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6K views 24 replies 4 participants last post by  bandit571 
#1 ·
A start up

Try something a little…different, this time around. First, I needed to resaw a bunch of scraps down..
Table Wood Flooring Hardwood Wood stain


Figured IF I could cut exactly down the center, I could double the wood supply…well..
Wood Road surface Flooring Plank Hardwood


Missed it by that much, Chief…Tablesaw can not reach all the way, so..
Wood Anvil Motor vehicle Bumper Automotive exterior


Which left..
Wood Handwriting Rectangle Flooring Font


And a tired me from the Cardio Workout…Those narrow scraps did not required any hand saw work…but, like the rest of these boards..
Wood Typesetting Building material Composite material Roof


Required a plane to smooth things out..
Wood Hand tool Machine Tool Metalworking hand tool


Or 3. All this work, to get a few parts made…
Wood Flooring Hardwood Metal Art


To build a chest with a pair of drawers…
Wood Rectangle Composite material Hardwood Flooring


2 will get glued up as a lid..
Wood Wood stain Plank Hardwood Flooring


Once the edges were jointed…
Wood Bumper Automotive exterior Gas Hardwood


Boards are 5/16" thick….sitting there, no glue, no gaps, no leaning over…needed the vise as a 3rd hand, to help in the glue-up..
Wood Gas Building material Building Metal


And a caul at the top…vise jaws acting as a caul as well.

Other parts?
Wood Rectangle Table Hardwood Plank


Narrow piece for across the front, above the drawers, long piece will get trimmed down and will be the back of the case….the other two will be the ends. Lots of plane work to do….getting wavy edges straight, and parts the same width..
Wood Building material Hardwood Roof Composite material


Some were a bit wider than others…
Wood Composite material Gas Roof Lumber


Will be a few grooves needed, one above and one below the top drawer. Need to hide those grooves, too. And, one rebate to hide the plywood edge.

Stay tuned….the cussing, er…FUN, is about to begin….Plan? All done with the Single Brain Cell Sketch Up….
 

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#2 ·
A start up

Try something a little…different, this time around. First, I needed to resaw a bunch of scraps down..
Table Wood Flooring Hardwood Wood stain


Figured IF I could cut exactly down the center, I could double the wood supply…well..
Wood Road surface Flooring Plank Hardwood


Missed it by that much, Chief…Tablesaw can not reach all the way, so..
Wood Anvil Motor vehicle Bumper Automotive exterior


Which left..
Wood Handwriting Rectangle Flooring Font


And a tired me from the Cardio Workout…Those narrow scraps did not required any hand saw work…but, like the rest of these boards..
Wood Typesetting Building material Composite material Roof


Required a plane to smooth things out..
Wood Hand tool Machine Tool Metalworking hand tool


Or 3. All this work, to get a few parts made…
Wood Flooring Hardwood Metal Art


To build a chest with a pair of drawers…
Wood Rectangle Composite material Hardwood Flooring


2 will get glued up as a lid..
Wood Wood stain Plank Hardwood Flooring


Once the edges were jointed…
Wood Bumper Automotive exterior Gas Hardwood


Boards are 5/16" thick….sitting there, no glue, no gaps, no leaning over…needed the vise as a 3rd hand, to help in the glue-up..
Wood Gas Building material Building Metal


And a caul at the top…vise jaws acting as a caul as well.

Other parts?
Wood Rectangle Table Hardwood Plank


Narrow piece for across the front, above the drawers, long piece will get trimmed down and will be the back of the case….the other two will be the ends. Lots of plane work to do….getting wavy edges straight, and parts the same width..
Wood Building material Hardwood Roof Composite material


Some were a bit wider than others…
Wood Composite material Gas Roof Lumber


Will be a few grooves needed, one above and one below the top drawer. Need to hide those grooves, too. And, one rebate to hide the plywood edge.

Stay tuned….the cussing, er…FUN, is about to begin….Plan? All done with the Single Brain Cell Sketch Up….
There was a slight pause…..As I went through and cleaned out the tool well…..Had a bunch of tools, screws, and shavings, thing was too full….After I get it all emptied out..
Automotive tire Road surface Motor vehicle Wood Mode of transport


Only the tools needed for the current project were allowed back in….
Motor vehicle Hood Automotive tire Wood Bumper


So..stay tuned, Part 2 is coming up shortly..
 

