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1880s Counter

20K views 271 replies 35 participants last post by  Smitty_Cabinetshop 
#1 ·
What is it, what you gonna do with it?

Here we go again…

It was a dark and stormy night. Well, no, not really stormy. Or even night. But it was dark. And wet. My son was with me, along with my dad and daughter, in October of 2018 to discover and salvage whatever millwork we could find in a 135 year old commercial building in a nearby town. The brick structure was slated for demo; the roof had leaked for years, all the windows in the rear were bricked shut decades earlier, and the upper floors had been vacant at least a couple of generations. One part of the middle floor was rotted through. It was safe, but caution was the order of the day.

After finding a unique door and claiming it, my son spotted (via the flashlight app on his iphone) a bar, or counter, along a back brick wall. Think something like this:



Only, not as nice. Here's the only (bad) picture I took of the piece when it was still in the building.



At that point, it was already upside down. And that pic is of the end cap that survived. Now, I can't say "Let's start at the beginning" because, well, this blog post is the first. What I'm saying is, it'd be nice to show you more of the counter together, but I can't. We got it out from under bricks and other building detritus, and got it to the door. Then we got it partially out the door and into the hall. But only one end. Too long to get into the hall and stand up, for the trip down the stairs. So we had to take it apart. Beat it apart, really.

Oh, and did I mention it wasn't complete? One end was there, the other was cut off and the 'return' was nowhere to be found. Not complete, and rotten in places. Yep, wet and crumbly. But there was something about it that captured my imagination. After the beat-up and take down, the parts were carted across town to my dad's shop space. And there it sat for over a year. In early December of last year, I resolved to do something with it. And that has "something" has been proceeding to the point a blog was in order. So, here we go.

Next installment, pictures of the pieces as they sat in dad's shop space, waiting for their turn in the sun as it were. And, more talk of what to do with this thing. In other words, maybe answer the questions in the title of this installment?? Yeah, I know. But these things take time. Until then, thanks for looking.
 

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#2 ·
What is it, what you gonna do with it?

Here we go again…

It was a dark and stormy night. Well, no, not really stormy. Or even night. But it was dark. And wet. My son was with me, along with my dad and daughter, in October of 2018 to discover and salvage whatever millwork we could find in a 135 year old commercial building in a nearby town. The brick structure was slated for demo; the roof had leaked for years, all the windows in the rear were bricked shut decades earlier, and the upper floors had been vacant at least a couple of generations. One part of the middle floor was rotted through. It was safe, but caution was the order of the day.

After finding a unique door and claiming it, my son spotted (via the flashlight app on his iphone) a bar, or counter, along a back brick wall. Think something like this:

Wood Rectangle Table Wood stain Outdoor furniture


Only, not as nice. Here's the only (bad) picture I took of the piece when it was still in the building.

Sleeve Wood Flooring Rectangle Tints and shades


At that point, it was already upside down. And that pic is of the end cap that survived. Now, I can't say "Let's start at the beginning" because, well, this blog post is the first. What I'm saying is, it'd be nice to show you more of the counter together, but I can't. We got it out from under bricks and other building detritus, and got it to the door. Then we got it partially out the door and into the hall. But only one end. Too long to get into the hall and stand up, for the trip down the stairs. So we had to take it apart. Beat it apart, really.

Oh, and did I mention it wasn't complete? One end was there, the other was cut off and the 'return' was nowhere to be found. Not complete, and rotten in places. Yep, wet and crumbly. But there was something about it that captured my imagination. After the beat-up and take down, the parts were carted across town to my dad's shop space. And there it sat for over a year. In early December of last year, I resolved to do something with it. And that has "something" has been proceeding to the point a blog was in order. So, here we go.

Next installment, pictures of the pieces as they sat in dad's shop space, waiting for their turn in the sun as it were. And, more talk of what to do with this thing. In other words, maybe answer the questions in the title of this installment?? Yeah, I know. But these things take time. Until then, thanks for looking.
Great find! Anxious to see what you do with it, Smitty.
 

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#3 ·
What is it, what you gonna do with it?

Here we go again…

It was a dark and stormy night. Well, no, not really stormy. Or even night. But it was dark. And wet. My son was with me, along with my dad and daughter, in October of 2018 to discover and salvage whatever millwork we could find in a 135 year old commercial building in a nearby town. The brick structure was slated for demo; the roof had leaked for years, all the windows in the rear were bricked shut decades earlier, and the upper floors had been vacant at least a couple of generations. One part of the middle floor was rotted through. It was safe, but caution was the order of the day.

After finding a unique door and claiming it, my son spotted (via the flashlight app on his iphone) a bar, or counter, along a back brick wall. Think something like this:

Wood Rectangle Table Wood stain Outdoor furniture


Only, not as nice. Here's the only (bad) picture I took of the piece when it was still in the building.

Sleeve Wood Flooring Rectangle Tints and shades


At that point, it was already upside down. And that pic is of the end cap that survived. Now, I can't say "Let's start at the beginning" because, well, this blog post is the first. What I'm saying is, it'd be nice to show you more of the counter together, but I can't. We got it out from under bricks and other building detritus, and got it to the door. Then we got it partially out the door and into the hall. But only one end. Too long to get into the hall and stand up, for the trip down the stairs. So we had to take it apart. Beat it apart, really.

Oh, and did I mention it wasn't complete? One end was there, the other was cut off and the 'return' was nowhere to be found. Not complete, and rotten in places. Yep, wet and crumbly. But there was something about it that captured my imagination. After the beat-up and take down, the parts were carted across town to my dad's shop space. And there it sat for over a year. In early December of last year, I resolved to do something with it. And that has "something" has been proceeding to the point a blog was in order. So, here we go.

Next installment, pictures of the pieces as they sat in dad's shop space, waiting for their turn in the sun as it were. And, more talk of what to do with this thing. In other words, maybe answer the questions in the title of this installment?? Yeah, I know. But these things take time. Until then, thanks for looking.
I'm visualizing bellying up to the bar and having a pint of stout. Should I wait till your done?

Looking forward to the blog Smitty and thanks for posting.
 

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#4 ·
What is it, what you gonna do with it?

Here we go again…

It was a dark and stormy night. Well, no, not really stormy. Or even night. But it was dark. And wet. My son was with me, along with my dad and daughter, in October of 2018 to discover and salvage whatever millwork we could find in a 135 year old commercial building in a nearby town. The brick structure was slated for demo; the roof had leaked for years, all the windows in the rear were bricked shut decades earlier, and the upper floors had been vacant at least a couple of generations. One part of the middle floor was rotted through. It was safe, but caution was the order of the day.

After finding a unique door and claiming it, my son spotted (via the flashlight app on his iphone) a bar, or counter, along a back brick wall. Think something like this:

Wood Rectangle Table Wood stain Outdoor furniture


Only, not as nice. Here's the only (bad) picture I took of the piece when it was still in the building.

Sleeve Wood Flooring Rectangle Tints and shades


At that point, it was already upside down. And that pic is of the end cap that survived. Now, I can't say "Let's start at the beginning" because, well, this blog post is the first. What I'm saying is, it'd be nice to show you more of the counter together, but I can't. We got it out from under bricks and other building detritus, and got it to the door. Then we got it partially out the door and into the hall. But only one end. Too long to get into the hall and stand up, for the trip down the stairs. So we had to take it apart. Beat it apart, really.

Oh, and did I mention it wasn't complete? One end was there, the other was cut off and the 'return' was nowhere to be found. Not complete, and rotten in places. Yep, wet and crumbly. But there was something about it that captured my imagination. After the beat-up and take down, the parts were carted across town to my dad's shop space. And there it sat for over a year. In early December of last year, I resolved to do something with it. And that has "something" has been proceeding to the point a blog was in order. So, here we go.

Next installment, pictures of the pieces as they sat in dad's shop space, waiting for their turn in the sun as it were. And, more talk of what to do with this thing. In other words, maybe answer the questions in the title of this installment?? Yeah, I know. But these things take time. Until then, thanks for looking.
We're going to need more beer
 

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#5 ·
What is it, what you gonna do with it?

Here we go again…

It was a dark and stormy night. Well, no, not really stormy. Or even night. But it was dark. And wet. My son was with me, along with my dad and daughter, in October of 2018 to discover and salvage whatever millwork we could find in a 135 year old commercial building in a nearby town. The brick structure was slated for demo; the roof had leaked for years, all the windows in the rear were bricked shut decades earlier, and the upper floors had been vacant at least a couple of generations. One part of the middle floor was rotted through. It was safe, but caution was the order of the day.

