chests.....I prefer to show the bevels off....


Stay tuned

[steven c newman]

Tenon work, this evening....
480200
Long rails...and..
480201
The short rails...and here it gets interesting....have to reset the tablesaw just a bit...
480202
Mainly where the fence is relocated to....

Cut now is to make a notch...
480203
Takes one pass..
480202
Plus a sideways pull to clean it up...

16 Rail tenons have been done....Can now set up to chop the 20 mortises needed...counting the 4 for the dividers...
480204
Should make for a LONG day.....will have to reset the Mortise jig, and install it on the bench..next time I am in the shop...

Stay tuned..

[steven c newman]

Reset the Mortise jig for the narrower stock...and replaced one bad jaw in the jig...then installed the jig right on top of the bench leg....NO bounce being allowed..
480264
Slide a stile part-way into the jig, do a quick layout..
480265
Then slide the stile back into the jig, clamp it in place, and start to chop..
480266
A few more trips in the mortise to be...
480267
Had a couple "crumbs" to shake out, otherwise wasn't too bad...
480268
And THAT is why I used the haunched tenon....
480269

"NEXT!"...1 done, only 19 more to do....

Stay tuned :D

[steven c newman]

Hmmm...update:
480377
4 mortises done...
480378
And now have 8 done...
480379
These 2 make 10 mortises done....we are half way there....

Trying to keep track of which part goes where...
480380
And, once the dividers have been fixed, the last 4 (out of 20) will be installing those dividers...centered in the long frames....

Spent 1 hour, on a Monday no less, and got 6 mortises chopped and dry fitted....getting slow in me dotage?

Stay tuned....( went and picked up three more Spalted Maple planks, today...1 x 6 x 10'....cost me $10..)

[steven c newman]

Goal this morning, was to get the last of the mortises chopped...
480432
And get the 2 end frames to where I could try a full dry fit...
480433
Which left just 4 mortises to do...once the dividers were trimmed a bit..
480434
Then chop a mortise in the center of each of the long rails..
480435
And do a glue up..
480436
Or 2..
480437
Extra clamp was because one end was wider (1") than the other...pull it down to equalize things.

And, that was it for most of these tools...
480438
Needed to clean all of this mess off...
480439
Because the next task was to set up to raise 6 panels....most of which will need flattened...
Stay tuned..:D

[steven c newman]

Raised panels? Well..
480440
I have these 6 panels to do...and most will need to be flattened first..
480441
Then a jig set up to hold the panels while I bevel the end grain ends first..
480442
And get out a few tools...
480443
One combo square to set how far down I need to go, the other to set how far back from that edge to go...the Millers Falls No. 9 will do the bevel work


3 hours of shoptime, this morning...I think that will about do for one day?

Stay tuned..:D

[steven c newman]

While I WAS going to attempt all those bevels by hand...
480522
And the rebates...
480523
plus flatten each panel....after about the second bevel....on just the first panel...decided to stop and rethink....because...6 panels = 24 bevels + 24 rebates+ flatten12 panel faces + fine tune each for fit with a block plane......and reset that jig too many times.

Luckily, The Dungeon Woodshop is a Hybrid Shop. So, instead of 6 days of working on 6 panels....I spent 4 hours yesterday ( and the body is paying the price of the "overtime") using the tablesaw to rough out the remaining 22 bevels, and 14 of the rebates...still have the remaining 8 rebates to do...
480524

I still needed to flatten each panel with a plane, then plane all the bevels smooth and clean...rebates were just a single saw cut on the tablesaw, followed by a Stanley #45....jig was reset to allow for the longer panels...
480525
Was able to do a few dry fits...
480528
Found one of the bevels was a tad too fat...will fix that next trip to the shop.
480529

Had a "Gulley-washer" roll through last night...means the Dungeon Creek has risen...may just take today off...rest things up....let things dry out, too...

