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Ceiling Fan Frame

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Project by Karson posted 05-20-2019 12:32 AM 537 views 0 times favorited 19 comments Add to Favorites Watch

When we bought the home we now live in a year ago it had a florescent light in the middle of the kitchen. It was a 2’ X 2’ frame with double bulbs. Some times they would come on and some times they wouldn’t. My wife also wanted a ceiling fan.

Woodworker to the action. A year later after thinking about what I could do, I took down the existing light.

Wow they had installed the light before they painted the ceiling so If I wanted to paint the bare spot I would get to paint 3 rooms and a hall so that the paint would match. Choice #1

Choice #2 – make a box 2’ X 2’ and install the fan inside it.

I opted for #2.

I bought a 2’X4’ piece of maple 1/4” plywood and I looked around my veneer to see what I had.

Momentary Pause here—

Since I moved to Virginia from Delaware and my veneer and wood was moved over 6 months and was stacked in different piles and spaces. It was put at the nearest spot that was empty. I then threw some 2X4 and plywood on the rafters to stash the veneers. They again were placed where they would fit. So to say “I looked around to see what I had!” really meant that the first place I looked was where the “Trojan Horse Platform Ladder” happened to be sitting (See My Workshop: Note this was the old one not the new one, But the Trojan Horse was moved and Rebuilt) and on the rafter above it was a few sheets of Russian Karelian Birch wood veneer. I needed sheets that would be at least 24” long and wide enough to cover 24”. I found 3 sheets that were 8 1/4” and 25” long so when I cleaned up the edges I was just able to get the 24” in width.

Unfortunately the sheets were not book matched. I had bought this veneer from someone who had selected his pieces and I got the left overs. They were close enough in matching that I slip matched them instead of book matching them. You also shouldn’t book match an odd number of sheets Unless it is really necessary. But in my case there were some missing sheets of veneer between what I had so so the match wouldn’t have even been close.

I found my veneer bag and pump buried in different places after the move. I hooked it together and the pump would not pull any vacuum. So I thought the bag might have gotten punctured in the move. So a few days to find my air compressor and blow up my bag with a soap spray. No leaks found. But it was still not pulling vacuum. It would pull vacuum if I put my finger over the end of the hose. I then found that the attachment to the bag had broken it seal and there was no seal. So I went to joewoodworker.com to get some new attachment pieces.

They were installed but still no vacuum being pulled. I took apart the piping to my apparatus and I found that the check valve was full of saw dust that it had sucked from the bag over the years.. I reassembled all the parts to put the filter in front of all other parts of the system. I had been filtering the air before it went to the pump but not before it went to any other parts of the system. That’s now been fixed and I have vacuum.

I glued the veneer on the plywood and then I took it to a woodworkers meeting to show and tell. Then I left it in my van overnight and over day. When I took it out the plywood was warped. ”””” YOU ARE NEVER SUPPOSED TO VENEER ONLY ONE SIDE OF PLYWOOD!””” So I put the sheet on a flat surface, put lots of weight on it and let it stabilize for a few days. Then I glued some backer veneer on the other side. It became pretty flat. I then took the other 2’’ X 2” piece and glued it on the back. So now my panel was 1/2” thick instead of 1/4” thick. And flat as could be.

I took some 1” thick Sapele and made the frame cutting a 1/2 X 1/2” rabbit on the bottom inside edge so that I could glue the panel into the frame.

My concern now became how am I going to mount this frame unto the ceiling. There was only one joist and that was where the electric box had been attached to the light I removed. I finally decided to put some 1-1/2” Brass screws close to the 4 corners. You can almost see them in the closest 2 corners about 4” from the sides. I used brass screws and brass finish washers. They were screwed into plastic wall hangers rated for 50 lbs each. Then I screwed the fan hanger attachment with 2” screws into the joist. The other end of the fan attachment is screwed into my 1/2” thick panel. So nothing is attached to the electrical box holding up this assortment of parts.