After finding a unique door and claiming it, my son spotted (via the flashlight app on his iphone) a bar, or counter, along a back brick wall. Think something like this:

Wood Rectangle Table Wood stain Outdoor furniture


Only, not as nice. Here's the only (bad) picture I took of the piece when it was still in the building.

Sleeve Wood Flooring Rectangle Tints and shades


At that point, it was already upside down. And that pic is of the end cap that survived. Now, I can't say "Let's start at the beginning" because, well, this blog post is the first. What I'm saying is, it'd be nice to show you more of the counter together, but I can't. We got it out from under bricks and other building detritus, and got it to the door. Then we got it partially out the door and into the hall. But only one end. Too long to get into the hall and stand up, for the trip down the stairs. So we had to take it apart. Beat it apart, really.

Oh, and did I mention it wasn't complete? One end was there, the other was cut off and the 'return' was nowhere to be found. Not complete, and rotten in places. Yep, wet and crumbly. But there was something about it that captured my imagination. After the beat-up and take down, the parts were carted across town to my dad's shop space. And there it sat for over a year. In early December of last year, I resolved to do something with it. And that has "something" has been proceeding to the point a blog was in order. So, here we go.

Next installment, pictures of the pieces as they sat in dad's shop space, waiting for their turn in the sun as it were. And, more talk of what to do with this thing. In other words, maybe answer the questions in the title of this installment?? Yeah, I know. But these things take time. Until then, thanks for looking.
I'm willing to buy the first round of beer. Waiting with bated breath to see what your product looks like .
 

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#6 ·
What is it, what you gonna do with it?

Here we go again…

It was a dark and stormy night. Well, no, not really stormy. Or even night. But it was dark. And wet. My son was with me, along with my dad and daughter, in October of 2018 to discover and salvage whatever millwork we could find in a 135 year old commercial building in a nearby town. The brick structure was slated for demo; the roof had leaked for years, all the windows in the rear were bricked shut decades earlier, and the upper floors had been vacant at least a couple of generations. One part of the middle floor was rotted through. It was safe, but caution was the order of the day.

After finding a unique door and claiming it, my son spotted (via the flashlight app on his iphone) a bar, or counter, along a back brick wall. Think something like this:

Wood Rectangle Table Wood stain Outdoor furniture


Only, not as nice. Here's the only (bad) picture I took of the piece when it was still in the building.

Sleeve Wood Flooring Rectangle Tints and shades


At that point, it was already upside down. And that pic is of the end cap that survived. Now, I can't say "Let's start at the beginning" because, well, this blog post is the first. What I'm saying is, it'd be nice to show you more of the counter together, but I can't. We got it out from under bricks and other building detritus, and got it to the door. Then we got it partially out the door and into the hall. But only one end. Too long to get into the hall and stand up, for the trip down the stairs. So we had to take it apart. Beat it apart, really.

Oh, and did I mention it wasn't complete? One end was there, the other was cut off and the 'return' was nowhere to be found. Not complete, and rotten in places. Yep, wet and crumbly. But there was something about it that captured my imagination. After the beat-up and take down, the parts were carted across town to my dad's shop space. And there it sat for over a year. In early December of last year, I resolved to do something with it. And that has "something" has been proceeding to the point a blog was in order. So, here we go.

Next installment, pictures of the pieces as they sat in dad's shop space, waiting for their turn in the sun as it were. And, more talk of what to do with this thing. In other words, maybe answer the questions in the title of this installment?? Yeah, I know. But these things take time. Until then, thanks for looking.
I'm willing to drink the first round of beer :) Looking forward to reading Smitty!
 

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#7 ·
What is it, what you gonna do with it?

Here we go again…

It was a dark and stormy night. Well, no, not really stormy. Or even night. But it was dark. And wet. My son was with me, along with my dad and daughter, in October of 2018 to discover and salvage whatever millwork we could find in a 135 year old commercial building in a nearby town. The brick structure was slated for demo; the roof had leaked for years, all the windows in the rear were bricked shut decades earlier, and the upper floors had been vacant at least a couple of generations. One part of the middle floor was rotted through. It was safe, but caution was the order of the day.

After finding a unique door and claiming it, my son spotted (via the flashlight app on his iphone) a bar, or counter, along a back brick wall. Think something like this:

Wood Rectangle Table Wood stain Outdoor furniture


Only, not as nice. Here's the only (bad) picture I took of the piece when it was still in the building.

Sleeve Wood Flooring Rectangle Tints and shades


At that point, it was already upside down. And that pic is of the end cap that survived. Now, I can't say "Let's start at the beginning" because, well, this blog post is the first. What I'm saying is, it'd be nice to show you more of the counter together, but I can't. We got it out from under bricks and other building detritus, and got it to the door. Then we got it partially out the door and into the hall. But only one end. Too long to get into the hall and stand up, for the trip down the stairs. So we had to take it apart. Beat it apart, really.

Oh, and did I mention it wasn't complete? One end was there, the other was cut off and the 'return' was nowhere to be found. Not complete, and rotten in places. Yep, wet and crumbly. But there was something about it that captured my imagination. After the beat-up and take down, the parts were carted across town to my dad's shop space. And there it sat for over a year. In early December of last year, I resolved to do something with it. And that has "something" has been proceeding to the point a blog was in order. So, here we go.

Next installment, pictures of the pieces as they sat in dad's shop space, waiting for their turn in the sun as it were. And, more talk of what to do with this thing. In other words, maybe answer the questions in the title of this installment?? Yeah, I know. But these things take time. Until then, thanks for looking.
...
 

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#8 ·
What is it, what you gonna do with it?

Here we go again…

It was a dark and stormy night. Well, no, not really stormy. Or even night. But it was dark. And wet. My son was with me, along with my dad and daughter, in October of 2018 to discover and salvage whatever millwork we could find in a 135 year old commercial building in a nearby town. The brick structure was slated for demo; the roof had leaked for years, all the windows in the rear were bricked shut decades earlier, and the upper floors had been vacant at least a couple of generations. One part of the middle floor was rotted through. It was safe, but caution was the order of the day.

After finding a unique door and claiming it, my son spotted (via the flashlight app on his iphone) a bar, or counter, along a back brick wall. Think something like this:

Wood Rectangle Table Wood stain Outdoor furniture


Only, not as nice. Here's the only (bad) picture I took of the piece when it was still in the building.

Sleeve Wood Flooring Rectangle Tints and shades


At that point, it was already upside down. And that pic is of the end cap that survived. Now, I can't say "Let's start at the beginning" because, well, this blog post is the first. What I'm saying is, it'd be nice to show you more of the counter together, but I can't. We got it out from under bricks and other building detritus, and got it to the door. Then we got it partially out the door and into the hall. But only one end. Too long to get into the hall and stand up, for the trip down the stairs. So we had to take it apart. Beat it apart, really.

Oh, and did I mention it wasn't complete? One end was there, the other was cut off and the 'return' was nowhere to be found. Not complete, and rotten in places. Yep, wet and crumbly. But there was something about it that captured my imagination. After the beat-up and take down, the parts were carted across town to my dad's shop space. And there it sat for over a year. In early December of last year, I resolved to do something with it. And that has "something" has been proceeding to the point a blog was in order. So, here we go.

Next installment, pictures of the pieces as they sat in dad's shop space, waiting for their turn in the sun as it were. And, more talk of what to do with this thing. In other words, maybe answer the questions in the title of this installment?? Yeah, I know. But these things take time. Until then, thanks for looking.
Thanks everyone. And the second installment is up and open for your perusal!
 

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#9 ·
What is it, what you gonna do with it?

Here we go again…

It was a dark and stormy night. Well, no, not really stormy. Or even night. But it was dark. And wet. My son was with me, along with my dad and daughter, in October of 2018 to discover and salvage whatever millwork we could find in a 135 year old commercial building in a nearby town. The brick structure was slated for demo; the roof had leaked for years, all the windows in the rear were bricked shut decades earlier, and the upper floors had been vacant at least a couple of generations. One part of the middle floor was rotted through. It was safe, but caution was the order of the day.

After finding a unique door and claiming it, my son spotted (via the flashlight app on his iphone) a bar, or counter, along a back brick wall. Think something like this:

Wood Rectangle Table Wood stain Outdoor furniture


Only, not as nice. Here's the only (bad) picture I took of the piece when it was still in the building.

