A Design Problem

[steven c newman]

Sorted through the "Leftovers", and decided I need to go out and pick up a supply of Ash 1 x 6 planks..
Linen Closet, Lumber Run.jpg
Three 1 x 6 x 10' planks...$8.00 total....had to cut them down to fit in the trunk of the Chevy Equinox....


On the way back home, Boss decided she wanted a couple new plants for the house...and I needed to buy a new tape measure, as the old one quit working....so..
Linen Closet, NEW Tape Measure.jpg
12' is usually more than enough for MY shop...and, this cost almost the same as that stack of lumber did.

Legs are about shot, for today....was also out and about, trying to find anything worth buying at the Yard Sales....nope...

maybe tomorrow, I can start making a wee bit of sawdust? Stay tuned...

[steven c newman]

So...hauled the two 1 x 10s to the shop, today....first order of business....was to cross cut the planks down to around 30" "halves..
First try..
Linen Closet, Raise panels, work holding.jpg
Tablesaw as a work holding?
Linen Closet, Raise panels, 1st cross cut.jpg
30" came out to about..here...with almost 31" as a cut-off...
Linen Closet, Raised panels, gave it a try.jpg
And gave this saw a try...had issues following the line, AND supporting the cut-off...

tried something else...and maybe get a straighter cut..
Linen Closet, Raise panels, better cross cut.jpg
seemed to work a lot better...was even able to trim the "extra" off the end..
Linen Closet, Raise panels, needs trimmed.jpg


So, now I had 4 pieces about 30" long,,but, they needed to be ripped down the center...
Linen Closet, Raise panels, ripped for width.jpg
Set up a rip fence..at about 4-7/8" width...run the best edges against the fence...then, run the "cut-off" through..as things were a bit tapered...cut edge against the fence, rough edge gets skimmed down to parallel...
Set all blanks aside, for a bit..
Linen Closet, Raise panels, 8 rips.jpg
While I re-arrange things a bit....
Linen Closet, Raise panels, cross cut blanks.jpg
Once I found the exact center of one blank...I could cross cut the 8 blanks down to 16 panels....
Stay tuned..

[steven c newman]

Ok..16 blanks...not too sure about the "Live Edge" one, yet..
Linen Closet, Raise panels, 16 blanks.jpg
We'll see how it goes...

Saw need to be re-arranged, again..
Linen Closet, Raise panels, bevel set.jpg
Zero Clearance Overlay, tilt the blade to 15 degrees...add the rip fence at about 1/2 away from the bottom of the blade...make sure things are squared..

Run each edge through..
Linen Closet, Raise panels, after the cut.jpg
Start with one end, rotate around for the next edge...this merely shows how thing were looking...blade has stopped, piece set back to show off...

4 cuts per panel...times 16 panels...
Linen Closet, Raise panels, busy day.jpg
yep, was a busy afternoon at the saw...results?
Linen Closet, Raise panels, 16 done.jpg
16 Raised Panels...details?
Linen Closet, Raise panels,details.jpg
Will take a plane along the raised face...not sure yet, if there will be a rebate on the insides on these panels...depends on the grooves, and the fit into the grooves.

Was not a happy camper with the way the last batch of doors came out...might try a stopped groove this time around...

First off, will need to start milling parts for the frames to house these panels...

Stay tuned...

[steven c newman]

Ok..last night, 2 planks to the shop...trimmed to 45", while chopping off the worst ends...split down the middle to get two blanks per plank...@ 2-3/4" width..
Clamp the four Stiles for the 2 bottom doors into a stack..
Linen Closet, Lumber Supply, 4 stiles.jpg
In the hopes that they will stay flat/straight....they are standing with the Lumber Supply for a simple reason..
Linen Closet, Lumber Supply, too thick.jpg
The thinnest of this mob is over 7/8" thick! A friend of mine has a Lunch Box Planer I can use...( as soon as he gets back from cutting Firewood) and all of these plank will be going to "Weight Watchers" until they are all 3/4" thick....helps the joinery when all the parts are the same thickness...