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#3 ·
Start on finger joints

Once everything is planed to size….Needed to set the drawer fronts, and the spacings of the front.
Wood Gas Rectangle Hardwood Metal


Ok…laying on the piece for the chest"s back….there is a piece that goes across the front. Then a drawer space, then a divider, then the bottom drawer space. When I ripped the back to match the sides, I kept the cutoff…Will use it to make the drawer divider….behind it will be a 1/4" plywood "floor" for the drawer to slide on. There will also be another plywood floor, behind the bottom edge of the top piece…..

Clear as mud, right? Wasn't too sure I'd keep that top piece. might have a better one. Laid out a few boards, to chose the 2 drawer fronts from…
Wood Table Natural material Wood stain Plank


The problem with the 2 bottom ones, was one was too thin…save it for later….which made the thicker one a nice top piece….and the old one a drawer front…hand a matching one like it…laid all these parts out..
Wood Saw Tool Hand tool Crosscut saw


Trying to get the best grain pattern…..I also wanted to find out where two grooves will need to be, so I can space fingers to hide the grooves..and then use a spacer…
Automotive tire Hood Wood Motor vehicle Bumper


To set out how the fingers should go….marked a bunch of lines, and then saw cut the lines….needed a way to protect my bench from all the chopping to be made…piece of plywood as a chopping block…
Wood Composite material Gas Saw Roof


Set the panel on it..
Wood Composite material Building material Bumper Gas


Add a clamp to both..
Wood Flooring Road surface Hardwood Roof


And chop 1/2 way down…flip over..
Wood Gas Composite material Metal Fastener


And finish the chops. All set for the end of the case….ends had "issues" besides needing jointed..
Wood Composite material Building material Brick Rectangle


Shorter one was not square, on either end…other one needed trimmed to match….lots of cuts on the mitre box..
Used the just cut fingers, to lay out for the end….Mark the lines, cut on the waste side of the lines, chop, flip, and chop again…time for a dry fit?
Wood Loom Creative arts Art Tool


Back right corner is done….maybe Tuesday, I can do the other back corner….then do the front of the case….
Stay tuned….
 

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#4 ·
More finger joints made

Well, Tuesday brought a few errands to run….wound up with just 2 hours of shop time, to get something..done.

There are a LOT of saw cuts to make….would take too long using my handsaws…been using the bandsaw..
Automotive tire Wood Automotive wheel system Auto part Gas


Didn't feel like taking all day to make all of these….bandsaw was having issues, though…started throwing the drive belt…..got to looking around….turned out the pulley had "migrated" too far in…
Automotive tire Wood Vehicle Motor vehicle Electrical wiring


And that cup the old guard attached to would just knock the belt off the pulley…..allen wrench, and a large screwdriver…to gently move it back out to where it belonged…then torqued the "H" out of the set screw…saw now is quiet as a mouse when it is running..
Anyway….
Wood Gas Composite material Metal Fastener


Same as before….lay out the fingers, cut the lines, chop the waste out, and fit it to the end panel..
Wood Table Gas Lumber Hardwood


Then flip this mess over, and do a bit of layout, again..
Wood Hardwood Plank Lumber Wood stain


Need to locate where 3 grooves and a rebate need to be, and make sure a pin will hide them…once I got the locations marked, time to set up the Stanley 45…
Wood Motor vehicle Engineering Automotive exterior Metal


With a #12 straight cutter. Set the depth of cut, and the fence. Fence will get reset a couple of times…
Wood Rectangle Composite material Flooring Gas


Set up a jig, to hold all the parts…changes as needed, first the back of the case gets a groove to hold the floor board….
Wood Ruler Office ruler Rectangle Tool


Then adjust the fence for the end pieces to get a groove for the drawer divider. got those done…then, across the front of the case, is a strip of ash, this is the front of the compartment…and need a rebate to house the plywood floor. change the jig a bit…
Wood Floor Flooring Hardwood Gas


To hide the edge of the plywood panel. it will be glued and clamp into this rebate…time to chop, again…
Wood Bumper Saw Automotive exterior Hand tool


End with the single notch, is the front of the case, the strip with the rebate gets the 4 or so fingers. Had to make a mark, to make sure I didn't cut one too many…parts fit together like this..
Wood Rectangle Asphalt Road surface Gas


That stick is the drawer divider's front edge. One end done, do the other end the same way…then a dry fit, with clamps…
Automotive tire Wood Bumper Motor vehicle Gas


Will need to cut the 2 plywood panels to size..
Wood Lumber Roof Metal Composite material


Then a LOT more clamps…and some glue….and while then cures, I can get a start on 2 drawers, I hope.

Stay tuned…
 

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#5 ·
More finger joints made

Well, Tuesday brought a few errands to run….wound up with just 2 hours of shop time, to get something..done.