Sleeve Wood Flooring Rectangle Tints and shades


At that point, it was already upside down. And that pic is of the end cap that survived. Now, I can't say "Let's start at the beginning" because, well, this blog post is the first. What I'm saying is, it'd be nice to show you more of the counter together, but I can't. We got it out from under bricks and other building detritus, and got it to the door. Then we got it partially out the door and into the hall. But only one end. Too long to get into the hall and stand up, for the trip down the stairs. So we had to take it apart. Beat it apart, really.

Oh, and did I mention it wasn't complete? One end was there, the other was cut off and the 'return' was nowhere to be found. Not complete, and rotten in places. Yep, wet and crumbly. But there was something about it that captured my imagination. After the beat-up and take down, the parts were carted across town to my dad's shop space. And there it sat for over a year. In early December of last year, I resolved to do something with it. And that has "something" has been proceeding to the point a blog was in order. So, here we go.

Next installment, pictures of the pieces as they sat in dad's shop space, waiting for their turn in the sun as it were. And, more talk of what to do with this thing. In other words, maybe answer the questions in the title of this installment?? Yeah, I know. But these things take time. Until then, thanks for looking.
This one feels smokey. Im going scotch boys.
 

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#10 ·
Okay, What Exactly Do I Have?

The title of this post has actually been a recurring question since the counter was pulled out of a derelict building fifteen months ago. How bad was that structure? Here's what it looked like six months ago.

Brown Property Sky Wood Branch


Anyway, in the kick-off to this series I talked about getting back to the beginning. There's one bad picture of the piece before it was moved, and a very bad memory bank in my head that doesn't remember what it looked like before it was taken apart. Seriously, no recollection / clear picture of any framing that might have held the carcase together. And in many cases, over the past several months, I've wondered just exactly how it came apart.

So I'll share with you those questions and a number of pictures that are keys to our future story.

Here's the counter, in pieces, sitting in dad's shop space.
Wood Road surface Asphalt Automotive exterior Flooring


Take a close look at the 'angled piece' or 'rail' sitting on the floor. Specifically the end profile at the bottom right of the photo. That assembly makes up the top edging profile of the cabinet. It's on that built-up moulding that the top ultimately sits on. Follow that rail piece towards the back of the photo, and it comes off the floor because there is a return elbow (el, L). The full length of the counter is just under 11', and only the left end has a return L. The right end was rather unceremoniously cut off, once upon a time.

One kinda-close up of that rail profile, rotated to get a better sense of what it actually consists of. I count seven individual pieces of wood making up the overall profile: three rectangular boards, one pc of 1/2" quarter round, a 5/8" half-round, and two very custom pieces of millwork.

Wood Stairs Gas Composite material Tints and shades


Here's the end piece that survived, left of the brown board in the first pic. Note the bottom is gone / rotted away.

Wood Outdoor bench Floor Flooring Hardwood


Building Wood Asphalt Track Rolling


Hand Wood Building House Material property


Then there's the top.
Wood Flag Automotive tire Flooring Floor


It had some kind of linoleum (?) glued to it, and with water damage underneath. The piece is a single board, 1 1/2" thick, 24 1/2" wide, and just under 11' long. Amazing. One end in great shape, the other toast from the rot. Here it is during clean-up.

Table Wood Flooring Floor Gas


Note the mystery 2Ă—4 nailed to what is the underside of the top. That fits somewhere, somehow. And no, I'm not being coy. All these traces are clues; I honestly have been piecing together how this thing is meant to go back together.

Next time, I'll review the middle sections of the vertical assembly and present some reproduction builds that have been underway. Thanks for looking!
 

Attachments

#11 ·
Okay, What Exactly Do I Have?

The title of this post has actually been a recurring question since the counter was pulled out of a derelict building fifteen months ago. How bad was that structure? Here's what it looked like six months ago.

Brown Property Sky Wood Branch


Anyway, in the kick-off to this series I talked about getting back to the beginning. There's one bad picture of the piece before it was moved, and a very bad memory bank in my head that doesn't remember what it looked like before it was taken apart. Seriously, no recollection / clear picture of any framing that might have held the carcase together. And in many cases, over the past several months, I've wondered just exactly how it came apart.

So I'll share with you those questions and a number of pictures that are keys to our future story.

Here's the counter, in pieces, sitting in dad's shop space.
Wood Road surface Asphalt Automotive exterior Flooring


Take a close look at the 'angled piece' or 'rail' sitting on the floor. Specifically the end profile at the bottom right of the photo. That assembly makes up the top edging profile of the cabinet. It's on that built-up moulding that the top ultimately sits on. Follow that rail piece towards the back of the photo, and it comes off the floor because there is a return elbow (el, L). The full length of the counter is just under 11', and only the left end has a return L. The right end was rather unceremoniously cut off, once upon a time.

One kinda-close up of that rail profile, rotated to get a better sense of what it actually consists of. I count seven individual pieces of wood making up the overall profile: three rectangular boards, one pc of 1/2" quarter round, a 5/8" half-round, and two very custom pieces of millwork.

Wood Stairs Gas Composite material Tints and shades


Here's the end piece that survived, left of the brown board in the first pic. Note the bottom is gone / rotted away.

Wood Outdoor bench Floor Flooring Hardwood


Building Wood Asphalt Track Rolling


Hand Wood Building House Material property


Then there's the top.
Wood Flag Automotive tire Flooring Floor


It had some kind of linoleum (?) glued to it, and with water damage underneath. The piece is a single board, 1 1/2" thick, 24 1/2" wide, and just under 11' long. Amazing. One end in great shape, the other toast from the rot. Here it is during clean-up.

Table Wood Flooring Floor Gas


Note the mystery 2Ă—4 nailed to what is the underside of the top. That fits somewhere, somehow. And no, I'm not being coy. All these traces are clues; I honestly have been piecing together how this thing is meant to go back together.

Next time, I'll review the middle sections of the vertical assembly and present some reproduction builds that have been underway. Thanks for looking!
Nobody can ever say Smitty is not up for a challenge. I admire your desire to preserve/restore history. Waiting to see how this turns out, but I already know it will be spectacular.
 

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#25 ·
One (Re-)Turn Deserves Another

If you've paid attention thus far, you know the counter was cut off on one end, and that a single example of a 'return' is all I have. Aside from being incomplete (bottom rotted away), it will serve as a good pattern for a recreation piece for the other end of the counter.

I propped it in the face vice of the bench to have a look.

Wood Gas Machine Art Motor vehicle


Building Wood Asphalt Track Rolling


Wood Temple Art Wall Road surface


I need to rehab this original piece to replace rot, but first it must be duplicated! Face boards are 7/8" stock. Stiles (?) are a full 1" thick. Applied moulding are three pieces per side on a recessed rectangle. I have old pine in all those dimensions, and if I don't, I'll make it.

Through the magic of the internet (and lacking pics, because I didn't know I was going to blog it at the time), here's dressing the inset panel…

Plane Scrub plane Rebate plane Wood Jack plane


and then the completed face panel as I begin work on the inset mouldings! Wow, that's amazing, right? But then creating a frame in nothing big in and of itself, so let's get to the dressing. I have cove for the inset, but it wasn't 7/8 on one side. A bit of shimming took care of that.

Wood Door Rectangle Floor Plank


Cut the cove on the Goodell-Pratt (as I will all the moulding from this point)...

Motor vehicle Hood Automotive design Automotive tire Wood


and used the shoot plane to get it just right (as I did with all twelve pieces of this inset assy).

Wood Bumper Automotive exterior Auto part Metal


Then had to come up with 5/8" wide half-round moulding. I thought about using the No. 55, but there'd be nothing to rest the plane on (intended to do this to a long edge of 5/8" stock).

Gesture Rectangle Wood Gas Tints and shades


So it became a job for the H&R set. Doesn't need to be perfect, just needs to be consistent.

Wood Floor Hardwood Flooring Plank


Then needed 3/8" half-round, 1/2" deep. Used a beading plane to create the round…

Wood Flooring Door Floor Hardwood


then ripped it free with the table saw, creating the piece I needed.

Gesture Finger Wood Thumb Nail


Presto, the completed 'mirror image' copy! First, the original:

Rectangle Wood Road surface Composite material Gas


Then the reproduction:

Rectangle Wood Flooring Hardwood Plank


I'll spare the gory detail, but I then turned to the original to replace the rotted bottom face board and 'stretch' the stiles to a much more useable length.

Wood Gas Rectangle Font Tree


And I said this installment would talk about board stretching. Here's a board that needs help.

Wood Road surface Asphalt Automotive exterior Floor


I have no clue as to how long it needs to be, but what's there ain't enough. I located some appropriate (7/8" thick) pine stock and cut the rot away until I got to solid material. I also wanted as much glue surface as possible.