What you'll see on the inside of the chest..
480530

Next time...rebate the end panels and get them fitted to the frames....fix that fat bevel....maybe try for a glue up this weekend?

Tablesaw to do bevels: Tilt the blade 10 degrees. Set the rip fence to match the existing beveled panel's bevel location...once each panel has been flattened, run each each through with the panel standing vertical..take back to the jig, finish each bevel with both a #4 and a #60-1/2 plane...

Rebate: Blade back to 90 degrees after the last bevel is done....blade is then checked for 90 degrees, before I lower it to 1/4" above the table's top. Fence is moved to 1/4" from the outside of the saw blade...panels are then ran through on the flat, only...End grain waste removed with a chisel....long grain waste removed with the Stanley #45...Check the fit into the rail's grooves, adjust by planing the bevel.

4 hours on a Wednesday? No wonder it is called "Hump Day"....sweep the shop, trudge SLOWLY back upstairs....call it a day.

Stay tuned..

[Richard Hutchings]

I've never raised panels before but thought about it a lot :-) Seems like this method doesn't leave much room for a good fit.

[steven c newman]

Remember way back when...when Norm Abram built a "Shaker Blanket Chest" season #1? He used this same style of beveled panels, except...the bevels were faced to the inside of the chest....

Have been building chests ever since then....before Norm came along, I was just using 1/4" plywood.

I do use a different system at the corners of the chests I build....that Tongue & Groove joint is a very nice glue joint for the corners. Needs no other fasteners...no need for counter bored screw holes to be plugged...
Plus, IF you match the grain just right...the joint just blends away.

Took the day off from the shop...hope nobody minds.....

Back at it tomorrow? We'll see....was a LONG, ROUGH day, yesterday. No money for the yard sales this weekend....guess I could just work in the shop?

[steven c newman]

2 hour time limit, as no "overtime" is allowed on Fridays...first off...had to fix the reason for 2 splits....rebates had not been taken deep enough...we have ways..
480585
Then glue the splits back together..might as well glue the whole assembly while I'm at it..
480586
And promptly ran out of clamps long enough to glue up the other long side assembly...will just have to wait..

Tablesaw was now cleaned off...had a few cuts to make..
480587
Reset the jig to hold these end panels, so I can pop the waste of the end grain ends..
480588
Wide chisel. And, since the router plane is still set to the correct depth...ran it along to level things out....then flip the board over...
480589
Plane to fine tune the fit..and the bevel....rotate and repeat...all the end grain ends done...

Reset the jig just a bit, and start on the long grain rebates...can't just pop the waste off, though...
480590
Then clean up with the router plane..
480591
Again, just like the end grain ends...flip over, fine tune the fit and bevels...repeat...dry fit..
480592
Set this aside, repeat for the other end assembly...

BRB, stay tuned..

[steven c newman]

Inside view?
480593
Trying to get the panel centered...
Dry fit #2?
480594
while Dry Fit #1 is over on the tablesaw, getting clamps preset..
480595
May just notch the tongue, so the clamp's pads have a better place to sit, we'll see..
Bench was getting a bit filled up...(name that tool?)
480596
And the floor needed swept...
480597

And the "timer" had rung...time to stop for today..

Stay tuned...

[steven c newman]

Well, late last night..cut 4 notches, and glued up an end Frame & Panel..
480656
Details.
480657
Just big enough to house the clamp's pads....let this sit overnight...

This morning. ...cut 4 more notches, removed the clamps from the first glue up...
480658
And glued up the other Frame 7 Panel end....and set it aside....note: all the tools that were on the bench have been put away, for now...need the space..
480659
Same with the tablesaw...
480660
All of this had to go....the first long side glue up was to be placed back on the tablesaw...after the saw was rotated to the left.... clamps were removed, side panel was set over on the top of the bench....and the second long side was then glued up..
480661
And now both of this morning's glue ups are sitting here.