There are a LOT of saw cuts to make….would take too long using my handsaws…been using the bandsaw..
Automotive tire Wood Automotive wheel system Auto part Gas


Didn't feel like taking all day to make all of these….bandsaw was having issues, though…started throwing the drive belt…..got to looking around….turned out the pulley had "migrated" too far in…
Automotive tire Wood Vehicle Motor vehicle Electrical wiring


And that cup the old guard attached to would just knock the belt off the pulley…..allen wrench, and a large screwdriver…to gently move it back out to where it belonged…then torqued the "H" out of the set screw…saw now is quiet as a mouse when it is running..
Anyway….
Wood Gas Composite material Metal Fastener


Same as before….lay out the fingers, cut the lines, chop the waste out, and fit it to the end panel..
Wood Table Gas Lumber Hardwood


Then flip this mess over, and do a bit of layout, again..
Wood Hardwood Plank Lumber Wood stain


Need to locate where 3 grooves and a rebate need to be, and make sure a pin will hide them…once I got the locations marked, time to set up the Stanley 45…
Wood Motor vehicle Engineering Automotive exterior Metal


With a #12 straight cutter. Set the depth of cut, and the fence. Fence will get reset a couple of times…
Wood Rectangle Composite material Flooring Gas


Set up a jig, to hold all the parts…changes as needed, first the back of the case gets a groove to hold the floor board….
Wood Ruler Office ruler Rectangle Tool


Then adjust the fence for the end pieces to get a groove for the drawer divider. got those done…then, across the front of the case, is a strip of ash, this is the front of the compartment…and need a rebate to house the plywood floor. change the jig a bit…
Wood Floor Flooring Hardwood Gas


To hide the edge of the plywood panel. it will be glued and clamp into this rebate…time to chop, again…
Wood Bumper Saw Automotive exterior Hand tool


End with the single notch, is the front of the case, the strip with the rebate gets the 4 or so fingers. Had to make a mark, to make sure I didn't cut one too many…parts fit together like this..
Wood Rectangle Asphalt Road surface Gas


That stick is the drawer divider's front edge. One end done, do the other end the same way…then a dry fit, with clamps…
Automotive tire Wood Bumper Motor vehicle Gas


Will need to cut the 2 plywood panels to size..
Wood Lumber Roof Metal Composite material


Then a LOT more clamps…and some glue….and while then cures, I can get a start on 2 drawers, I hope.

Stay tuned…
I thinks I got it figured out.
 

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#6 ·
And a glue up

Cut a couple plywood panels today …Jointed the sawn edges straight…and squared things up…test fit for the drawer divider..
Wood Motor vehicle Gas Engineering Track


Then the floor for the compartment…..needed to plane a bit of one edge..
Wood Automotive tire Tool Composite material Gas


As I needed to fit it into the front rebate….test fit, replane a bit…checked for square, again..finally..
Wood Composite material Gas Rectangle Metal


Ok…tear this all down..clean up a few spots…set things out, ready to glue them up…..
Wood Composite material Lumber Road surface Hardwood


A "War Zone"? Too many parts, too many clamps, glue everywhere…
Wood Automotive tire Motor vehicle Gas Engineering


And…not enough hands….
Wood Hand tool Tool Engineering Auto part


Plywood panels wound up getting glued in place, too….set this mess a ways down the bench…
Wood Gas Engineering Steel casing pipe Toolroom


As I needed some elbow room at the bench vise…
Saw Wood Vise Plane Metalworking hand tool


Lets see, lid came out of the clamps yesterday..( needed the clamp) blank was plenty long, but not wide enough. Trimmed the blank for length…had a board to use as an add-on….both it and the edge of the lid needed planed straight….then a rubbed glue joint..
Wood Rectangle Hardwood Composite material Wood stain


Yes, there IS a glue joint there…look at the arrow. Then I wanted to add what few clamps I had left to make sure the glue joint stayed that way..
Motor vehicle Automotive tire Wood Automotive exterior Gas


This time, I could use the vise as a 3rd hand…and a caul…that piece of folded sandpaper? Seems that clamp likes to wander off, while I am tightening it down….sandpaper keeps it in it's place. Bench is full of glue-ups, until tomorrow…then I get to hang all them clamps back up….and hope nothing flies apart…

Stay tuned…
 

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#7 ·
And a glue up

Cut a couple plywood panels today …Jointed the sawn edges straight…and squared things up…test fit for the drawer divider..
Wood Motor vehicle Gas Engineering Track


Then the floor for the compartment…..needed to plane a bit of one edge..
Wood Automotive tire Tool Composite material Gas


As I needed to fit it into the front rebate….test fit, replane a bit…checked for square, again..finally..
Wood Composite material Gas Rectangle Metal