Wood Steelworker Saw Tool Engineering


Out of clamps.

Wood Wood stain Hardwood Plank Lumber


I then set the table saw fence, ripped the addition it to proper width, then made a copy of said piece.

Next time, more clues emerge on how this thing needs to be reconstructed. And a revisit of the top. Until then, thanks for looking!
 

Attachments

#26 ·
One (Re-)Turn Deserves Another

If you've paid attention thus far, you know the counter was cut off on one end, and that a single example of a 'return' is all I have. Aside from being incomplete (bottom rotted away), it will serve as a good pattern for a recreation piece for the other end of the counter.

I propped it in the face vice of the bench to have a look.

Wood Gas Machine Art Motor vehicle


Building Wood Asphalt Track Rolling


Wood Temple Art Wall Road surface


I need to rehab this original piece to replace rot, but first it must be duplicated! Face boards are 7/8" stock. Stiles (?) are a full 1" thick. Applied moulding are three pieces per side on a recessed rectangle. I have old pine in all those dimensions, and if I don't, I'll make it.

Through the magic of the internet (and lacking pics, because I didn't know I was going to blog it at the time), here's dressing the inset panel…

Plane Scrub plane Rebate plane Wood Jack plane


and then the completed face panel as I begin work on the inset mouldings! Wow, that's amazing, right? But then creating a frame in nothing big in and of itself, so let's get to the dressing. I have cove for the inset, but it wasn't 7/8 on one side. A bit of shimming took care of that.

Wood Door Rectangle Floor Plank


Cut the cove on the Goodell-Pratt (as I will all the moulding from this point)...

Motor vehicle Hood Automotive design Automotive tire Wood


and used the shoot plane to get it just right (as I did with all twelve pieces of this inset assy).

Wood Bumper Automotive exterior Auto part Metal


Then had to come up with 5/8" wide half-round moulding. I thought about using the No. 55, but there'd be nothing to rest the plane on (intended to do this to a long edge of 5/8" stock).

Gesture Rectangle Wood Gas Tints and shades


So it became a job for the H&R set. Doesn't need to be perfect, just needs to be consistent.

Wood Floor Hardwood Flooring Plank


Then needed 3/8" half-round, 1/2" deep. Used a beading plane to create the round…

Wood Flooring Door Floor Hardwood


then ripped it free with the table saw, creating the piece I needed.

Gesture Finger Wood Thumb Nail


Presto, the completed 'mirror image' copy! First, the original:

Rectangle Wood Road surface Composite material Gas


Then the reproduction:

Rectangle Wood Flooring Hardwood Plank


I'll spare the gory detail, but I then turned to the original to replace the rotted bottom face board and 'stretch' the stiles to a much more useable length.

Wood Gas Rectangle Font Tree


And I said this installment would talk about board stretching. Here's a board that needs help.

Wood Road surface Asphalt Automotive exterior Floor


I have no clue as to how long it needs to be, but what's there ain't enough. I located some appropriate (7/8" thick) pine stock and cut the rot away until I got to solid material. I also wanted as much glue surface as possible.

Wood Steelworker Saw Tool Engineering


Out of clamps.

Wood Wood stain Hardwood Plank Lumber


I then set the table saw fence, ripped the addition it to proper width, then made a copy of said piece.

Next time, more clues emerge on how this thing needs to be reconstructed. And a revisit of the top. Until then, thanks for looking!
Gutsy. I like it.

Im out of scotch.
 

Attachments

#39 ·
Figuring things out

Went to dad's shop space and did some "assembly," or staging of the pieces of the counter to revisit how it needs to come together. Yes, a great many of the pics have the piece upside down; that's the way I'm able to work it at this stage. Enough discussion, let's take a look.

The top is on the concrete; to that, I've added the complex moulding assy that has not been completely deconstructed as well as parts of each of the returns.

Wood Road surface Outdoor bench Rectangle Flooring


Once that was in place, I stood up one end cap.

Wood Motor vehicle Automotive design Gas Vehicle


And then, the other.

Table Wood Floor Flooring Engineering


That's a pretty good look as to what needs to be done. But wait, he said, there's more! We've got mid-sections pieces as well!

Wood Gas Composite material Machine Engineering


One key is the long center panel, that's recessed. It's quite long, and each board has a 45 degree lap cut to join them for making the distance of the counter's total width.. Knowing how long this joined piece needs to be is a question that needs to be answered. I'd also like to re-cut these pieces to mate up a little better.

Wood Road surface Asphalt Line Automotive tire


Wood Table Rectangle Road surface Automotive tire


Yeah, boards are different widths! Anyway, I want to cut and re-join these boards. So to the RAS.

Automotive tire Wood Motor vehicle Gas Engineering


Here's what I cut off one.

Wood Machine tool Saw Gas Hardwood


The other board has a bit a cupping that will have to be addressed to get a tight joint. More on that in a later installment.

Wood Natural material Wood stain Floor Plank


Then, there's the top. I marked a very rough cut-off during mark up, to bring this 11' monster down to a more manageable size.

Table Cabinetry Furniture Wood Desk


Table Wood Plank Wood stain Hardwood


Lots of rot remains. That will have to be addressed… with breadboard ends that extend? Or patched pieces? I just don't know. And more will have to be discovered re: getting the boards and trim applied towards the bottom of this assy, where it meets the floor. And, of course, the order of assy remains a question. Lots of unknowns, don't need any missteps. In the meantime, I'm off to get a quart of paint that matches this green as closely as possible, for touchups where old wood meets new cuts. Until then, thanks for looking.
 

Attachments

#40 ·
Figuring things out

Went to dad's shop space and did some "assembly," or staging of the pieces of the counter to revisit how it needs to come together. Yes, a great many of the pics have the piece upside down; that's the way I'm able to work it at this stage. Enough discussion, let's take a look.

The top is on the concrete; to that, I've added the complex moulding assy that has not been completely deconstructed as well as parts of each of the returns.

Wood Road surface Outdoor bench Rectangle Flooring


Once that was in place, I stood up one end cap.

Wood Motor vehicle Automotive design Gas Vehicle


And then, the other.

Table Wood Floor Flooring Engineering


That's a pretty good look as to what needs to be done. But wait, he said, there's more! We've got mid-sections pieces as well!

Wood Gas Composite material Machine Engineering


One key is the long center panel, that's recessed. It's quite long, and each board has a 45 degree lap cut to join them for making the distance of the counter's total width.. Knowing how long this joined piece needs to be is a question that needs to be answered. I'd also like to re-cut these pieces to mate up a little better.

Wood Road surface Asphalt Line Automotive tire


Wood Table Rectangle Road surface Automotive tire


Yeah, boards are different widths! Anyway, I want to cut and re-join these boards. So to the RAS.

Automotive tire Wood Motor vehicle Gas Engineering


Here's what I cut off one.

Wood Machine tool Saw Gas Hardwood


The other board has a bit a cupping that will have to be addressed to get a tight joint. More on that in a later installment.

Wood Natural material Wood stain Floor Plank


Then, there's the top. I marked a very rough cut-off during mark up, to bring this 11' monster down to a more manageable size.

Table Cabinetry Furniture Wood Desk


Table Wood Plank Wood stain Hardwood


Lots of rot remains. That will have to be addressed… with breadboard ends that extend? Or patched pieces? I just don't know. And more will have to be discovered re: getting the boards and trim applied towards the bottom of this assy, where it meets the floor. And, of course, the order of assy remains a question. Lots of unknowns, don't need any missteps. In the meantime, I'm off to get a quart of paint that matches this green as closely as possible, for touchups where old wood meets new cuts. Until then, thanks for looking.
Looking good.

What is the new length of the top?
 

Attachments

#53 ·
Front Panel 'King Board'

It happens at some point during every significant project. I get a bit hung up over completion details and then progress slows, while I play around the edges of the project or piece. In this case, it's the inset panel of the counter that has my undivided attention. It needs to be cut down, and the end 'length' is not critical as it's buried behind 6" + of other pieces on both ends. Cutting the 45Ëš lap joint, gluing it, and getting it cut to length is all my distracted self has been able to tackle over the past several days.

Last installment I had this:
Wood Saw Tool Hardwood Machine tool


Set it up on the bench for gluing by clamping each end, then gluing the middle and clamping it down.

Table Wood Floor Flooring Plank


Wood Road surface Asphalt Flooring Floor


Wood Bicycle tire Automotive tire Bicycle fork Engineering


Today I cut it to the 80" rough length. Counted 90 rings on the pine board.