Long side over on the bench? Glue joints cleaned up...then a dry fit...
480662
With the other cleaned up panel.....no glue yet.....BTW, do you see any notches showing up?
480663
Neither did I..

Waiting on glue to dry, after 1 hour of shop time, this morning...

Stay tuned:D

[steven c newman]

Other End came out of the clamps, this morning..and was cleaned up, and dry fitted...
480734
As was the other long side...and it was flipped over, ready for the glue up
480735
So..bead of glue along all the tongues...assemble all 4 sides, and clamp up..
480736
Diagonal pipe clamp to pull things into square...let this sit a day or 2...
480737
And...now that the bench has been cleaned off, again..
480738
I can set this old grinder up...we have work to do...
480739
1/2 way done..
480740
Still have these bits to do...waiting on the Clothes Dryer to get done...yep, I also have Laundry Detail, today...

Stay tuned...

[John Kananis]

Thanks for sharing your progress, Steven.

[steven c newman]

Hmmm, quick update....glue up happened..
480933
Once the other 2 sides were out of the clamps, that is. Bead of glue on the 4 tongues...3 clamps on each end.....plus a diagonal one, to pull things into square...was about 1/8" out..

Bad Thunderstorms last night...Dungeon Creek rose.....floor is still too wet to work in the shop....let things sit another day. I did remove those clamps...and that was about it, for today...

You'll have that, on the bigger jobs.....

[steven c newman]

1/4" Luann Plywood panel has been bought..2'x4' = $15....A NEW saw blade for the tablesaw =$30...And some hinges....-10% discount. Too bleeding hot for doing anything IN the shop...

Will see how this evening turns out...


Trees and powerlines are down all over Logan County, OH....bad storm the other night..85mph winds...and, what the wind didn't get, all that lightning did...

[steven c newman]

Floor is starting to dry out, a bit..
480989
The Dungeon Creek. clamps are off, turned the case to where I need to work on it..
480990
In doing so, I blocked access to the 4 larger Mitre Boxes....we have ways..
480991
Mitered the ends of the 2 long cleats...and glued them in place...
480992
Just glue...no screws needed....then fit the end cleats...
480993
Used a couple cauls, as I didn't want a marks from the clamps..no pads...grrrr..other end?
480994
These clamps did have pads...

Clamps sticking out in all directions, did not want to get stabbed by one....flipped the case over, and turned it a bit..
480995
So the bars on those clamps can't reach out and touch someone ( ME!)

Plywood has been bought, needs cut to size and glued in place...I did pick up a new blade for the tablesaw, today..
480998
As the 3 yr old DeWalt is getting a bit dull.....same size, same teeth...same price....also picked up some better sized hinges

Stay tuned..:D

[steven c newman]

Alrighty snuck in a single 1/2 hour BEFORE the Boss wanted to "Go to the Store"....

All them clamps and the 2 cauls are taken off....What I could get to with the case still on the tablesaw, mainly the glue joints for the cleats...sanded with 80 grit, then a block plane leveled things up....then moved the case over to the bench...sit in on a dry block of wood...lock it in place with the bench vise...worked on the glue joints where the ends meet the front/back sides...removed any dried glue, leveled the joints with both a #62 and the No.9 smooth plane....then sanded everything else...

While that was happening.....old tablesaw blade was removed, new blade installed....cleaned under the insert, straightened out a slight bend...Once the case was done being worked over on both ends, it went back onto the tablesaw...for now.

Maybe later this evening..I can sneak back to the shop, and see about cutting and installing the plywood panel....we'll see...Film @ 2300 hrs...I hope...

Stay tuned...(BTW...that Stanley No. 80 was also put to work...)

[steven c newman]

Laundry Detail...so...old saw blade?
481060
No saw blade put to work..
481061
Cut for length, then the rip fence to rip for width....then a test fit...(3 tries)
481064

Plane a bit, test, plane a bit more, test...trim the end a bit...finally.