Ok…tear this all down..clean up a few spots…set things out, ready to glue them up…..
Wood Composite material Lumber Road surface Hardwood


A "War Zone"? Too many parts, too many clamps, glue everywhere…
Wood Automotive tire Motor vehicle Gas Engineering


And…not enough hands….
Wood Hand tool Tool Engineering Auto part


Plywood panels wound up getting glued in place, too….set this mess a ways down the bench…
Wood Gas Engineering Steel casing pipe Toolroom


As I needed some elbow room at the bench vise…
Saw Wood Vise Plane Metalworking hand tool


Lets see, lid came out of the clamps yesterday..( needed the clamp) blank was plenty long, but not wide enough. Trimmed the blank for length…had a board to use as an add-on….both it and the edge of the lid needed planed straight….then a rubbed glue joint..
Wood Rectangle Hardwood Composite material Wood stain


Yes, there IS a glue joint there…look at the arrow. Then I wanted to add what few clamps I had left to make sure the glue joint stayed that way..
Motor vehicle Automotive tire Wood Automotive exterior Gas


This time, I could use the vise as a 3rd hand…and a caul…that piece of folded sandpaper? Seems that clamp likes to wander off, while I am tightening it down….sandpaper keeps it in it's place. Bench is full of glue-ups, until tomorrow…then I get to hang all them clamps back up….and hope nothing flies apart…

Stay tuned…
Full bench?
Motor vehicle Wood Gas Machine Vehicle
 

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#8 ·
out of the clamps

walked down to the shop this afternoon..this was what the bench looked like..
Motor vehicle Wood Gas Machine Vehicle


Task was to slowly remove each clamp…listening for any creaks, cracks, groans, or pops….none came, from the wood at least….as for this old body….

Cleaned things up….fingers were a tad proud….sanded them down flush, a dab of glue in any cracks….the back of the case was the easy one..
Rectangle Wood Floor Hardwood Flooring


Sanding dust blended with the glue spots….sealed things up nicely….
Then the sides…
Wood Rectangle Natural material Gas Composite material


And the other side…
Product Wood Rectangle Composite material Hardwood


It was the front that had a little problem…..the divider between the drawers..
Rectangle Wood Outdoor furniture Gas Natural material


The Ash front was thicker than the plywood panel…..Stanley 60-1/2 block plane to peel away the excess. The a Stanley #3 to level the corners of the case….had a couple spots sitting a bit proud…

Next…lid came out of the clamps, too…
Wood Rectangle Composite material Wood stain Hardwood


Then checked to see IF it is now big enough…
Outdoor bench Plant Automotive tire Wood Outdoor furniture


Will trim the over hang back a bit…

I had a plywood panel I thought would work for the base of the case….usual luck…nope….so, found a couple pieces close to each other in size…jointed two edges, and glue clamps and cauls…
Wood Automotive exterior Gas Saw Composite material


And, I had just put those 3 clamps away, and the c clamps too….I also made sure I have the two blanks for the drawer fronts..
Wood Lumber Hardwood Plank Building material


Yes, that is the Stanley 60-1/2 block plane…so…now my almost empty bench is full, again..
Wood Composite material Roof Gas Metal


Which kind of shuts the shop down…until the glue dries….was getting a bit worn out, anyway..
Stay tuned…have drawers to make, a lid to finish up, a base to trim, and glue to the case…

Plywood edges will get a thin Ash covering….

We'll see how tomorrow goes…
 

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#9 ·
out of the clamps

walked down to the shop this afternoon..this was what the bench looked like..
Motor vehicle Wood Gas Machine Vehicle


Task was to slowly remove each clamp…listening for any creaks, cracks, groans, or pops….none came, from the wood at least….as for this old body….

Cleaned things up….fingers were a tad proud….sanded them down flush, a dab of glue in any cracks….the back of the case was the easy one..
Rectangle Wood Floor Hardwood Flooring


Sanding dust blended with the glue spots….sealed things up nicely….
Then the sides…
Wood Rectangle Natural material Gas Composite material


And the other side…
Product Wood Rectangle Composite material Hardwood


It was the front that had a little problem…..the divider between the drawers..
Rectangle Wood Outdoor furniture Gas Natural material


The Ash front was thicker than the plywood panel…..Stanley 60-1/2 block plane to peel away the excess. The a Stanley #3 to level the corners of the case….had a couple spots sitting a bit proud…

Next…lid came out of the clamps, too…
Wood Rectangle Composite material Wood stain Hardwood


Then checked to see IF it is now big enough…
Outdoor bench Plant Automotive tire Wood Outdoor furniture