Wood Automotive exterior Motor vehicle Bumper Wheel


Automotive tire Bumper Wood Automotive exterior Asphalt


Wood Bumper Machine tool Hardwood Gas


And, another mock-up to wrap up this (short) installment. More next week, thanks!

Wood Automotive exterior Asphalt Gas Composite material
 

Attachments

#54 ·
Front Panel 'King Board'

It happens at some point during every significant project. I get a bit hung up over completion details and then progress slows, while I play around the edges of the project or piece. In this case, it's the inset panel of the counter that has my undivided attention. It needs to be cut down, and the end 'length' is not critical as it's buried behind 6" + of other pieces on both ends. Cutting the 45Ëš lap joint, gluing it, and getting it cut to length is all my distracted self has been able to tackle over the past several days.

Last installment I had this:
Wood Saw Tool Hardwood Machine tool


Set it up on the bench for gluing by clamping each end, then gluing the middle and clamping it down.

Table Wood Floor Flooring Plank


Wood Road surface Asphalt Flooring Floor


Wood Bicycle tire Automotive tire Bicycle fork Engineering


Today I cut it to the 80" rough length. Counted 90 rings on the pine board.

Wood Automotive exterior Motor vehicle Bumper Wheel


Automotive tire Bumper Wood Automotive exterior Asphalt


Wood Bumper Machine tool Hardwood Gas


And, another mock-up to wrap up this (short) installment. More next week, thanks!

Wood Automotive exterior Asphalt Gas Composite material
90??!!?
 

Attachments

#66 ·
Big Moves, Big Progress

Okay, big statements in the title, so let's get right to it. First color matching. Yep, I'm talking paint.

Wood Gas Automotive exterior Thumb Metal


I laid down a tan-ish base coat to approximate what I've seen as a lighter finish that's under the green that survives on most of the rest of the carcase. Then laid down the green.

Wood Gas Machine Metal Concrete


The finish on the surviving end-cap is NOT green like the millwork I used to get the color mixed, that's for sure. So the whole thing may end up getting a coat when all is said and done. But with the painting done, it was time to create a bit of half round that happened to be Nosing Plane sized from my set of wood planes.

Wood Automotive exterior Wood stain Floor Rectangle


Wood Gas Hardwood Lumber Automotive tire


Wood Tints and shades Font Metal Roof


I started out with the (crazy?) idea of standing this piece up before the end of the day. So, tighten up some unseen 'joints' where the rail build out meets the flat front.

Wood Natural material Plank Wood stain Hardwood


Door Wood Bumper Automotive exterior Hardwood


Then, with the front of the counter 'face down' on a table, I added sides.

Wood Flooring Floor Gas Hardwood


Table Wood Floor Machine tool Hardwood


Cut the bottom 'rail' board to length (the board that defines the primary recessed panel) and put it in place.

Automotive tire Machine tool Asphalt Gas Automotive wheel system


Wood Flooring Floor Wood stain Rectangle


Wood Automotive exterior Bumper Gas Hardwood


And then stood the piece up, with two actual returns, for the first time in a very long time.

Wood Gas Shipping box Machine Hardwood


Huzzah!

Next time, the panel is placed, we talk about more applied mouldings for the panel as well as the base, and see if there's been progress on the top! Thanks for looking.
 

Attachments

#67 ·
Big Moves, Big Progress

Okay, big statements in the title, so let's get right to it. First color matching. Yep, I'm talking paint.

Wood Gas Automotive exterior Thumb Metal


I laid down a tan-ish base coat to approximate what I've seen as a lighter finish that's under the green that survives on most of the rest of the carcase. Then laid down the green.

Wood Gas Machine Metal Concrete


The finish on the surviving end-cap is NOT green like the millwork I used to get the color mixed, that's for sure. So the whole thing may end up getting a coat when all is said and done. But with the painting done, it was time to create a bit of half round that happened to be Nosing Plane sized from my set of wood planes.

Wood Automotive exterior Wood stain Floor Rectangle


Wood Gas Hardwood Lumber Automotive tire


Wood Tints and shades Font Metal Roof


I started out with the (crazy?) idea of standing this piece up before the end of the day. So, tighten up some unseen 'joints' where the rail build out meets the flat front.

Wood Natural material Plank Wood stain Hardwood


Door Wood Bumper Automotive exterior Hardwood


Then, with the front of the counter 'face down' on a table, I added sides.

Wood Flooring Floor Gas Hardwood


Table Wood Floor Machine tool Hardwood


Cut the bottom 'rail' board to length (the board that defines the primary recessed panel) and put it in place.

Automotive tire Machine tool Asphalt Gas Automotive wheel system


Wood Flooring Floor Wood stain Rectangle


Wood Automotive exterior Bumper Gas Hardwood


And then stood the piece up, with two actual returns, for the first time in a very long time.

Wood Gas Shipping box Machine Hardwood


Huzzah!

Next time, the panel is placed, we talk about more applied mouldings for the panel as well as the base, and see if there's been progress on the top! Thanks for looking.
Aww yea! Right side up and lookin proud. Good work smitty.
 

Attachments

#80 ·
And to Top It All Off...

The top has been a nagging issue. On the back burner, but an outstanding issue nonetheless. It started as a wet, rotting mass under glued-down linoleum.

Wood Flag Automotive tire Flooring Floor


After some cleanup, and with a rough cut to length, the problem of rot was isolated to one corner area.

Wood Flooring Floor Road surface Composite material


I've decided to cut the board to a narrower width and restore it to size with donor material. That'll get rid of 90% of the rot and also get me a solid edge the entire run of the piece. It's not something I'm totally happy doing, but it's in the best interest of the top re: integrity and overall strength. It's drastic but gets me a very strong countertop (hopefully), and if I do it right it will not be too much of an obvious fix. Do I hate losing 24 inch width of this single, awesome board? Of course. But, as glorious as the 24"x8' board is, the counter needs a top. And with the rot as bad as it is, I could only do a 5' counter if the top was to stay as is. Something had to give.

Wood Asphalt Floor Flooring Gas


Wood Automotive tire Tool Flooring Floor


Automotive tire Cabinetry Road surface Tire Wood


Wood Road surface Asphalt Trunk Automotive exterior


There's still this to deal with, but remember it was cut long. So a lot of this is going away when final length is set.

Table Wood Wood stain Rectangle Floor


Time to bring this board 'home,' to my shop, for final work. And now you'll get a better sense of scale for this whopper.

Wheel Tire Vehicle Car Automotive tire


Wood Building Wheel Shelving Table


Next time, finding the right adder to restore the top to proper width. Thanks for looking.
 

Attachments

#81 ·
And to Top It All Off...

The top has been a nagging issue. On the back burner, but an outstanding issue nonetheless. It started as a wet, rotting mass under glued-down linoleum.

Wood Flag Automotive tire Flooring Floor


After some cleanup, and with a rough cut to length, the problem of rot was isolated to one corner area.

Wood Flooring Floor Road surface Composite material


I've decided to cut the board to a narrower width and restore it to size with donor material. That'll get rid of 90% of the rot and also get me a solid edge the entire run of the piece. It's not something I'm totally happy doing, but it's in the best interest of the top re: integrity and overall strength. It's drastic but gets me a very strong countertop (hopefully), and if I do it right it will not be too much of an obvious fix. Do I hate losing 24 inch width of this single, awesome board? Of course. But, as glorious as the 24"x8' board is, the counter needs a top. And with the rot as bad as it is, I could only do a 5' counter if the top was to stay as is. Something had to give.

Wood Asphalt Floor Flooring Gas


Wood Automotive tire Tool Flooring Floor


Automotive tire Cabinetry Road surface Tire Wood


Wood Road surface Asphalt Trunk Automotive exterior


There's still this to deal with, but remember it was cut long. So a lot of this is going away when final length is set.

Table Wood Wood stain Rectangle Floor


Time to bring this board 'home,' to my shop, for final work. And now you'll get a better sense of scale for this whopper.

Wheel Tire Vehicle Car Automotive tire


Wood Building Wheel Shelving Table


Next time, finding the right adder to restore the top to proper width. Thanks for looking.
I'm enjoying following this one.

Just a thought, but how about salvaging your cutoff and scarfing a donor piece to replace the rotted portion?
 

Attachments

#91 ·
Square Up, Trim Out

So, in the beginning, we started with a single complex moulding assy that supported the underside of the top. It was 11' long and had one 'return,' or 90Ëš el that was on the left end of the piece.