Bead of glue was laid down onto those cleats.....then the panel was laid down into the glue..
481070
And "tacked down" into the glue with a few (14) screws....floor still a bit damp, so..
481071

Thinking this just might be the "Front" of the chest? As for those cleaned up ends..
481072
trying to level the glue joints...mainly at the corner "posts"

Stay tuned...:D

[steven c newman]

Well....I said 4 planks to the shop...one had a bit too much wane/barky edge....3 seemed to be about right...
481103
Width wise, at least....needed to cut them for rough length...tablesaw was busy, so..
481104
Mark a cut line or two...clamp to the end of the bench..
481105
Get the saw moving....
481106
Will need to joint a few edges. As for that saw?
481107

One of the reasons I like these older saws.....and, once you hold one, you will find it hard to sit the saw back down....that handle was made to FIT a workman's hand....by someone who knew how it should be made.


Went out Rust Hunting the rest of the morning....and picked out a can of stain for this chest..."Colonial Maple"...we'll see how it tests out, later.

That was my Cardio Workout for today....

[steven c newman]

Jointer work...after a bit of rust hunting..
481172
Decided this will be the center plank of the lid's panel....so, both edges will need jointed, for a glue joint...
481173
1st edge...Stanley No.8c at work on Maple...checked the edge with a steel straight edge...
481174
3' Tinner's Ruler....and check for a square edge...
481175
Also ran an "educated thumb" along, checking for rough spots...flip the plank over..
481176
2nd edge...plane was set a bit too shallow....started to take a bigger bite, less strokes...
481177
Not exactly "Moxxon TP"...
481180
Same as before, checking with the square and straightedge...then test to see IF one of the other planks will sit still...
481186
Will start on the 2nd plank, later....1 done, 2 to go.....then see about a "collar" to house this raised panel...and build a lid...trying to decide on the corner joint to use for the collar...will have a groove to hide...

Stay tuned:D

[steven c newman]

Rest of the planks have been jointed, and sorted for best matches...,then glued into a panel
481222
Will let this sit a day, or 2....while I get the tablesaw freed up, so I can mill a few parts....to make the collar to hold this panel.....have to decide what corner joint to use, as there will be a groove to hide. Maybe a half blind dovetail? :confused: We'll see...

Stay tuned...:D

[steven c newman]

Moved the box off of the tablesaw...need to cut down a plank...an UGLY plank..
481254
Was a 1x6 at one end, but..
481255
Barely a 1 x4 at the other end? Needed 36-1/8" length times 2 pieces. I also need 2 pieces at 17" long....too much barkiness left over from the 3' chunk...had a cutoff that should do..
481256
So...IF I set the rip fence to a strong 2"....
481257
I'll have two sides and two ends,,
481258

Edges will need jointed...question is (rather 2 questions..) is this too tall for the lid?
481259
And, since the raised panel will sit in a groove...that will need to be hidden on the ends..
481260
Thinking MAYBE a half blind dovetail joint....hmmm...

481261
Of course, the just sawn boards wanted to curl....clamped to close up the curl, and let this sit a day....

New saw blade? was cutting that Maple like it was balsa wood....also cuts a tad thinner kerf, than the older, worn out DeWalt blade...


1/2hour this morning = panel glued up....20 minutes this evening = parts for the collar to hold that panel...plus got the yard mowed....not too bad of a day?