Will trim the over hang back a bit…

I had a plywood panel I thought would work for the base of the case….usual luck…nope….so, found a couple pieces close to each other in size…jointed two edges, and glue clamps and cauls…
Wood Automotive exterior Gas Saw Composite material


And, I had just put those 3 clamps away, and the c clamps too….I also made sure I have the two blanks for the drawer fronts..
Wood Lumber Hardwood Plank Building material


Yes, that is the Stanley 60-1/2 block plane…so…now my almost empty bench is full, again..
Wood Composite material Roof Gas Metal


Which kind of shuts the shop down…until the glue dries….was getting a bit worn out, anyway..
Stay tuned…have drawers to make, a lid to finish up, a base to trim, and glue to the case…

Plywood edges will get a thin Ash covering….

We'll see how tomorrow goes…
Now, brings up which to start on first…

Clean up and install the base? With the Ash trim?

Clean up the lid, decide on a bread board edge, or not…and install?

Or, just build two drawers, and get them fitted?

Might be a busy day…
 

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#10 ·
Just another day in the shop...

Clamps came off again…a bit of work..clamps go back on somewhere else….gave myself a 2 hour time limit…and wound up with a bit of "overtime", anyway…..

First up? That plywood base panel….out of the clamps, and sanded flat. Then trimmed down a bit….and glued to the bottom of the case…
Wood Gas Table Metal Chair


There was one area I couldn't use the clamps and glue…
Wood Gas Composite material Cylinder Metal


Nothing to glue to….a clamp would have done more harm than good, anyway….set the mess aside, for now.

Next was that lid blank. Out of the clamps. Turned out the "add-ons" were a bit thicker than the panel…sanders and a plane to level the playing field a bit….Then decided to add..bread board ends….tablesaw to rough in the tenons, And a Routah to clean and adjust..
Wood Motor vehicle Art Gas Machine


Wasn't much room for error, either..
Wood Hardwood Gas Wood stain Auto part


Even this was a tad too thick ( this split off the side of a grooved end piece)....make a new end piece, slim the tenons down a bit…try another dry fit..
Wood Rectangle Wood stain Composite material Hardwood


Finally got a decent fit…one tenon was a tad too long, and not square to the panel…Got that all corrected…and then a few clamps, cauls, and a bead of glue….vise is helping out..as a third hand, and a caul
Hood Automotive tire Wood Automotive exterior Bumper


There goes anything else on the bench for today…..I then cut 2 drawer front blanks for length..
Table Wood Tire Rectangle Outdoor furniture


Case is sitting on it's top, due to them clamps. Cuts were made over on the Stanley #358 Mitre Box….doesn't take long to saw through 5/16" thick Ash. I found that IF I merely hold the saw enough to just move it back and forth, and NOT use a deathgrip on the handle, or try to "guide" the saw…..it cuts nice and fast ( just the weight of the saw) and SQUARE.

Now, about that plywood base….in order to "hide" that plywood edge, I need a bit of Ash..
Wood Plank Wood stain Hardwood Workbench


2 long and skinny ones, for the front and back of the case, then rip as needed for the sides from that wider slab…
Wood Road surface Automotive tire Asphalt Flooring


Thinking about adding a square block in each corner ( Feet?) and do a bit of scroll work…
Waiting on the shop to warm up a bit this morning…..have all day to either sit and yak, or work on 2 drawers

Stay tuned.."Film @ 2300 hrs"
 

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#11 ·
One of "Them Days"

More remove clamps for a bit, then add them back on, again….wasn't that great of a day, and stretched out to over 3 hours. Then Uncle Charles (Horse) decided to cramp up my toes…..made it rough to walk around down in the shop, and go up and down the stairs…..so

first task…clamps off of the lid….needed the vise, anyway. Was able to plane and sand the lid flat and almost smooth…set in one the case ( clamps were also gone from it)...
Wood Table Outdoor bench Gas Composite material


Hmmm, should fit….but something didn't look quite right….Grain is supposed to be at an angle….but not the bread board edges…checked for square to the "front"..
Wood Outdoor bench Gas Composite material Metal


Yep..about a tablesaw blade's thickness out of square….rectangle was leaning a bit to starboard…..buzzed that off.
Wood Composite material Gas Hardwood Plywood


Then rounded the corners a bit…didn't need to much. Also made sure the hinges were the right size…then the real fun began….the case needed to be flush with the plywood base….and close to flat and square all around….
Wood Rectangle Hardwood Composite material Wood stain