I didn't take pictures, but several weeks ago my Dad convinced me to cut this long piece at the 8' mark, at a 45Ëš angle, and use that cutoff to make the right return. I used the small crosscut saw from my tool tote that Bob Summerfield sharped and restored for me, and it worked like a charm. And, most importantly, I didn't hit any nails in the process. This shows the fresh cuts from a mock up, a couple weeks ago; I was happy to see the cuts were pretty close.



Let's move on to completing the re-build of that entire upper moulding assembly for real, then.

The right side cuts, matched up and crowned for the first time ever on the completed base, looks quite good.



What I called crown is that 1/2" x 3 1/2" flat stock at the top of the moulding assy, and it's what the top will ultimately rest on. And yes, I believe the top simply sits on top of the counter / is not nailed into place. But we'll see when the time comes if it stays that way.

But, getting back to the tasks of the day, I wanted to set that crown to a base assembly that's square. So a couple of temp braces were added.



What's with the 'stuff' under the front leg, and the items weighing down the counter at either end? The assembled piece has a bit of a twist to it, probably because of the conditions I found it in (wet, rotted base, etc.) fifteen months ago. So we're playing the 'patience' card by putting opposite stress on the counter between workdays. It's getting better, so there's that. Anyway, the center panel then needed attention. Where, you ask? Well, the center panel board is cupped, and it's driving me crazy because of gaps and the impact those gaps will have on the three sets of moulding that need to be applied to 'raise' said center panel. Pictures might help explain the concern, you say? Okay.





So, what to do? Well, Dad convinced me to remove the center panel and plane down the 'hump' of the board that sits behind the vertical AND that part that will sit behind the larger piece of moulding to be applied. Then we'll re-set the center panel and carry on. So, here we go. I started by marking the panel in pencil where the moulding would reach. Then it was removed and brought over to the bench, where I clamped a straight edge, knifed a line, and make the first blows via rasp to get the paint off.



Then, to the block plane (SW No. 118 that lives in the tote, for the terminally curious).





The 7/8" cove was applied in the crease,



then the nosing was applied inside that.



Things were looking good! Well, as good (or better/tighter) a trim up than the piece had when we found it! Can't imagine nailing on those pieces by hand, with cut nails, as it was a hundred and thirty + years ago. That's some serious skill with a hammer!



I brought the G-P to Dad's shop for moulding cuts, btw.



And the No. 51/52 shoot board plane made the trip too (no pics, sorry). Dad was very impressed with that tool.

Anyway, the last applied piece was the 5/8" half round.



And the center panel is complete and looking good!



If you're wanting an update on the top, sorry. But today's work got me a critical piece of info: The top must be 93 3/4" long. And at least 23 9/16" deep.


Okay, that's it for now. Next time, an update on the top. Promise. :) And at some point, doing something to 'finish' the backside of this piece got into my head. The initial thought? Something like this:


Thanks for looking.
 

Attachments

#92 ·
Square Up, Trim Out

So, in the beginning, we started with a single complex moulding assy that supported the underside of the top. It was 11' long and had one 'return,' or 90Ëš el that was on the left end of the piece.

Wood Motor vehicle Automotive exterior Bumper Gas


I didn't take pictures, but several weeks ago my Dad convinced me to cut this long piece at the 8' mark, at a 45Ëš angle, and use that cutoff to make the right return. I used the small crosscut saw from my tool tote that Bob Summerfield sharped and restored for me, and it worked like a charm. And, most importantly, I didn't hit any nails in the process. This shows the fresh cuts from a mock up, a couple weeks ago; I was happy to see the cuts were pretty close.

Wood Flooring Rectangle Gas Road surface


Let's move on to completing the re-build of that entire upper moulding assembly for real, then.

The right side cuts, matched up and crowned for the first time ever on the completed base, looks quite good.

Furniture Table Desk Wood Chair


What I called crown is that 1/2" x 3 1/2" flat stock at the top of the moulding assy, and it's what the top will ultimately rest on. And yes, I believe the top simply sits on top of the counter / is not nailed into place. But we'll see when the time comes if it stays that way.

But, getting back to the tasks of the day, I wanted to set that crown to a base assembly that's square. So a couple of temp braces were added.

Wood Automotive exterior Gas Hardwood Flooring


What's with the 'stuff' under the front leg, and the items weighing down the counter at either end? The assembled piece has a bit of a twist to it, probably because of the conditions I found it in (wet, rotted base, etc.) fifteen months ago. So we're playing the 'patience' card by putting opposite stress on the counter between workdays. It's getting better, so there's that. Anyway, the center panel then needed attention. Where, you ask? Well, the center panel board is cupped, and it's driving me crazy because of gaps and the impact those gaps will have on the three sets of moulding that need to be applied to 'raise' said center panel. Pictures might help explain the concern, you say? Okay.

Wood Floor Rectangle Gas Composite material


Wood Finger Gas Metal Composite material


So, what to do? Well, Dad convinced me to remove the center panel and plane down the 'hump' of the board that sits behind the vertical AND that part that will sit behind the larger piece of moulding to be applied. Then we'll re-set the center panel and carry on. So, here we go. I started by marking the panel in pencil where the moulding would reach. Then it was removed and brought over to the bench, where I clamped a straight edge, knifed a line, and make the first blows via rasp to get the paint off.

Wood Tool Saw Automotive exterior Gas


Then, to the block plane (SW No. 118 that lives in the tote, for the terminally curious).

Wood Flooring Floor Road surface Outdoor shoe


Wood Flooring Floor Hardwood Composite material


The 7/8" cove was applied in the crease,

Human body Sleeve Tree Font Event


then the nosing was applied inside that.

Rectangle Font Event Electric blue Monochrome photography


Things were looking good! Well, as good (or better/tighter) a trim up than the piece had when we found it! Can't imagine nailing on those pieces by hand, with cut nails, as it was a hundred and thirty + years ago. That's some serious skill with a hammer!

Road surface Wood Asphalt Vehicle Track


I brought the G-P to Dad's shop for moulding cuts, btw.

Table Wood Artisan Engineering Machine


And the No. 51/52 shoot board plane made the trip too (no pics, sorry). Dad was very impressed with that tool.

Anyway, the last applied piece was the 5/8" half round.

Sleeve Gesture Circle Astronomical object Event


And the center panel is complete and looking good!

Vehicle Automotive tire Road surface Infrastructure Asphalt


If you're wanting an update on the top, sorry. But today's work got me a critical piece of info: The top must be 93 3/4" long. And at least 23 9/16" deep.
Tape measure Wood Rectangle Tool Measuring instrument


Okay, that's it for now. Next time, an update on the top. Promise. :) And at some point, doing something to 'finish' the backside of this piece got into my head. The initial thought? Something like this:
Wood Table Rectangle Floor Flooring


Thanks for looking.
Still continuing to impress Smitty.

This is fun to watch and educational!
 

Attachments

#100 ·
What's the Latest on the Top?

I ripped the top that was just under 24 1/2" wide to get rid of 90% of the rot problem.

Wood Automotive tire Tool Flooring Floor


The challenge then is to replace the rotten wood with good stuff. Dad offered a vintage "red pine" 2x that we dug out of inventory. Here it is after cutting it to rough length.

Table Wood Road surface Flooring Hardwood


Let the planing begin. And it did. A lot. When it got to the right thickness (just under 1 1/2"), it headed to the bench. First, had to remove the crochet.

Table Wood Motor vehicle Workbench Saw


Then, in the vises it went.

Table Wood Hardwood Wood stain Plank


Some edging with the No. 8 (H&H) got it in shape as well. It took a bit of work.

Brown Table Wood Trunk Plank


The S5 got some action as well. Love having that plane at the bench.

Plane Saw Motor vehicle Tool Wood


Wood Motor vehicle Engineering Track Machine


Then red pine met old growth white pine. And the match was, well….

Wood Plank Rectangle Hardwood Wood stain


.
.
.
.
.
.
.
.
.
.

Yeah, I'm thinking what you're thinking: It's not working, it ain't right. So I turned to the LJ community with my struggle. Scarf joints. everyone said. Piece together old and new as much as possible. The piece that was cut from the top got some attention, then.