[steven c newman]

Got bored, last night....even though Shop is normally closed on Mondays.....spent a little time in the shop, anyway.....all but the cauls came off the glued up panel, made it a bit easier to move around, and to get my fat body past the bench. Box came off the tablesaw for a little bit. Reset up the rip fence...2" tall collar was judged to be too tall...so..
481354
We will try 1-3/8" width....ran all 4 pieces through....best side against the fence..
481355
Checked the length of the long sides...trimmed those to match the box, NOT the panel...and, make sure the ends were square. Needed to then move the tablesaw out of the way..
481356
And haul this out to where I can use it....set the fence up..
481357
Checked the Start & STOP lines on the fence so they match the thickness of the tail board..1st cut...
481358
4 at this setting, 1 on each end of the 2 long side pieces...reset the fence a bit, by eyeball (MK II ?) and go again..
481359
Ok, all done with the router table, it can go back into it's storage spot, until needed again...Tablesaw moved back to it's "Home Station", box and lid plopped on top of it...
481360
Which leaves...
481361
Cutting the 2 short ends for final length....stay tuned for part 2, of the Monday Night Follies..

[steven c newman]

Need to cut that much off? Can't use the tablesaw, now....and I don't trust the bandsaw to cut a straight line...so..
481362
Reset the Millers Falls Mitrebox to 90 degrees, from the last setting of 45 degrees....checked with a square...clamp a part in place..
481364
With a 3rd hand....about 18 strokes to make the cut....times two cuts..
481365
My Cardio for the day? BTW, that back saw was rehabbed by me...and sharpened by me. Cuts well enough, no shooting board required.

So, sometime today, Boss willing...
481366
I need to cut the matching tails and fit them to whichever pair of sockets they go to.....once the collar is dry fitted and marked.....I can then plough a groove to house the panel....then I can trim the panel to final size, and start raising it....and a rebate around the underside....May get a lid glued up by Friday or Saturday?

Will be needing this set on HIGH...
481367
Swept the floor, called it a night....see what happens, when I get bored....:rolleyes:

Stay tuned..:D

[steven c newman]

2 hours IN the shop, this afternoon...hauled a needful thing to the shop..
481414
First thing to get done..
481415
Clean up the sockets, and cut the tails..for all 4 corners..
481416

Took about an hour,,then need to mill some grooves..short ones...
481417
And LONG ones...
481418
Check that the grooves line up...
481419
Clear off the bench, sit the panel and the collar on the bench..
481420
Tomorrow, I will trim the panel to fit in the grooves, and see about making it into a raised panel....might even rebate the underside....but, first..
481421
Need to trim the panel for square and for size...tomorrow....I am whooped, right now...right between the shoulder blades is hurting.

Stay tuned....

[steven c newman]

2 hours in the shop, today....made quite a mess, too..
481454
And....
481455
Not much better out here...

Film at 2300 hrs...stay tuned..

[Richard Hutchings]

Got bored, last night....even though Shop is normally closed on Mondays.....spent a little time in the shop, anyway.....all but the cauls came off the glued up panel, made it a bit easier to move around, and to get my fat body past the bench. Box came off the tablesaw for a little bit. Reset up the rip fence...2" tall collar was judged to be too tall...so..
481354
We will try 1-3/8" width....ran all 4 pieces through....best side against the fence..
481355
Checked the length of the long sides...trimmed those to match the box, NOT the panel...and, make sure the ends were square. Needed to then move the tablesaw out of the way..
481356
And haul this out to where I can use it....set the fence up..
481357
Checked the Start & STOP lines on the fence so they match the thickness of the tail board..1st cut...
481358
4 at this setting, 1 on each end of the 2 long side pieces...reset the fence a bit, by eyeball (MK II ?) and go again..
481359
Ok, all done with the router table, it can go back into it's storage spot, until needed again...Tablesaw moved back to it's "Home Station", box and lid plopped on top of it...
481360
Which leaves...
481361
Cutting the 2 short ends for final length....stay tuned for part 2, of the Monday Night Follies..


I like your method for cutting blind dovetails. Pins first I guess.

[steven c newman]

Yep, easier for me to then lay out the tails...

