Blanket Chest Project #2: A very long, busy Day 2

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Blog entry by bandit571 posted 11-05-2020 04:42 PM 427 reads 0 times favorited 2 comments Add to Favorites Watch
« Part 1: Starting up Part 2 of Blanket Chest Project series Part 3: day 3, all 2 hours worth »

Started out at 1100hrs…main shop time ended around 1430hrs….then a few return trips while on Laundry Detail last night…trying to remember all the stuff as I worked along….

Ok, started by hauling Plank #3 to the shop…moved the tablesaw out to where I could do a few saw cuts…needed two blanks to make the 4 long rails and 1 blank for a pair of dividers that go between them…

had to work around a couple bad ends….next, set up the rip fence, again…and try to rip 6 pieces of 2-5/8” wide Ash…had to pick the straightest edge, run that against the fence…set aside the first piece, and run the board through again…first blank didn’t look too bad..

Even kept the skinny piece for later. Second blank had issues…

Basically, I squared off the other end, came back and cross cut that red line…then make the other 3 long rail blanks to match….as for the dividers, I just square the ends, so the two were the same length…

Great…another knot to work around….
Reset the tablesaw to cut tenons…lots of tenons….1/2” from the fence to the left edge of the saw teeth…height was adjusted…each version test out in a handy grooved part…first setting was a tad too high…lowered the blade a bit..

These 4 are rails for the end frames….next, the 2 dividers..

And finally the 4 long rails…

Then, I needed to clear the bench a bit, and set up the bench clamp

Couple edges were a tad rough..and would be hard to sand smooth once things are built, so..

that recently re-handled Craftsman Jack plane ( Millers Falls No. 14) smooth the edges right out..Then the Stanley 45 could get to work…

Edges of the grooves were also a bit …fuzzy…so..

Used the Wards 78 to add a slight bevel, and remove the fuzzy….soon had the 4 rails done..

Then the 2 dividers….had to cut through that knot…about like a speed bump….1st hour done, time for a bathroom break, grab a Diet Mountain Dew…and remember to turn the shop fan ON when I get back to the shop…

All parts were now stacked up over on the tablesaw…guess I’m done with it for a while….bench cleared off, mortise jig was taken down from a shelf, and set up…right over a leg in the bench..Mortise Jig?

One of the few jigs I actually maintain in the shop…can be adjusted to hold about any thickness…

Visegrips to lock a part in place. lay out a few tools, all set to chop, right? Not exactly….need to lay out where the mortise will be…and first I need a haunched tenon cut…

Which is nothing more than notch the end o a tenon….longer section goes into the mortise, while the notched part fills a groove….so when the mortise gets chopped…the test fit ..

Top of each leg will look this way. Because the rails do not reach all the way to the curved part of the foot…there is a 1” long stretch where the groove would show…we have ways..

So, before the mortise gets chopped, I made a saw cut across the groove, then a wide chisel to remove the “extra groove”..and create a step detail..

No groove showing, now….dry fit the frame…

Groove showing? That is where the frames for the ends of the chest will get glued into…next? Need two more mortises, centered in the long rails…first I had to FIND the center point ( 11-1/2” in from each end), AND the center of the tenon (1” in) then made sure both rails get the mortise in the same location…

During all of this fitting of tenons to mortises…there was a problem with too fat tenons…I wanted snug fit, but not split out the side fit….needed a way to thin each and every tenon….and still keep the thing centered on the part’s end…

A couple of passes on each face does the trick….full dry fit?

I need these frames made ( no glue!) so I can get the size of the raised panels to be glued up…

Got to about this point ( 1430 hrs) tummy rumbling (Lunch?) time to sweep the floor and call it a day…

One frame down..three to go…maybe another day?

Well, turned out I had Laundry detail that evening….since the Laundry Room and my shop are about in the same spot…while doing the washing…2 more mortises get chopped…..change clothes over to the dryer…4 more chops done….on the way to unload the dryer, I take a camera along….unload the clothes, take 2 pictures, and do a few measurements….and haul that full, HEAVY hamper back upstairs..

First frame had been clamped up, and set out of the way..

second frame is still on the bench…measurements marked …

And THAT was the end of a very LONG day….might have gotten a few things done?
Stay tuned…have 2 smaller frames to cobble Day #3
Thanks for looking in…hope this wasn’t too long of a read..

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

2 comments so far

View Dave Polaschek's profile

Dave Polaschek

10291 posts in 2043 days

#1 posted 11-05-2020 07:17 PM

Coming right along…

-- Dave - Santa Fe

View Eric's profile


5107 posts in 1334 days

#2 posted 11-06-2020 02:10 AM

You are getting there

-- Eric, building the dream

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