Wood Wheel Table Machine Engineering


Cut to get the most usable piece:
Wood Automotive tire Road surface Flooring Floor


Get a fresh (and square) edge on one end of the main top board.
Saw Plant Wood Abrasive saw Circular saw


Then cut it to final length, just a hair over 93 3/4".
Wood Rectangle Composite material Flooring Gas


And then decide the potential of two scarf joints is too much, especially when seeing the ratty edges I'd have to live with. I needed a solid alternative. And for me, the key was white pine, old growth and creamy in color. Because we've salvaged so much for so long w/ all the renovations Dad has done my whole life, I've had the opportunity to work with that wood a lot. I know it when I see it, and red pine wasn't cutting it. Then, in Dad's shop I spotted this board that I've since brought home to my shop:

Brown Wood Bag Rectangle Beige


I know it's the right stuff. 6' long, a full 2" thick, absolutely clear, white pine. So let the planing begin (again!).
Wood Gas Road surface Asphalt Bumper


Got it down to thickness, then took a single pass on the rougcut side to get a nice, smooth surface but one at the same time that wasn't 'factory fresh.' And it looked good to my eye.

Wood Plank Hardwood Wood stain Composite material


So, let's do this. Cut a 45 on each, and get the pieces glued up so we're ready to joint the two resultant boards
in the next few days!
Wood Metalworking hand tool Hardwood Gas Plank


Wood Flooring Floor Gas Hardwood


And as a nod to using all the pieces of the 'new' board as well as the original cutoff piece, I milled them to be the outside edging for the top! There will be seems, but I can handle that.
Wood Picnic table Hardwood Machine tool Plank


Okay, so that's a top installment. Next time, it'll be a final piece and setting on top the counter for the first time in quite a while. Thanks for looking!
 

Attachments

#101 ·
What's the Latest on the Top?

I ripped the top that was just under 24 1/2" wide to get rid of 90% of the rot problem.

Wood Automotive tire Tool Flooring Floor


The challenge then is to replace the rotten wood with good stuff. Dad offered a vintage "red pine" 2x that we dug out of inventory. Here it is after cutting it to rough length.

Table Wood Road surface Flooring Hardwood


Let the planing begin. And it did. A lot. When it got to the right thickness (just under 1 1/2"), it headed to the bench. First, had to remove the crochet.

Table Wood Motor vehicle Workbench Saw


Then, in the vises it went.

Table Wood Hardwood Wood stain Plank


Some edging with the No. 8 (H&H) got it in shape as well. It took a bit of work.

Brown Table Wood Trunk Plank


The S5 got some action as well. Love having that plane at the bench.

Plane Saw Motor vehicle Tool Wood


Wood Motor vehicle Engineering Track Machine


Then red pine met old growth white pine. And the match was, well….

Wood Plank Rectangle Hardwood Wood stain


.
.
.
.
.
.
.
.
.
.

Yeah, I'm thinking what you're thinking: It's not working, it ain't right. So I turned to the LJ community with my struggle. Scarf joints. everyone said. Piece together old and new as much as possible. The piece that was cut from the top got some attention, then.

Wood Wheel Table Machine Engineering


Cut to get the most usable piece:
Wood Automotive tire Road surface Flooring Floor


Get a fresh (and square) edge on one end of the main top board.
Saw Plant Wood Abrasive saw Circular saw


Then cut it to final length, just a hair over 93 3/4".
Wood Rectangle Composite material Flooring Gas


And then decide the potential of two scarf joints is too much, especially when seeing the ratty edges I'd have to live with. I needed a solid alternative. And for me, the key was white pine, old growth and creamy in color. Because we've salvaged so much for so long w/ all the renovations Dad has done my whole life, I've had the opportunity to work with that wood a lot. I know it when I see it, and red pine wasn't cutting it. Then, in Dad's shop I spotted this board that I've since brought home to my shop:

Brown Wood Bag Rectangle Beige


I know it's the right stuff. 6' long, a full 2" thick, absolutely clear, white pine. So let the planing begin (again!).
Wood Gas Road surface Asphalt Bumper


Got it down to thickness, then took a single pass on the rougcut side to get a nice, smooth surface but one at the same time that wasn't 'factory fresh.' And it looked good to my eye.

Wood Plank Hardwood Wood stain Composite material


So, let's do this. Cut a 45 on each, and get the pieces glued up so we're ready to joint the two resultant boards
in the next few days!
Wood Metalworking hand tool Hardwood Gas Plank


Wood Flooring Floor Gas Hardwood


And as a nod to using all the pieces of the 'new' board as well as the original cutoff piece, I milled them to be the outside edging for the top! There will be seems, but I can handle that.
Wood Picnic table Hardwood Machine tool Plank


Okay, so that's a top installment. Next time, it'll be a final piece and setting on top the counter for the first time in quite a while. Thanks for looking!
Very cool!
 

Attachments

#158 ·
Top, Trim-out, and Infrastructure

Lots of content added to comments section of last blog entry, but I'll catch everyone up on progress. Specifically, the top has been cut to final width, planed with various smoothers (4, 4 1/2, 1), and edged with stock that matches the stuff originally found around the top. I decided to paint said edging, as the original was.

Furniture Wood Outdoor furniture Chair Flooring


Wood Naval architecture Rectangle Composite material Plank


Automotive tire Wood Road surface Asphalt Motor vehicle


Wood Flooring Hardwood Bumper Gas


Bicycle Wheel Tire Automotive tire Bicycle wheel rim


Then it was placed on the counter carcase at Dad's shop; AND IT FIT! :)

Wood Floor Flooring Automotive tire Asphalt


Today it was about cutting and applying the large original beading profile that is part of the base build-up. I made additional large bead with the nosing plane.

Furniture Outdoor bench Table Wood Outdoor furniture


Wood Gas Tints and shades Road surface Machine


Wood Wood stain Gas Hardwood Plywood


The final bottom skirt board sits proud of the corner stiles by 1/2". For that, and to start on what will be my back cabinet buildout, I opted for some 2Ă—4 infrastructure.

Wood Road surface Asphalt Flooring Floor


Next time, I'll work that framing along each end cap, and (hopefully) complete the bottom skirt board mitering / install.

Wood Asphalt Automotive exterior Rectangle Bumper


Wood Gas Automotive exterior Machine Rolling


In the meantime, the piece is looking quite good to my eye.

Table Furniture Wood Wood stain Plant


Table Wood Asphalt Automotive tire Gas


As always, thanks for looking!
 

Attachments

#159 ·
Top, Trim-out, and Infrastructure

Lots of content added to comments section of last blog entry, but I'll catch everyone up on progress. Specifically, the top has been cut to final width, planed with various smoothers (4, 4 1/2, 1), and edged with stock that matches the stuff originally found around the top. I decided to paint said edging, as the original was.

Furniture Wood Outdoor furniture Chair Flooring


Wood Naval architecture Rectangle Composite material Plank


Automotive tire Wood Road surface Asphalt Motor vehicle


Wood Flooring Hardwood Bumper Gas


Bicycle Wheel Tire Automotive tire Bicycle wheel rim


Then it was placed on the counter carcase at Dad's shop; AND IT FIT! :)

Wood Floor Flooring Automotive tire Asphalt


Today it was about cutting and applying the large original beading profile that is part of the base build-up. I made additional large bead with the nosing plane.

Furniture Outdoor bench Table Wood Outdoor furniture


Wood Gas Tints and shades Road surface Machine


Wood Wood stain Gas Hardwood Plywood


The final bottom skirt board sits proud of the corner stiles by 1/2". For that, and to start on what will be my back cabinet buildout, I opted for some 2Ă—4 infrastructure.

Wood Road surface Asphalt Flooring Floor


Next time, I'll work that framing along each end cap, and (hopefully) complete the bottom skirt board mitering / install.

Wood Asphalt Automotive exterior Rectangle Bumper


Wood Gas Automotive exterior Machine Rolling


In the meantime, the piece is looking quite good to my eye.

Table Furniture Wood Wood stain Plant


Table Wood Asphalt Automotive tire Gas


As always, thanks for looking!
Oh my! It sure is easy on the eyes Smitty. Real nice workmanship on the nosing.
 

Attachments

#202 ·
Cutting Skirtboard Bevels

Started with this, needed to complete framing.
Wood Gas Automotive exterior Machine Rolling


Musical instrument Wood Bumper Gas Automotive exterior


Then all that framing needed a 1/2" shim job to get it all prepped for skirting. That was a pain to complete, too. But while I was at it, a number of screws were put in place to tie all the pieces together a little more rigidly. 2" finish nails were shot in as well. We've got a pretty tight old carcase now.
Wood Table Art Hardwood Flooring


Skirt boards need a number of perfectly cut (!) inside and outside bevels. How to do that ran the gamut.

Free handed:
Wood Wood stain Plank Table Hardwood


Wood Automotive tire Flooring Hardwood Gas


With a shootboard made to assist:
Wood Hood Hardwood Machine Flooring


To this:
Wood Automotive design Motor vehicle Tool Art


And then, as another option, this:
Saw Tool Bumper Gas Automotive exterior


So, what works? Well, the free hand method is fastest and actually has really good results, but the shooting board is a FAIL when it comes to final cleanup. Why? Not sure, but it's just not good enough.

