Shop storage projects #15: A back for the case, and...

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Blog entry by bandit571 posted 01-26-2017 04:09 AM 1301 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 14: Face frame rails are done Part 15 of Shop storage projects series Part 16: Top is done.... »

And a frame for the top gets a start. Well, the other night, I snuck back down to the shop, meaning merely take the clamps off, and put the clamps away…...wound up doing a bit more.

Once the clamps were off, I flipped the case onto it’s front. I used one pipe clamp to hold it onto the top of the bench. Didn’t want it to fall off onto the floor…

Slapped the sheet of plywood in place, and marked out where to try the cuts at. Cordless circular saw was just about eye-level…..made all the cuts. Somehow. Had just enough screws to attach the back to the case…..and set the case onto the floor, on it’s on four feet..

Since I already had the resaw work done, I did a bit of joinery work…I cut 45 degree mitres on the “short rails”

Mainly with this old saw. I had to trim the ends a bit anyway..

Yep, a bit rough. I used these to mark out a fancy cut on the Long Rails..

Then left for the night….
Today was a plane day. I used a cambered jack to remove the wavy stuff and the saw marks. To hold things still long enough for that to happen, I added a couple blocks to the bench top..

There was this stop block. It did have a “V” cut on one side, to capture beveled cuts. About the same as the one I added to the end vise..

That way, I could use the vise, and not worry about hit things with the planes..

A cambered jack plane to start. It worked fast getting rid of the waves from the resaw, and the saw marks…Next

On the long rails, I used a No.6c small jointer plane to smooth out the gouges left by the cambered jack. It also jointed the long edge. On the shorter rails, a slightly shorter plane was used..

A Stanley No. 5-1/2 Jumbo Jack. Ok, I now had all four rails surfaced S4S. Needed to set up a sash cutter plane..

Problem here was how to hold onto the short rails, and not have the fence on the Stanley 45 hitting stuff. Unlike the side’s rails in the case, that were on an edge, these had to be flat on the bench….or, like above. Screws are counter sunk, and are in the places that will be used to join the frame together. Short rails just hung onto the side of the bench. The rebate side of the sash cutter only cut so wide…..and left a ridge to the outside..

Just the way this cutter was set up. Rounded edge ( molded edge) was to the outside. The little ridge was removed with a ward’s (Stanley) #78. Clean up was with the old woodie shoulder plane and the block plane.

Was getting a bench-full of tools… On the long rails, since a mounting holes was IN the rebate area, I could counter sink a screw to hold the rail to the bench, long enough to make the molding profile…..but, the sash cutter left a 1/2” wide ridge along the out side edge…..78, or the shoulder plane was having a hard time taking a 1/4” high by 1/2 wide slab……

I used that Cambered jack. Got down fast, but when it got close, i switched back to the 78 and shoulder plane.
I got all the molded edges done, rebate flattened out….time for a test fit….oops, the square cut on the long rails, were not quite right. Square a new line, bandsaw to cut it. I used that screw hole to line up a smaller pilot hole in the matching half of the joint. With both pieces in the vise, and lined up just right, a screw was driven home..

No glue, as of yet, test fit only. Tomorrow, I can get the other three corners fitted, and a cross brace dovetailed in.

Brace runs from front to back, about the same area as the kickers. It gets dovetailed to the long rails, and is set even with the rebates. It’s main job is to support the middle of the 1/4” plywood top panel. Secondary job is to keep the rails from bowing out. More saw & chisel work…..keeps up, and I’ll have to sharpen them up before I do the 5 drawers…

Shoulders are sore, a 2-finger pain killer is sitting here on my desk. I think that will be more than enough, for one day. Waded around ankle deep in shavings today….even swept the floor three times. Well, until the next episode, stay tuned…...

-- A Planer? I'M the planer, this is what I use

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