[steven c newman]

Need a panel 16" x 35".....and have square ends, and no taper on the length....we have way...one edge of the panel was jointed, anyway..will pull from that edge to square the ends..
481479
Minimum that the circular saw can cut....without the guard hanging up....second mark?
481480
Matches the distance between the saw blade and the edge of the saw's foot plate....because...
481481
The guide fence needs those extra marks. Clamp it in place, run the saw through, while pressing it against the fence...
481482
Nothing to it...then rotate the panel around, measure from the freshly cut end down 35"....repeat all the above steps....panel is the right length, with both ends square to the jointed edge.

The other edge? Tapers from 17-1/8" down to 16- 3/4".....and I need just 16" for width...
481483
This is just to mark a line 16" from the "good" edge...clamped in place so it doesn't move....until AFTER the cut line is drawn. Once again, measure for the guide off set...so the saw is cutting the line...and make the cut...
481484
That is the "cut-off" laying there...on it's way to the scrap bin...
481485
Then ran the cordless jointer along the freshly sawn edge...wave reduction...
481486
Need to scrub and flatten both faces....at least get the worst out...want it reasonably flat around the edges of the panel.....best looking face (NOT this one) will be a Raised Panel look...other will be the underside of the lid....and just gets a rebate.....

Stay tuned..

[steven c newman]

Scrub Jack?
481487
Seems to be a good use for this old Craftsman Jack plane....going across the grain at a diagonal....followed up by...


481488
Flattening the hills plane..starts out at the diagonals, then winds up here...both faces were worked over...had some waves going on..
481489

Was finally able to sand things a bit with 80 grit...for now....then set up the Stanley 45..
481490
Cutter is a 5/16" wide straight cutter....rebate is to be 1/4" deep..
481491
By 5/16" wide...working on what will be the underside of the panel...was getting a bit tuckered out...but..
481492
Same plane, no changes...no spurs used...just a saw cut out on the end, to prevent any blow-outs...

Still had to sweep up the shop, and haul a full hamper of just dried clothes upstairs....and seek out a Gatorade bottle, from the fridge...
481493
Before the broom, and..
481494
Busy day, today?

Stay tuned...might try to start raising panels, tomorrow? And the last 2 rebates, before I flip the panel over...:D

[steven c newman]

Plan for today:
Get the other 2 rebates done..
481533
#3 was easy enough (why are my toes cramping?)#4?
481536
Needed a knife wall, and the router plane...and the Stanley 45.....

Next was the bevels
481537
ends were first....WAS going to use a #4 plane ( KK 4) but.....saner minds prevailed..
481538
McRough to start, McFine to finish.....got the two ends fitted..
481539
Then tried the long side bevel....Stanley No.8c tried to help out...
481540
Getting serious...toes still cramping..fitted a side..
481541
Decided to just sweep up..
481542
1 hour and 15 minutes of just hand planes....then Sir Uncle Charles hit, and hit HARD...almost did NOT make it back upstairs...cramps everywhere....if it moved, it cramped


I think I'll wait until tomorrow, to get the last bevel fitted...and MAYBE try for a glue up?

Still cramping...stay tuned :o

[steven c newman]

Walked back down to the shop, last night..SLOWLY...Needed get a couple things set up for later today..
481597
Rotated the panel around, and laid out for the last bevel....noticed a few rough spots....can't have that, can we...
481598
Even had to sharpen this 1st....fresh 45 degree bevel, then form a slight hook off that bevel...Stanley No. 80,,,works just fine...

While the collar was on the panel, didn't like the look....too sharp of a corner between the top edge of the collar...and the bevel of the panel...so..
481599
Will dry fit the collar only, with it's clamps, and run this bit around on the inside edge....May do a small round-over around the outside..AFTER the glue up....

Trying to avoid getting to hot, today....still issues with the cramps....

Stay tuned....