The No. 31 compound jig?
Wood Automotive exterior Bumper Hardwood Asphalt


Hood Musical instrument Wood Automotive design Motor vehicle


It works quite well, actually, but cutting a full width, 45Ëš bevel in the face of a 1Ă—6 is slo-o-o-w-w-w-w going, let me tell you. I will finish a number of cuts that way, simply in the name of Galoot Indexing, but it's not the way to make 18 bevels.

The Porter Cable Model 314 Trim Saw got most of the action today…

Here's how far I got:
Furniture Table Musical instrument Wood Bench


Wood Asphalt Road surface Automotive exterior Bumper


Wood Floor Table Flooring Gas


There are a number of smalls cut and ready to install, once their neighboring pieces are cut. I'm learning to minimize waste, as there are only a few pieces of stock made to complete this bottom work. Yes, I pieced boards together to get the three pieces I'm using.

A view from the back (ready for a board bottom).
Table Wood Gas Asphalt Hardwood
 

Attachments

#203 ·
Cutting Skirtboard Bevels

Started with this, needed to complete framing.
Wood Gas Automotive exterior Machine Rolling


Musical instrument Wood Bumper Gas Automotive exterior


Then all that framing needed a 1/2" shim job to get it all prepped for skirting. That was a pain to complete, too. But while I was at it, a number of screws were put in place to tie all the pieces together a little more rigidly. 2" finish nails were shot in as well. We've got a pretty tight old carcase now.
Wood Table Art Hardwood Flooring


Skirt boards need a number of perfectly cut (!) inside and outside bevels. How to do that ran the gamut.

Free handed:
Wood Wood stain Plank Table Hardwood


Wood Automotive tire Flooring Hardwood Gas


With a shootboard made to assist:
Wood Hood Hardwood Machine Flooring


To this:
Wood Automotive design Motor vehicle Tool Art


And then, as another option, this:
Saw Tool Bumper Gas Automotive exterior


So, what works? Well, the free hand method is fastest and actually has really good results, but the shooting board is a FAIL when it comes to final cleanup. Why? Not sure, but it's just not good enough.

The No. 31 compound jig?
Wood Automotive exterior Bumper Hardwood Asphalt


Hood Musical instrument Wood Automotive design Motor vehicle


It works quite well, actually, but cutting a full width, 45Ëš bevel in the face of a 1Ă—6 is slo-o-o-w-w-w-w going, let me tell you. I will finish a number of cuts that way, simply in the name of Galoot Indexing, but it's not the way to make 18 bevels.

The Porter Cable Model 314 Trim Saw got most of the action today…

Here's how far I got:
Furniture Table Musical instrument Wood Bench


Wood Asphalt Road surface Automotive exterior Bumper


Wood Floor Table Flooring Gas


There are a number of smalls cut and ready to install, once their neighboring pieces are cut. I'm learning to minimize waste, as there are only a few pieces of stock made to complete this bottom work. Yes, I pieced boards together to get the three pieces I'm using.

A view from the back (ready for a board bottom).
Table Wood Gas Asphalt Hardwood
Smitty, I've got nothing to add on the long mitres. Gotta dig into my library of old stuff.

On a brighter note, it does look good. Will the back be left open and unfinished? Going up against the wall?
 

Attachments

#219 ·
Reassembly Complete!

Ah, so nice!

From this:
Wood Stairs Gas Composite material Tints and shades


Wood Road surface Asphalt Automotive exterior Flooring


Wood Outdoor bench Floor Flooring Hardwood


Table Wood Flooring Floor Gas


Table Textile Tablecloth Wood Gas


Wood Gas Shipping box Machine Hardwood


To this!
Rectangle Wood Gas Hardwood Molding


Furniture Table Wood Floor Flooring


Table Desk Wood Flooring Gas


Next time some basic framework in the back before sealing the top then taking a break on the project.

Table Wood Floor Flooring Hardwood


Thanks for looking!
 

Attachments

#220 ·
Reassembly Complete!

Ah, so nice!

From this:
Wood Stairs Gas Composite material Tints and shades


Wood Road surface Asphalt Automotive exterior Flooring


Wood Outdoor bench Floor Flooring Hardwood


Table Wood Flooring Floor Gas


Table Textile Tablecloth Wood Gas


Wood Gas Shipping box Machine Hardwood


To this!
Rectangle Wood Gas Hardwood Molding


Furniture Table Wood Floor Flooring


Table Desk Wood Flooring Gas


Next time some basic framework in the back before sealing the top then taking a break on the project.

Table Wood Floor Flooring Hardwood


Thanks for looking!
Yea boy! All the way back.
 

Attachments

#238 ·
Filling Holes...

Yep, that's what I did tonight, under the threat of quarantine! Not because anyone in the house is expected to be sick or exposed, but because Illinois is tight and getting tighter. Anyway, started by turning the top upside down and taping holes so they're be no bleed-through. Then turned it over and got ready to fill by taping the hole 'surrounds'.

Wood Table Automotive exterior Composite material Gas


Mixed up the epoxy, filled holes!

Wood Table Floor Flooring Composite material


Yeah, not exciting. Know what is exciting? The beams in the cellar of Dad's shop building. One part of it was built in 1849. Here's the hand-hewn main foundation timbers on stacked rock foundation.

Brown Bedrock Building material Composite material Rock


Floor joists are 3" wide. Know what kind of wood?

Brown Wood Beam Hardwood Tints and shades


This one should give it away.

Wood Trunk Wood stain Hardwood Rectangle


And next time, we see if the epoxy did it's job. Top will be sanded and otherwise 'made ready' for a finish. Thanks for looking.
 

Attachments

#239 ·
Filling Holes...

Yep, that's what I did tonight, under the threat of quarantine! Not because anyone in the house is expected to be sick or exposed, but because Illinois is tight and getting tighter. Anyway, started by turning the top upside down and taping holes so they're be no bleed-through. Then turned it over and got ready to fill by taping the hole 'surrounds'.

Wood Table Automotive exterior Composite material Gas


Mixed up the epoxy, filled holes!

Wood Table Floor Flooring Composite material


Yeah, not exciting. Know what is exciting? The beams in the cellar of Dad's shop building. One part of it was built in 1849. Here's the hand-hewn main foundation timbers on stacked rock foundation.

Brown Bedrock Building material Composite material Rock


Floor joists are 3" wide. Know what kind of wood?

Brown Wood Beam Hardwood Tints and shades


This one should give it away.

Wood Trunk Wood stain Hardwood Rectangle


And next time, we see if the epoxy did it's job. Top will be sanded and otherwise 'made ready' for a finish. Thanks for looking.
Plugging along ( pun intended)
 

Attachments

#257 ·
An Example in the Wild, and A Top Finish

Left off looking like this:

Table Desk Wood Flooring Gas


And saw what appeared to be one of theses 'store counters' in the wild…

Plant Flowerpot Wood Rectangle Cabinetry


Not a fancy backside build-out.

Table Outdoor furniture Plant Outdoor table Floor


Anyway, back to my piece. Applied wiping varnish (3-2-1, poly and spirits and BLO), about 10 coats. Green pad in between. Today, waxed with 0000 steel wool.

Table Furniture Wood Flooring Floor


After a drying half-hour, and a good rub-out, it looked great.

Furniture Building Wood Wood stain Rectangle


Furniture Table Wood Countertop Flooring


One more blog will finish this piece, and will come when I do whatever I do to the open side.

Thanks for looking!
 

Attachments

#258 ·
An Example in the Wild, and A Top Finish

Left off looking like this:

Table Desk Wood Flooring Gas


And saw what appeared to be one of theses 'store counters' in the wild…

Plant Flowerpot Wood Rectangle Cabinetry


Not a fancy backside build-out.

Table Outdoor furniture Plant Outdoor table Floor


Anyway, back to my piece. Applied wiping varnish (3-2-1, poly and spirits and BLO), about 10 coats. Green pad in between. Today, waxed with 0000 steel wool.

Table Furniture Wood Flooring Floor


After a drying half-hour, and a good rub-out, it looked great.

Furniture Building Wood Wood stain Rectangle


Furniture Table Wood Countertop Flooring


One more blog will finish this piece, and will come when I do whatever I do to the open side.

Thanks for looking!
Oh, I like yours so much better. I hope you leave the green. You've done an absolutely fantastic job.
 

Attachments

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