Hope Chest for Daughter #2

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Blog series by Mainiac Matt updated 07-07-2017 03:36 PM 26 parts 33607 reads 126 comments total

Part 1: Design approved and construction details planned out....

02-07-2014 02:52 PM by Mainiac Matt | 11 comments »

Daughter #2 has “approved” the design of her hope chest. Here’s my rendered solid model…. I started from the same NYWS that I used for her sisters, but with the following skill builder changes: 1. outside edges will be joined with Lock Miter instead of tongue tenon and groove.2. rails and styles will be profiled and joined with a cope cut instead of mortise and tenon .3. panels will be raised and back cut instead of flat.4. feet will be cut with a taper, ins...

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Part 2: Drafted shop drawings

02-12-2014 01:35 AM by Mainiac Matt | 3 comments »

I cleaned up my solid model and created a 5 page set of shop drawings….

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Part 3: Hauled in wood from the barn to acclimate

03-30-2014 10:09 PM by Mainiac Matt | 9 comments »

This pile of lumber was given to my good friend after painting a house. They apparently are the cutoffs from a deck build some years earlier and sat piled under the deck. He in turn gifted them to me. 38 boards of 4/4×3-1/2×50” S4S My wood expert friends at work say it’s Honduran Mahogany. I’ve had it up in the barn loft for ~5 years since and today my A1 helper and I lugged it into the basement to get acclimated. We’re hoping to get started on t...

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Part 4: Stock prep day

04-19-2014 04:44 PM by Mainiac Matt | 11 comments »

Sorted boards to get the straightest ones, then hit them with a wire brush to get the dirt off of them. Jointer-jointer-planer-table saw Flat face – square and flat edge – parallel and flat opposite face – parallel square and flat opposite edge When ripping I was only taking a skim cut to minimize loss of width. This can be really messy with most of the sawdust blowing back on me, so I set up the shop vac with a funnel to catch most of it…. I stickered...

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Part 5: Top is glued up

04-22-2014 02:03 AM by Mainiac Matt | 13 comments »

I am very happy with the quality of cut I am getting with the Fussion blade, and have no reservations about gluing up the panels right off of the TS. Smoother and straighter than my jointer produces (granted, it’s a really old jointer). My daughter came down and cut the biscuit joints and assisted with the glue up. I’m so glad she did, as we needed to move fast. We were much better organized and prepared than my first build, yet were still challenged to get it clamped up qui...

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Part 6: Cleaned up the top and sanded.... almost blew it.

04-25-2014 06:34 PM by Mainiac Matt | 12 comments »

So this is the one tool in my shop that has time and time again brought me to the brink of catastrophe…. Within the first 60 seconds of sanding with 100 grit, I had put several depressions in the top. And of course, I started on the better of the two sides. :^( I had no problems using the belt sander on my first daughters hope chest in Red Oak, but lesson learned today…. Mahogany is not nearly as hard of a hard wood and Oak. Here’s what we used for the saveR...

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Part 7: Aftèr a long delay, we have bread boards

06-10-2016 01:12 AM by Mainiac Matt | 4 comments »

It’s been a 2 year delay, so I guess I better get going on this project again… The bread boards were previously planed at the same time as the top boards. I cut the dados with a slot cutting router bit on the router table. Then I cut the top to length on the TS with a panel sled. I cut the tennons on the ends with a hand router and a rabbiting bit with a guide bearing. I cut the slots short on the front side of the bread boards to hide the joint… One of...

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Part 8: Back at it...

10-09-2016 10:17 PM by Mainiac Matt | 8 comments »

I’ve finally wrapped up my last interfering project and have cleared the decks for action to get back into this project… My intention is to work it until completion… Broke out the raised panel set and reviewed my plans… Then I sorted my stock, selected boards for the long rails, cut off the checked ends, cut them to 3/4” over sized, and set up the style bit on my router table…. I used 13,000 rpm on the router (Porter Cable 3HP VS) and it cut eff...

