Sometimes I still do Flatwork.......

[Stu Ablett in Tokyo Japan]

I've got to make some new wine shelves for the liquor shop.
I got a really good start on them today.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_festool_cut1.JPG
I sure like my Festool TS55 saw and rail system, makes this work easy!
I ripped the sheets 4 deep (9mm thick plywood).

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_festoolcut2.JPG
Yep, sure is slick!

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_sheet_goods_cut_up.JPG
Here is all the sheet goods ripped to width.

Next I had to cut stuff to length.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_cut_2_lenght.JPG
For the shorter pieces I was able to use the stop on my SCMS fence.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_not_quite_cut.JPG
Unfortunately, I could not quite cut all the way through (sure would like the
10" saw!!)

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_not_quite_finished.JPG
... but a couple of pulls with the saw, and everything is OK!

When cutting the longer pieces, I could not use my stop block
set up left of the blade,
I had to use a temp stop block on the right side of the blade.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_temp_stop_block1.JPG
I always use two pieces of plywood, one thin and the other thicker.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_temp_stop_sawdust_space.JPG
Doing this give me an undercut of sorts, this allows any sawdust somewhere to
go, so I do not have to worry about the sawdust throwing my cuts off, simple and easy, I like!

I decided to use the corner making bit on my router table for
the casework....

http://www.ablett.jp/workshop/images/wine_shelves/corner_bit1.JPG
This big sucker! I got the instruction on how to set it up from the Lee Valley website, worked great!

http://www.ablett.jp/workshop/images/wine_shelves/corner_bit2.JPG
Making some set-up cuts

[Stu Ablett in Tokyo Japan]

http://www.ablett.jp/workshop/images/wine_shelves/corner_bit4.JPG
That looks good, took less than 10 minutes to set it up.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_flat_push_jig.JPG
The sides of the casework are going to be about 150 cm tall, so I had to make a good push jig for the router table.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_flat_push_jig_2.JPG
Long arm and used the worktable for support, worked great!

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_standing_push_jig.JPG
Here is the jig I made to push the standing up pieces.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_standing_push_jig_2.JPG
Those pieces are 99 cm tall, again, worked great!

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_case_mock_up.JPG
I just dry fit one of the cases together to make sure my math was right (it was)
Next, I have to make a bunch of dados in the sides and the middle support pieces.
I made up a jig for my handheld router to do this.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_cut_dado3mm_bit_plus_6mm.JPG
it is a simple sled of sorts, I'm using a 6mm straight bit, and the shelves will be 9 mm,
so I did the first cut and then used a 3 mm drill bit to set up the second fence to do the return cut.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_dado_tight_fit.JPG
After few tries, I got a nice tight fit

Now I need to do repeatable dados, all spaced 95 mm apart,
what I did was use a pin drilled into the sled, when I cut a dado, I release the
clamp, and then slide the piece to the right, the pin engages the dado I just cut, and sets the spacing.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_cut_dado_pin.JPG
Nothing fancy, but it works

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelf_cut_dado3_slots.JPG
Here is the results on a test piece, they were exactly 95mm apart.

[Stu Ablett in Tokyo Japan]

http://www.ablett.jp/workshop/images/wine_shelves/plug_in_switch.JPG
One last thing, I got this from a box of stuff a buddy left me when he moved away from Japan.
It is basically a switch that you plug in between an appliance and the power,
this worked great, as I do not have to reach up onto the the vacuum cleaner each time to turn it off.

More later!
Cheers!

[Mike Cutler]

Nice work Stu. Clean, quick and organized. I like the use of the drill bit for an accurate offset.:cool:

[Mike Canaris]

Nice work Stu...thanks for the step by step pictorial.

[Stu Ablett in Tokyo Japan]

Thanks Mike and Mike :)

Got to keep it clean down in the Dungeon, or I'd be knee deep in no time!

Run the broom around the place at the end of the day (or night) and several times during the day, put stuff back into their places. I have so little space, I have to be really greedy with it, and not let stuff "go" or I'll pay for it, sure as can be.

Cheers!