Page #2 of The Plan arrived this morning...
Linen Closet, door corner joint details.jpg
Details how the top corner of a door goes together. Stiles are 2-3/4" wide....Rails are at 5" width...Corner joint is to be a mitered half lap..with the bead details making the turn.

Plan is..(once the parts have been mill to thickness)

Mill the rails for length
Mill the bead details along both edges of the Show face...
Mill the half lap joint

Set up the router table, and mill a stopped groove to house the raised panels in. do not let the bit enter the joinery area, as I do not want the groove to show..

Waiting on Page #3, detailing how the center Stile meets the center Rail, and how both are to meet the outside frame...fancy cope & stick mortise and tenon joints?

Stay tuned..might be a busy week?

[steven c newman]

Ok..load up 10 parts into the back of the Chevy....drive the 16 miles to a barn out in the countryside...even drove past the old Newman Family Cemetery..That was started back in 1796...

Goal was to plane all the boards to exactly 3/4" thick....couple boards were even thicker on one end than the other...Delta 12" Lunch Box Planer....and, we were dropping the head down a 1/16" at a time...as there wasn't a way to hold it at each 1/32".....Managed, somehow, NOT to send any knots flying...for once...

With all done, then load up the car, and head home...I am plum tuckered out, right thigh is sore from shoving on the end of the boards...with my friend on the other side pulling it through..couple boards, we had to back off the depth a hair....as things were not quite flat....had some thicker spots...

I think that will be it, for today's wood working....other than seeing IF Page #3 is done..
Stay tuned..

[Rafael Herrera]

Would you consider narrower rails and stiles, 2" or so?

Is weight a concern?

[steven c newman]

Weight is not the problem...available parts the right size is.....frames are being built around what the Raised Panels are sized at....did NOT want the raised panels to be a "lop-sided" glue up, just to gain another inch in width...it is what it is...

[steven c newman]

Page #3 has just arrived..
Linen Closet, door parts, Page #3.jpg
Will start cutting parts, tomorrow morning...will see how things go...Might have to do one door at a time?

Stay tuned..

[steven c newman]

Cross cutting.
Linen Closet, Bead work, 3 rails.jpg
Then narrow the 3 rails to 5" wide..

Ripping..
Linen Closet, Bead work, first rip.jpg
Getting rid of the barky stuff...for the 2 middle stile pieces..
Linen Closet, Bead work, Part is parts.jpg
Parts is parts

Bead work..
Linen Closet, Bead work, 2 beads done.jpg

Tomorrow's task?
Linen Closet, Bead work, tomorrow's chores.jpg
Was a busy day..
Linen Closet, Bead work, busy day.jpg
Having to stop and clear the plane...
Linen Closet, Bead work, clogged up.jpg
Try again, tomorrow, eh?

[steven c newman]

Ok..these will be "fun" to do..
Linen Closet, Bead work, corner details.jpg
Mitered Half Lap corners.....


Just the 4 corners...the rest will be more like this..
Linen Closet, Bead work, meeting a rail.jpg
using a 1/4" deep mortise.....where every bead meets another bead..they will get mitered...

Need to go and run 2 beads on each outside stile....then the joinery can start up...then the cussing can begin...
Stay tuned

[steven c newman]

Ok..that MIGHT be a problem..
Linen Closet, Stiles, Not a good thing.jpg
Well, since this is a Stile, and will get a Mitered Half Lap joint....
Linen Closet, Stiles, mitered off.jpg
problem solved...

A Crochet was used today..
Linen Closet, Stiles, Crochet in use.jpg
Because a stile needed jointed....
Linen Closet, Stiles, needed jointed.jpg
Not a problem...must have been an Ohio Board....was "high" in the middle.