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Part 9: gluing up panels with the new clamping cauls

10-12-2016 01:52 AM by Mainiac Matt | 0 comments »

Got a couple hours in the shop tonight. Sorting boards to match grain, color and shade, and then put together the first of several panel glue ups. It’s been >1 year since I joined and planed these, so I gave each board a quick rip on the TS to straighten the edges. The Fusion blade gave me a very clean cut that was ready for glue. First time using the new cauls (posted as a project some time ago if anyone wants to see more info) and they worked very well. I can hardly feel a se...

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Part 10: Panels Cleaned Up

10-23-2016 11:14 PM by Mainiac Matt | 2 comments »

I finished the 5 panel glue ups and put the clamping cauls and clamps away, and cleared the bench for the next step, cleaning up the panels. I wiped off as much of the glue that squeezed out off right away with wet paper towels, so the tops were in pretty good shape. The bottoms were a different story. I like to take the big boogers off by paring with a large 2” timber framing chisel, using it like a slick. Then I hit the joints with a card scraper. And I’m read...

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Part 11: How I prep card scrapers.

10-23-2016 11:37 PM by Mainiac Matt | 5 comments »

I make no claim to be a “real” galoot with the card scraper, but this process to renew the burr has worked for me. After a lot of use, the burr will get mangled and need to be created afresh. I start by setting up the scraper in a make shift jig using the bench vise and a couple scrap blocks of identical thickness. I set the scraper just above the blocks using a feeler gauge to get uniform height exposed. Then I file the old burr off with a mill file, using the jig to keep ...

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Part 12: panels cut to size and styles prepped

10-29-2016 05:32 PM by Mainiac Matt | 3 comments »

My first big mistake happened earlier this week when I set up the TS sled to cut my panels to size.One of these things is not like the other… 3/4” short to be precise… and of course it was the panel with the nicest wood figure. So after sulking for a few days, I went back into my design and made it 1.5” shorter, and cut the other side panels to match. I should have set up with a stop block like this the first time around… Then I moved on to prepping the st...

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Part 13: one step back

01-07-2017 07:40 PM by Mainiac Matt | 3 comments »

When I glued up my panels one of the end panels had some week spots that looked as if they might crack, but the grain was very interesting on these sticks and I wanted to use them if I could. Everything looked good after the initial glue up, but after a couple weeks sitting dormant while I was distracted, the panel cracked almost right down the middle. Fortunately, the crack was very close to parallel with the edge of the panel, so I decided to cut a kerf and see if I could rip it o...

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Part 14: A little metal working

01-08-2017 01:20 AM by Mainiac Matt | 4 comments »

This entry illustrates metal working in support of woodworking. I snapped the pics and added it to the blog thinking that some of you might find this work interesting. The panel raising bit from my new set is too big for the hole in my router table plate… So I broke down the table to have at modifying the aluminum plate. On a side note, you can see here that this beastly 3 HP PC VS router has been modified to put an incremental depth dial on the plunge mechanism, which is h...

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Part 15: First raised panels (ever)

01-10-2017 01:35 AM by Mainiac Matt | 6 comments »

Well this was a little nerve racking, but it seems to have turned out OK. After cutting a couple test pieces and adjusting the set up, I produced my first ever raised panel. I cut these in one pass and got just a little burn on one of the long edges… Here’s the router table set up… I used 1/4” scrap Masonite for a zero clearance sacrificial fence… The panel had already been sanded and the thickness was no longer perfectly uniform, and I thi...

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Part 16: Finished raising the rest of the panels

01-12-2017 03:17 AM by Mainiac Matt | 1 comment »

All six are done. All were routed in one shot. Follow on passes made here and there to even up the cuts. This one is my favorite and will go on the front face for sure…

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Part 17: Profile sanding the raised panel end grain.

01-15-2017 12:51 AM by Mainiac Matt | 2 comments »

Santa gave me a multi-tool for Christmas and I used a Home Depot gift card to buy some accessories for it. I picked up a Dremel profile sanding kit. Turns out the radius of one of the profiles matches the concave section of my raised panel Ogee, so I set up and sanded the end grain. Started with 120 grit and then stepped up to 180. Here’s the kit…. Here’s the profile I used… and here’s my setup on my downdraft TS outfeed table… This really ta...