[Stu Ablett in Tokyo Japan]

A couple more pics
http://www.ablett.jp/workshop/images/wine_shelves/router_sled1.jpg
http://www.ablett.jp/workshop/images/wine_shelves/router_sled2.jpg
http://www.ablett.jp/workshop/images/wine_shelves/router_sled3.jpg
The router sled, just some more shots.
Cheers!

[Bob Childress]

Nice work Stu! I especially like the jig for routing the tall case pieces on end. :) Very efficient and accurate. Great pics.

[Gail O'Rourke]

Stu - great pics....I was going to ask if you could have did your cross cuts first (with the Festool) and then cut your rips - then I looked at the pics again and realized that you cut all 4 sheets at the same time. You are a wild man.

Nice job.

[Stu Ablett in Tokyo Japan]

Stu - great pics....I was going to ask if you could have did your cross cuts first (with the Festool) and then cut your rips - then I looked at the pics again and realized that you cut all 4 sheets at the same time. You are a wild man.

Nice job.

Thanks Gail

If the boards were much wider, I would have cut them all with the Festool, but as I could just squeak them out with the SCMS I figured I'd do it that way.

These sets of shelves will be able to hold 126 kinds of wine, three bottles each, so they have to be strong, thus the all dado joints. I made some up years ago and they are still in use, but they have sagged in a few spots, as I used plywood that was a bit too thin.

I dunno about wild, but I am a bit tired..... :rolleyes: :D

[Jim Becker]

Very nice, Stu! I like the "hanging shop vac" idea... ;)

The joinery technique is interesting for the casework. Certainly strong, but challenging to maneuver the long pieces with a steady hand...but your jigs seemed to do the job quite nicely.

Question, given the "access logistics" for the dungeon, do you actually assemble pieces like this "upstairs"? (like...move the van to the street and use that space?)

[Stu Ablett in Tokyo Japan]

Very nice, Stu! I like the "hanging shop vac" idea... ;)

The joinery technique is interesting for the casework. Certainly strong, but challenging to maneuver the long pieces with a steady hand...but your jigs seemed to do the job quite nicely.

Question, given the "access logistics" for the dungeon, do you actually assemble pieces like this "upstairs"? (like...move the van to the street and use that space?)

After I did the corner joints, If I had to do it again, I'd just use dados, but that is how one learns what works :rolleyes: :D

No, I'll put these together down in the Dungeon, remember the hatch opens to a full 4'x4' when needed, for these I won't even have to open it all the way, just move the steps out of the way, lower the hoist, hook the cab and raise it. Yes I'll need help on one end either top or bottom, but my lovely wife will help me with that kind of thing.

I'm heading to the Dungeon now, so I'll talk to you guys in a few hours!

Cheers!

[Stu Ablett in Tokyo Japan]

An Update


I used my vacuum cleaner for dust collecting on the Festool TS55 and the router, it works OK, but, when I opened the vacuum to see if it needed cleaning............

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelves_lots_of_saw_dust.jpg
I realized that this vacuum works more than OK.

If I did not use the vacuum, all that dust would be clouding up the Dungeon.
(I really need to build a mini cyclone to go with this vacuum).

Now on to the real cuts.

I needed to make a way to start the boards, so make them all start at the same point.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelves_mark_1st_dado.jpg
I marked on the board where I wanted the dado to be......and lined it up with the jig.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelves_1st_dado_lined_up.jpg
I made up a spacer block so the next one would be the same as the first one.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelves_starting_spacer1.jpg
Nothing fancy, but it works well.

Now I know each board will start from the same point.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelves_screw_holddown.jpg
I only had one clamp to use on this jig, I have a toggle clamp...................somewhere....so I just used one screw to hold the board for the first two cuts,then I can use the clamp I have for the last 12 cuts.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelves_screw_hole.jpg
Now I did not want a hole in my cabinet, so I place the screw where the shelf dado would go.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelves_hide_the_hole.jpg
Cut the dado, and the hole will disappear behind the shelf.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelves_1st_dado.jpg
Here is the first dado cut, 95 mm for the inside edge of the cabinet

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelves_last_dado.jpg
Here is the last dado cut, 95 mm from the inside edge of the cabinet.
With 14 dados to do, even if my jig was out by half a millimeter that would be 7 mm out by the last cut, but is was dead on. Yes, you could say I'm pleased!

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelves_all_done.jpg
All done for now!