So this frame is about 1/2” bigger than the unpainted ceiling. Blessing #1. The fan works and the light works with the remote control. Blessing #2. My wife is happy. Blessing #3. She even let me cook steaks for supper as a reward.

So now I’m thinking In order to match the fan to the ceiling box I might veneer the fan blades with some more of that unmatched veneer. I am going the veneer the space above the Microwave/exhaust to cover up the exhaust pipe. But that will be another posting.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]





19 comments so far

View Grumpy's profile

Grumpy

25326 posts in 4246 days


#1 posted 05-20-2019 12:46 AM

Nice result buddy, just as well you had plenty of time to think about it.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View Karson's profile

Karson

35188 posts in 4795 days


#2 posted 05-20-2019 12:55 AM

It doesn’t pay to rush into something and screw everything up.

There were enough built in screw-up as it happened.

Thanks Tony.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View Vicki's profile

Vicki

1115 posts in 3739 days


#3 posted 05-20-2019 01:36 AM

Great idea. Looks nice, like you did it on purpose.

-- Vicki on the Eastern Shore of MD

View Karson's profile

Karson

35188 posts in 4795 days


#4 posted 05-20-2019 01:40 AM

Thanks Vicki

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View a1Jim's profile

a1Jim

117627 posts in 3972 days


#5 posted 05-20-2019 02:01 AM

Super idea Karson,very well done.

View Karson's profile

Karson

35188 posts in 4795 days


#6 posted 05-20-2019 02:02 AM

Thanks Jim

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View sras's profile

sras

5097 posts in 3524 days


#7 posted 05-20-2019 02:07 AM

Nice solution!

-- Steve - Impatience is Expensive

View Karson's profile

Karson

35188 posts in 4795 days


#8 posted 05-20-2019 02:09 AM

Thanks Steve

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View Woodwrecker's profile

Woodwrecker

4224 posts in 3970 days


#9 posted 05-20-2019 04:56 AM

Wow Karson!
I thought you died!
When you didn’t post anything in a year or so, I figured that was it for you.
That fan frame came out very nicely my friend.

View doubleDD's profile

doubleDD

8400 posts in 2438 days


#10 posted 05-20-2019 12:36 PM

That’s a genuine idea you came up with. Looks great. It sometimes takes time to come up with a solution but it was well worth it.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View Edward E Nock II's profile

Edward E Nock II

109 posts in 4539 days


#11 posted 05-20-2019 01:05 PM

Karson….... Good work as always!!!!!!!!!!!!!

ED

-- ED NOCK

View lew's profile

lew

12775 posts in 4150 days


#12 posted 05-20-2019 02:13 PM

Looks like that came out perfectly!

I gotta ask, what is the function of the PCV reservoirs?

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View GR8HUNTER's profile

GR8HUNTER

6108 posts in 1107 days


#13 posted 05-20-2019 02:30 PM

a very nice and well thought out solution to an ugly problem GREAT JOB :<))) GRATZ TOP 3

-- Tony---- Reinholds,Pa.------ REMEMBER TO ALWAYS HAVE FUN

View Walt's profile

Walt

261 posts in 3233 days


#14 posted 05-20-2019 06:53 PM

That is a perfect solution . I hope you can deal with the summers in Va.

-- Walt Wilmington Delaware, http://[email protected]

View Karson's profile

Karson

35188 posts in 4795 days


#15 posted 05-20-2019 08:34 PM

Lew:
The vacuum system sucks all of the air out of the storage tubes also while it sucking the air out of the bag. That gives a larger space of low air pressure. (I run about 22” of Mercury vacuum.) That way if there is a small leak it will take longer for the pump not to come on. I’ve found that the MDF sheet that is used inside the bag as the base for the veneering, has air between all of those wood chips which make up the sheet. The pump might come on a couple of times until all of those air molecules are sucked out and then it stabilizes quite well.

I usually start with the tanks empty of air, and the system not connected to the bag. When I get the bag sealed I open the valve and it sucks a lot of the air out of the bag to get it down quicker and allows you to smooth out any wrinkles that are starting to appear on your veneered piece..

Just really give you a good start to getting it going.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

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