[steven c newman]

Ok, decided a change of Planes was in order....
481646
As pushing either of these two was not getting things done....the jack is fine, going across the grain, and the jointer just wasn't needed for doing a beveled edge...try tilting it 10 degrees AND pushing it along....so...maybe something in between?
481647
An inch longer than a Jack ( Jumbo Jack?) and a tad wider (2-1/4" wide iron, vs 2" cambered?)
481648
Type 3 Millers Falls No. 15....tried it out on the last bevel...after a while, I took a break, mainly for a test fit..
481649
Then push the shavings onto the floor...
481650

To plane a beveled edge, you tilt the plane about 10 degrees, and work your way back to the stop line 1-1/2" back from the edge...shavings start as a narrow ribbon, and each pass, the ribbon SHOULD get wider.....when you see a "full width" shaving, you should be close to the stop lines....then I "fine tune" with smoothers...
481651
The WR #62 makes full width shavings...nice flat surface to the bevel...the Millers Falls No. 9,Type 4 is for doing spot work, where I don't NEED to go the full 35" length...
481652
In this case, right about the center, there was a thicker section..No.9 reduced that, so the last side of the collar will fit...

Dry fit the collar one last time....
481653
Except this time, it was for a corded router...:eek:
Stay tuned...:D

[steven c newman]

Router was set up to make a small cove . On the inside edge at the top of the collar...right above where the beveled face of the panel will be going....
481654
Had to do this in 2 steps, first go where the router could reach into...then rotate the frame around, and finish the molding. Will come back later, and dress up them corners, after a glue up...

Time to spread some glue ( no sign of Uncle SIR Charles,yet) and assemble this lid.....mallet assist was needed..then some "blue clamps" to pull things straight along the long edges, and at the dovetailed corners..
481658
Lay the lid on top of the blue clamps, after adjusting for square....then add the two outside pipe clamps..center one was to correct a slight bow...
481659
Going to let this sit a day, or so..( anyone seen my bench, around here?) maybe later today, I can removed the clamps, clean the clue joints up...maybe a small round-over around the outside top edge....then see about adding these things..
481660
And install the lid onto the chest....

Stay tuned..

[steven c newman]

Well, it did come out of the clamps, today...
481695
Corner joints were cleaned up..
481696
laid on top of the chest..
481697
Will have to fine tune the fit a bit...was too tired to do a whole lot....dug up a set of latches, though...
481698
Thinking maybe centered over either front raised panel....with a Brass handle in between....

Tested out a flavour of stain, on some scrap Spalted Maple...
481699
Let this dry overnight, try a coat of Amber Shellac over it, in the morning?

Have a set of nail-on white plastic foot pads.....may use them?

Haven't decided on a handle for the ends,yet....none on hand.

481700
Thinking something that folds down?

IF the Dungeon Creek doesn't rise on Sunday....and I eat me Wheaties...I can set the chest down on the floor, and start to install the hinges...
We'll see...stay tuned...MIGHT get this done before July 1st?

[steven c newman]

Three tasks to do...
481747
Timer set at 1 hour...Task #1
481748
Pads for the feet installed...Task #2 involved hinges...gappy hinges...
481749
Fixed that,,,
481750
Needed to clear a space on the floor..
481751
Set the chest onto the floor...
481752
And, lay out for those flattened hinges..
481753
And set out the tools to chop mortises to house the hinges...
481754

We have work to do, stay tuned :D

[steven c newman]

Needed a bit more light, Bilbo..
481755
And enough elbow for me to sit down on the shop stool...rotate the chest a bit...
481756
Wide chisel...3 whacks, move a bit, repeat. 3 whacks to insure I am down the required depth, consistently. Needed a way to level the mortise for that hinge to sit in..
481757
IF I set it up normally, it can't span the mortise. Also, I can't turn the cutter (veritas 1/4") 90 degrees INSIDE the plane...but, IF I bring the cutter to the outside..no such problems.
481758
The 2 mortises in the top of the chest were the easy ones...as for how they were spaced? lay the hinge at the corner, make a mark, move the hinge beyond that mark, and make a second mark...then the hinge is set beyond that second mark...why? T&G joint was in the way, prefer NOT to chop into them, or span them...

then install the the lid upside down on top of the chest..lay out where the mortises are with a square, as there are small marks transferred from the other mortises already done...clamp the lid in place, and chop and plane the lid's mortises....