In theory….but, it took almost an hour of beltsanding, handplane, palm sanding….rotate to the next side…went around the "block" four times, at least….why all this trouble? The next task was to add a layer of Ash around the base, like a molding….first I ripped and jointed and cut to length the 4 pieces….then glue and a few brass nails..
Wood Gas Engineering Automotive exterior Beam


nails to hold things still, until the clamps were installed. Front one got some fancy scroll work done…the back didn't..
Wood Bumper Automotive exterior Motor vehicle Engineering


When the glue bottle gets replaced, I'll add glued on feet in each corner. Sander to round the glued up corner joints…ends also got a bit of detail work…
Wood Outdoor furniture Automotive exterior Bumper Gas


Then set this over onto the tablesaw….the 2 drawer fronts needed planed for a better fit..
Wood Hardwood Tool Flooring Plank

I picked up a bag of drawer knobs the other day..should do the trick?
Hand tool Kitchen utensil Tool Metalworking hand tool Wood


Wanted these tight, but not too tight…..i want to open these in the summer as well…
Hinges….I had the pilot hole drill in the shop…that was the good news…set the hinges 2" in from the edge of the lid's ends…and make the holes….using the hinge as a layout guide…
Wood Tool Ruler Office ruler Metalworking hand tool


Drill is a North Brothers #41, with the smallest tip it had….6 turns for depth….Screwdriver to drive them TINY Phillips head screws?....was upstairs….and cramping toes made the stairs…fun…
Hand tool Saw Tool Wood Metalworking hand tool


About the only driver I have that FITS these screws…Can't install the lid to the case…clamps are in the way…

I was going to build 2 drawers, but..
Wood Motor vehicle Bottle Gas Bumper


This was empty….so…I ripped, cut and planed the rest of the parts for the drawers…even the plywood bottoms, Back needed planed flat and to thickness….
Wood Bumper Automotive exterior Hardwood Bicycle part


As they were a bit..rough. Plywood was cut to size on the bandsaw….and then the edges were planed straight.

And that was as far as I got….not too bad for a Saturday?
Stay tuned….we gaining on it…
 

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#12 ·
One of "Them Days"

More remove clamps for a bit, then add them back on, again….wasn't that great of a day, and stretched out to over 3 hours. Then Uncle Charles (Horse) decided to cramp up my toes…..made it rough to walk around down in the shop, and go up and down the stairs…..so

first task…clamps off of the lid….needed the vise, anyway. Was able to plane and sand the lid flat and almost smooth…set in one the case ( clamps were also gone from it)...
Wood Table Outdoor bench Gas Composite material


Hmmm, should fit….but something didn't look quite right….Grain is supposed to be at an angle….but not the bread board edges…checked for square to the "front"..
Wood Outdoor bench Gas Composite material Metal


Yep..about a tablesaw blade's thickness out of square….rectangle was leaning a bit to starboard…..buzzed that off.
Wood Composite material Gas Hardwood Plywood


Then rounded the corners a bit…didn't need to much. Also made sure the hinges were the right size…then the real fun began….the case needed to be flush with the plywood base….and close to flat and square all around….
Wood Rectangle Hardwood Composite material Wood stain


In theory….but, it took almost an hour of beltsanding, handplane, palm sanding….rotate to the next side…went around the "block" four times, at least….why all this trouble? The next task was to add a layer of Ash around the base, like a molding….first I ripped and jointed and cut to length the 4 pieces….then glue and a few brass nails..
Wood Gas Engineering Automotive exterior Beam


nails to hold things still, until the clamps were installed. Front one got some fancy scroll work done…the back didn't..
Wood Bumper Automotive exterior Motor vehicle Engineering


When the glue bottle gets replaced, I'll add glued on feet in each corner. Sander to round the glued up corner joints…ends also got a bit of detail work…
Wood Outdoor furniture Automotive exterior Bumper Gas


Then set this over onto the tablesaw….the 2 drawer fronts needed planed for a better fit..
Wood Hardwood Tool Flooring Plank

I picked up a bag of drawer knobs the other day..should do the trick?
Hand tool Kitchen utensil Tool Metalworking hand tool Wood


Wanted these tight, but not too tight…..i want to open these in the summer as well…
Hinges….I had the pilot hole drill in the shop…that was the good news…set the hinges 2" in from the edge of the lid's ends…and make the holes….using the hinge as a layout guide…
Wood Tool Ruler Office ruler Metalworking hand tool


Drill is a North Brothers #41, with the smallest tip it had….6 turns for depth….Screwdriver to drive them TINY Phillips head screws?....was upstairs….and cramping toes made the stairs…fun…
Hand tool Saw Tool Wood Metalworking hand tool


About the only driver I have that FITS these screws…Can't install the lid to the case…clamps are in the way…

I was going to build 2 drawers, but..
Wood Motor vehicle Bottle Gas Bumper


This was empty….so…I ripped, cut and planed the rest of the parts for the drawers…even the plywood bottoms, Back needed planed flat and to thickness….
Wood Bumper Automotive exterior Hardwood Bicycle part


As they were a bit..rough. Plywood was cut to size on the bandsaw….and then the edges were planed straight.