Contrary ( Difficult?) Grain, vs...
Linen Closet, Stiles, contrary grain.jpg
A bead cutter in the Stanley No. 45..

Got 2 out of the 4 Long Stiles beaded today..
Linen Closet, Stiles, shavings.jpg
Plane has been rather busy, lately?

[steven c newman]

There were 4 stiles, 2 per door...after some lay out work...it seems that I am doing the 2 upper doors first...so..last 2 stiles were worked over today..
Linen Closet, stiles, beads, jointed.jpg
One was in very bad need of a jointer..
Linen Closet, stiles, beads, jointer plane.jpg
Went ahead and jointed all four edges...2 per stile...had to decide which face was to be the "show face"...
Linen Closet, stiles, beads, not beadable.jpg
And this wasn't one of them...some other "defects" were ploughed through, though..
Linen Closet, stiles, beads, knot problem.jpg
Until both stiles had both of their beads run..
Linen Closet, stiles, beads, stile #3 done.jpg
Regardless of contrary grain...
Linen Closet, stiles, beads, difficult grain.jpg

So....I think I have enough parts milled, to build one upper door...while also milling the rest of the parts for the other Upper door...

Stay tuned...

[steven c newman]

This MIGHT take a couple posts to get caught up...after 105 minutes IN the shop, today...
Stiles needed trimmed to final length...all 4 of them...so..
Linen Closet, Stiles, Half Laps, follow that line.jpg
Since the tablesaw was buried underneath a mess of parts, and the Mitre Box & Saw were not set up for cross cuts...
Linen Closet, Stiles, Half Laps, Frame saw 18 in..jpg
Gave this a try...
Linen Closet, Stiles, Half Laps, square cut.jpg
Not too hateful?

Needed to start on the Mitered Half Laps...needed to find an angle...
Linen Closet, Stiles, Half Laps, setting the angle.jpg
Bevel gauge was then set to that line..as I had a few more to do...again, with the frame saw..
Linen Closet, Stiles, Half Laps, waste laid out.jpg
Then used a marking gauge to lay out the waste to be removed.

Miter Box was set up to make stopped depth cuts..
Linen Closet, Stiles, Half Laps, mitre box & saw.jpg
At least it is a true 90 degree cut..
Linen Closet, Stiles, Half Laps, stopped cut.jpg
Then stand the stile up in the end vise..
Linen Closet, Stiles, Half Laps, rip cut.jpg
Stay tuned...

[steven c newman]

Saw until the waste pops off..
Linen Closet, Stiles, Half Laps, completed.jpg
Wide chisel to pare where the No. 3 couldn't go...

Repeat 3 more times..
Linen Closet, Stiles, Half Laps, first pair.jpg
Now have 2 stiles for ONE Door...

When the first angled cut was made, needed to be planed a bit..
Linen Closet, Stiles, Half Laps, shooting.jpg
Stanley No.3, Type 15 seemed to work just fine...wide chisel?
Linen Closet, Stiles, Half Laps, paring chisel.jpg
Paring off the saw marks..

Tomorrow's Task?
Linen Closet, Stiles, Half Laps, next task.jpg
Top and Bottom Rail need to match the Stiles at the corners...

I also put the plane to work as a smoother, today..
Linen Closet, Stiles, Half Laps, smoother.jpg
The "Inside Faces" were a tad rough in spots...

tablesaw was buried?
Linen Closet, Stiles, Half Laps, out of service.jpg
Yeah, you could say that...

Stay tuned..

[steven c newman]

Hmm. basic Geometry I guess.....if one angle is around 60 degrees..then the matching angle will be around 30 degrees...
Linen Closet, Rails, angle found.jpg
Used the cut-off from the Stile...
Linen Closet, Rails, angle finder.jpg

Then see how it works..
Linen Closet, Rails, half lap done.jpg
One rail done.....right now the "Problem" is removing just enough waste...with a D8 Rip saw...

Stay tuned...