Install the hinges: VIX bit and a drill/driver system..
481762
timer dings...
And..
481763
That will do for today..90 minutes in the shop....O.T. on a Sunday?

stay tuned

[steven c newman]

Monday morning..wake up to the sounds and SMELLS of a crew paving the city street out in front of the house...don't ya just LOVE the smell of FRESH Asphalt in the morning...neither do I.


Laundry Detail this morning...also have a work zone IN the shop..but at least it smells better...
481786
Excuse the mess, BTW..

Latches...get centered above each raised panel ..
481787
Panels are 14" wide, so...center line would be..7"

Just a small selection of tools is needed..
481788
Square to help locate where the latches go...pencil to mark where the screws go...drill for the pilot holes ( old candle to wax the threads) and a Ratchetool to drive the Phillips headed screws...
481789
and..
481790

Stain/Amber Shellac Sample? NO-GO at this station...tossed the small can of stain into the quart can of Witch's Brew....mix well..try again..
481791

Red will need a seal coat...Green is close to what I want...colourwise...just now tried the Amber Shellac....not a fan, this time.....may just use poly gloss over the stain, we'll see


Intend to run a small round-over bit around all the exposed outside corner/edges...maybe tomorrow?

Clothes are now in the dryer...waiting for those to get done....makes the shop TOO warm and steamy right now...there's always tomorrow..

Stay tuned...

[steven c newman]

Way too earl-eye in the marnin for me, but..
481831
Router bit set up and ready...hope my back is...
481832
ALL outside hard,90 degree corners got a round over....and after each end/side/top was done with the router...
481833
EVERYTHING got a good sanding....then more flipping and flopping around up on the tablesaw, again...
481834
1st coat of Witch's Brew was brushed on....there will be more coats, as some of the spalted areas acted like a sponge....stain went on, and soaked in out of sight...

Later this evening, I'll add a second coat of stain where needed...and let things dry overnight....Tomorrow is prep for varnish....

Stay tuned..:D

[steven c newman]

Have given the entire outside of this chest a coat of Amber Shellac...front view?
481853
A view of an end...
481854
a view at the hinges...
481855
The view along the top of the view is about the same..
481856

Will see what this looks like in the morning....

Stay tuned...

[Richard Hutchings]

Wow, that is looking fantastic!

[steven c newman]

handles have been bought...need to install all 3....and going with the Amber Shellac as the top coat....

[steven c newman]

Time for a PIP...before the final coat....
481935
Front view, with the lid closed, and..
481936
Opened. Ends are looking better, too..
481937
Will try a 3rd coat of shellac in the morning..
481938
Kind of boring around here, with the hinges...

Real fun will be when I try to get this AND me up the stairs and to the Dinning Room....tain't all that light...

And..need to start clearing off the top of the bench..
481939
Amazing how fast this stuff piles up..

Stay tuned...almost done....:D

[steven c newman]

Top coat of poly gloss was applied this morning..waiting on that to dry.....anyone want to help hauling this box upstairs?

[steven c newman]

Calling this Project ..DONE...Clear Gloss Poly has dried, and been rubbed down....

Thanks for following along! :D

Now....thinking about WHAT to build in July....:confused:

[steven c newman]

Cleaned out the place to sit this chest..took a bit of work. Son actually carried the chest upstairs by himself.....then we both moved it into it's new home..
482052
And see how it blends in.....then the loading could begin...
482053
Almost filled up. Yes, the ONLY place on the inside to receive any sort of finish..was just the underside of the lid

watch your fingers, when you close the lid...
482054

calling this The Hobbit Tool Chest....thanks for looking in!