And that was as far as I got….not too bad for a Saturday?
Stay tuned….we gaining on it…
Really starting to take shape, I usually use slotted screws but felt bad about tossing away all the screws that came with some of the packages of hinges, found that the #0 Phillips grace from L.V. works perfectly.
 

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#13 ·
Sunday's Follies

Sunday…was a 3 hour affair…to get one drawer into the clamps vacated by the case….that needed cleaned, sanded, and shaped….first the case work..needed to remove a bunch of clamps..
Wood Lumber Hardwood Metal Typesetting

And see what it looks like…
Wood Hardwood Machine Engineering Lumber


At least nothing fell off….Sanded the corner round…leveling the joints…
Wood Musical instrument Grey Flooring Floor


The molding across the back had a line of dried glue, from a squeeze out…extra board to support the glue removal tool…..worked my way on around…
Wood Rectangle Composite material Gas Flooring


Until this spot…molding was sitting higher than the floor of the case…sander can't reach, so..
Wood Motor vehicle Bumper Automotive exterior Automotive design

A low angle block plane got most of it down flush, wide chisel to reach into the corner…decided to add the lid..
Automotive tire Wood Automotive design Tire Rectangle


Pilot holes for the hinge screws was by the Yankee #41….6 turns was just enough depth….there was one hole with 7 turns..and it punch all the way through….Close the lid..
Automotive tire Wood Grille Stairs Outdoor furniture


And set this out of the way…got chopping to do..
Automotive tire Wood Bumper Motor vehicle Gas


First, both drawer fronts need a rebate milled…to hide the plywood edge of the bottom…Then I used one of the sides to lay out some fingers…
Wood Automotive tire Gas Metal Screw


And got out the usual suspects to do some chopping..
Wood Tool Metalworking hand tool Hand tool Gas


Then cut, chop, transfer, cut, chop, and tranfer again..
Wood Flooring Gas Rectangle Composite material


then made sure the bottom was correct…it wasn't…too long, too wide, one end not square..fixed that..decided to cut the back to just fit,,was tired of cutting fingers….then glue the entire mess up
Automotive tire Wood Motor vehicle Bumper Bicycle part


had thought about just nailing it together,,,,Ash and tiny nails do not play nice together….idea got vetoed. Let this sit overnight….Monday will be a work day in the shop, looks like…
Stay tuned…
 

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#14 ·
Monday, monday

Decided to press my luck..normally the Shop is closed on Mondays….Decided to see what I could get done…

Removed a bunch of clamps, for one..
Hand tool Automotive tire Bicycle part Font Bumper


Which, with any luck, will get used again, shortly….
Wood Table Rectangle Gas Font


Means this drawer is out of the clamps. This is the Bottom of the 2 drawers. It needed the joints cleaned up, leveled, the plywood bottom planed and sanded to match the drawer better…then a few test fits…until it slid in without binding in the case….then decided to add the 2 knobs…
Hand tool Tool Wood Metalworking hand tool Saw


That little drill bit was close to the right size…just a tad too big….glue was mooshed around in the holes, and on the tenons of the knobs…tenons were then rolled a bit in sawdust….to help fill the gap….then I clamped them both in place..
Wood Tool Gas Machine Engineering


Had to use this for a clamp, was saving all the rest for the other drawer build..
Wood Gas Lumber Tool Automotive tire


Same as before…finger joints at the corners….might get good at these, after a while? This time around, I did all four corners with finger joints…..use the drawer sides to space the fingers better,,,watching which sides of the lines to cut
Wood Lumber Gas Tool Motor vehicle


Standing up on it's own..next…I checked the plywood bottom for size…had to plane both long edges, to get it the correct size…at least the other ends were square…time for glue and clamps…and the cussing…
Automotive tire Motor vehicle Wood Gas Auto part


getting there…
Automotive tire Motor vehicle Wood Gas Engineering


Needed a few more. Which shut down the bench for the day…..hard to pick this mess up and cart it around, anyway. Just over 2 hours in the shop….guess I could un-clamp those knobs?
Wood Automotive tire Motor vehicle Gas Bumper


And slide the drawer all the way in. Tomorrow, I can repeat all of this, and hopefully find the right sized drill bit..
Stay tuned…almost done…
 

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#15 ·
Last drawer, and a PIP?