More tomorrow!

Cheers!

[Alan DuBoff]

Looks good Stu. You could make capsule hotels out of it and rent it out down by the station!:D

Great project, thanks for the details...a pic says a thou as they say...

[Chris Padilla]

You plan to haul it outta the dungeon in pieces or put together?

[Don Baer]

You plan to haul it outta the dungeon in pieces or put together?

Chris,
Read post #12....:D

Stu,
Great job.

[Chris Padilla]

Oops...was flicking the mouse wheel a little too fast...I have the same problem in my BMW! :rolleyes:

Stu, nice quick setup of the lock-miter bit. See, you are a smart man or found really good instructions. I have a hard time dealing with that bit. I did okay for the flat cut but the vertical cut, well, I had a lot of tear-out of the plys of my plywood. I even rescued some of the torn out plys and reglued them back in! :(

[Jim Becker]

Oops...was flicking the mouse wheel a little too fast...I have the same problem in my BMW!

Only you would have a mouse wheel in the Beemer... LOL! :D

[Stu Ablett in Tokyo Japan]

Oops...was flicking the mouse wheel a little too fast...I have the same problem in my BMW! :rolleyes:

Stu, nice quick setup of the lock-miter bit. See, you are a smart man or found really good instructions. I have a hard time dealing with that bit. I did okay for the flat cut but the vertical cut, well, I had a lot of tear-out of the plys of my plywood. I even rescued some of the torn out plys and reglued them back in! :(

Thanks Chris.

The instructions on the Lee Valley page are tops.

Lee Valley Instructions (http://www.leevalley.com/wood/page.aspx?c=2&p=30119&cat=1,46168)

On that page, just below where it says "45° Lock Miter Bit" it says "Instr" click on that and it opens in a new window, at the very bottom of the page is a "Click here to print" button.

Worked like a charm, took ten minutes to set it up, including installing the bit.

Cheers!

[Stu Ablett in Tokyo Japan]

Minor update..........

I got some more done, but I also tweaked my jig a bit.

http://ablett.jp/workshop/images/wine_shelves/wine_shelves_router_landing_pad.jpg
I put a resting place for the router at the beginning of the cut, this saves me moving it off the jig each time. I also put a stop block there, and while not in the pic yet, I put one on the other end too.To make things move easier, I waxed the sides of the router and the jig rails

http://ablett.jp/workshop/images/wine_shelves/wine_shelves_rail_wax.jpg
http://ablett.jp/workshop/images/wine_shelves/wine_shelves_side_wax.jpg
Boy what a difference! The router slides so much easier!
You have to be careful, you do not want wax on anything you are going to paint or stain.

With a new 6 mm bit, things are going well!

[Stu Ablett in Tokyo Japan]

Minor update

I got all the pieces cut, well except for the backs, and I dry fit one of the shelves tonight..........

45969

.........it all slid together easy as pie :D

I'm hoping I can get them all glued and shot by Sunday, so I can install them in the L shop (and get them out of my Dungeon).

Cheers!

[Stu Ablett in Tokyo Japan]

OK, another little update, getting in done!

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelves_production_cutting.jpg
I had to cut up a lot of these shelves, and it was sure nice having a SCMS to do this one, once that I'd ripped them to width with the Festool saw and rail set.
I gang cut 4 pieces at a time, and it went quickly, and now I have to sand the edges.

http://www.ablett.jp/workshop/images/wine_shelves/wine_shelves_one_glued_up.jpg
Well, there is one done, two to go, and then the trim for the front edges.

Then I have to install them in the L shop!

:D

[Art Mulder]

Stu... how are you finishing that puppy!? Please tell me you have a spray gun? (I, myself, don't have a spray setup yet. But I think if I faced a piece like that with all those tiny nooks and crannies inside... I'd go buy one reall quick.)

[Stu Ablett in Tokyo Japan]

Naw, no finish, seems they only stay in the shop for about 5 years or so and we change something.
These are going in a different location, than the ones I'm replacing, but the old ones are still in great shape after about 6 years. Also it seems most people like the look of the raw wood around the wine, I guess it is like wine boxes, they are not finished either.

BTW, I got all the major gluing done..........

46017

...........so now just the front edges to do, lots of cutting....

Cheers!