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Part 18: Hand sanding & sealing the panels

01-16-2017 01:38 AM by Mainiac Matt | 3 comments »

Went to Home Depot today and bought sanding sponges, sand paper and a nice little sanding block… All hand sanding tonight, working through the grits 150 – 180 – 220 Then I vacuumed the panels, blew them off with air, wiped them down with a tack clothe (mistake?), buffed the out with a cotton rag, and hit them with a rattle can of Shellac as a seal coat. My daughter doesn’t want a gloss finish, so I’m thinking satin laquer, and she wants to be abl...

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Part 19: I screwed up big time :^(

01-18-2017 12:41 AM by Mainiac Matt | 3 comments »

The Amana AGM raised panel set I’m using has a back cutter and came set up with a large bearing. Everything turned out great, but I did think that the depth of the Ogee wasn’t quite what I thought it should be and the panels don’t drop into the styles very far. The instructions that came with the set seemed great, but did not include any illustrations or reference to the back cutter feature. So I used the bits as they came set up from the factory…...... ...

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Part 20: Re-routed and sanded the raised panels

01-21-2017 09:50 PM by Mainiac Matt | 2 comments »

Here you can see the difference in the profile when I used the correct guide bearing… Lots of sanding… I had a small blowout from scraping the glue off of one of the panels and there was some pretty deep grain , so I decided to try out filling the grain using Timber Mate on this one. Here they are all done with one coat of spray shellac. Now I just need to figure out how to match the color of the wood filler.

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Part 21: Cope cuts, Cross cuts and Bevel cuts

01-30-2017 12:57 AM by Mainiac Matt | 2 comments »

I banged out a quick cross cut sled as my sliding miter is a little fickle maintaining a square cur… Then I cut all of the rails and styles to their final length I had to sneak in a side project to make a coping sled (see my latest project post)... So I was then able to make all of my cope cut on the rail ends… I’m going to use 45 deg. bevel rip cuts on the to join the outer styles in each corner. This is only the second time I’ve ever tilted the blade on ...

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Part 22: Corners glued up and first frame glued up.

02-06-2017 12:59 AM by Mainiac Matt | 3 comments »

I glued up one corner with biscuits and clamp blocks and a second with no biscuits and painters tape…. Painter tape option was much easier and actually came out nicer. So I did the remaining two with tape. Glued up the first frame tonight…

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Part 23: Interior done finish started

02-25-2017 07:46 PM by Mainiac Matt | 7 comments »

Pine cleats glued and screwed. Plywood bottom installed, and cedar liner glued in… Finish sanded one side and padded three coats of shellac. It took me a while to find the lid stays I purchased long ago… The package says this is antique brass… But it looks dull black. I’m not crazy about it

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Part 24: Padding Shellac

03-07-2017 02:13 PM by Mainiac Matt | 3 comments »

Some people have expressed interest in the shellac finish I’m using…. Here’s a write up on how I do it, which I learned from Peter Gedrys. You can see some of his amazing work here Here’s the finished front (in really bad light) Here’s the top with just one coat on it. Go to minute 25 in Peter’s finishing seminar video to learn this from the master. Here’s the routine, as I’m doing it. I sand through the grits on the RO jitterbu...

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Part 25: Mission lacquer count down...

03-11-2017 05:02 PM by Mainiac Matt | 4 comments »

4 thin coats of a shellac padded on and dry Touch sanded with 400 grit and soapy water… Wiped down with water, dry cotton rag, and then a quick wipe with lacquer thinner Space ace reporting for duty… 10, 9,8,7,6,5,4,3,2,1…......

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Part 26: All done

07-07-2017 03:36 PM by Mainiac Matt | 2 comments »

I finally wrapped up the finish with three coats of padded blonde shellac (4 on the lid) and then three coats of satin sheen rattle can lacquer (4 on the lid). Hardware installation…. full mortise lock, recessed strike plate, hinge and lid stays was all tricky and took much longer than it should have. the cat seems to approve…. Wrote up a project post here Thanks for following along this 3 year odyssey and for all the encouraging comments and helpful hints.

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