Ok,,,removed all them clamps this morning….took a while….one at a time, and hang each one up….whew..
Drawer needed sanded and planed..
Motor vehicle Wood Metalworking hand tool Stonemason's hammer Hand tool


Until the test fits showed it would slide in, without getting stuck….Finally happened….so
Motor vehicle Automotive tire Automotive exterior Wood Gas


Dug around to find an exact fit drill bit. Turns out that brace can hold normal twist drill bits…center marks on the drawer front, 2-1/4" in from the edge…used a pointy tool to start the bit exactly where I wanted the hole..
Wood Machine tool Metalworking hand tool Tool Gas


Brace allowed more control during the drilling….knobs fit better..
Wood Automotive tire Machine tool Gas Bumper


So I didn't really need all that much glue…
Wood Machine tool Tool Gas Hardwood


Needed a fingernail to remove some of the excess glue. Drawer front had an issue…seems on of the clamps had bowed it in a bit…..more than just sanding away the higher ends could cure….That "spare" drawer side I didn't need? Cut and planed it to fit…to where it shoved the center of the bow out a bit….with a dab of glue to hold it in place..

A look at things, so far..
Musical instrument Wood Table Drawer Outdoor bench


had thought about adding a pair of "dummy knobs" at the top…gave them idea up…too busy…open the drawers a bit
Wood Rectangle Automotive tire Outdoor furniture Hardwood


Then start the coat of stain..
Brown Wood Rectangle Wood stain Plant


Haven't decided on staining the insides of the drawers…..takes forever to get the smell out..
Wood Flooring Gas Hardwood Wood stain


To paraphrase Bilbo Baggins " It was just one small chest, hardly overflowing…and it still smells like..stain"
Wood Rectangle Bag Flooring Hardwood


Each direction is just under a full inch…width=11-1/2", height=6-1/2", depth=8=1/2" at the base…

Wood Rectangle Hardwood Table Wood stain


Grain features…
Wood Rectangle Hardwood Wood stain Flooring


Plan is to give this a coat or two of clear gloss poly….had to throw out the shellac, had gone bad.

i think the construction part of this is done….just the finish is left….thanks for looking in..
 

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#16 ·
Last drawer, and a PIP?

Ok,,,removed all them clamps this morning….took a while….one at a time, and hang each one up….whew..
Drawer needed sanded and planed..
Motor vehicle Wood Metalworking hand tool Stonemason's hammer Hand tool


Until the test fits showed it would slide in, without getting stuck….Finally happened….so
Motor vehicle Automotive tire Automotive exterior Wood Gas


Dug around to find an exact fit drill bit. Turns out that brace can hold normal twist drill bits…center marks on the drawer front, 2-1/4" in from the edge…used a pointy tool to start the bit exactly where I wanted the hole..
Wood Machine tool Metalworking hand tool Tool Gas


Brace allowed more control during the drilling….knobs fit better..
Wood Automotive tire Machine tool Gas Bumper


So I didn't really need all that much glue…
Wood Machine tool Tool Gas Hardwood


Needed a fingernail to remove some of the excess glue. Drawer front had an issue…seems on of the clamps had bowed it in a bit…..more than just sanding away the higher ends could cure….That "spare" drawer side I didn't need? Cut and planed it to fit…to where it shoved the center of the bow out a bit….with a dab of glue to hold it in place..

A look at things, so far..
Musical instrument Wood Table Drawer Outdoor bench


had thought about adding a pair of "dummy knobs" at the top…gave them idea up…too busy…open the drawers a bit
Wood Rectangle Automotive tire Outdoor furniture Hardwood


Then start the coat of stain..
Brown Wood Rectangle Wood stain Plant


Haven't decided on staining the insides of the drawers…..takes forever to get the smell out..
Wood Flooring Gas Hardwood Wood stain


To paraphrase Bilbo Baggins " It was just one small chest, hardly overflowing…and it still smells like..stain"
Wood Rectangle Bag Flooring Hardwood


Each direction is just under a full inch…width=11-1/2", height=6-1/2", depth=8=1/2" at the base…

Wood Rectangle Hardwood Table Wood stain


Grain features…
Wood Rectangle Hardwood Wood stain Flooring


Plan is to give this a coat or two of clear gloss poly….had to throw out the shellac, had gone bad.

i think the construction part of this is done….just the finish is left….thanks for looking in..
Varnish was applied today. Will see how it turned out, tomorrow…then post as a Project.

Thanks for following along!
 

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