A project in Maple

bandit571 said:

start ups

Still had a stack of Maple "scraps" sitting around, needed a project to use them up on…...maybe a small blanket chest? Let's see…

This is most of the wood supply….I also went and bought a 1×4 x 8' Maple plank, as I might need a few pieces to cover ..oops items….

I had this glued up panel from Charles Neil….and there was a 5/4 slab in the stack..

It did have a crack that finally gave way. Not sure why it was stained, either. Set up the resaw jig…

With the idea of ripping that 5/4 slab into corner posts, for a frame and raised panel case..

Then running a jointer along the edges, to get rid of the saw marks…

I also milled a few other parts up..

Mainly rails. Those corner posts needed a little extra work..

I wanted to get rid of that stain….

Easy enough to do…

Had four larger boards, and made a couple glued up panels….to be made into some raised panels…

Set all these aside for a day….

Figured out a profile for the "feet". Bandsaw to cut these out.

Did a bit of layout out work, to determine what size rails and a center stile I needed…wound up cutting the rails wrong…will recycle on the shorter ends..

The next day was not a good day…started out doing bevels

Finally got two panels all nicely raised..I thought….did a dry fit…to check for fits…

Something wasn't quite right….ploughed ahead, anyway…

Rails needed grooves to house the panels, tenons needed cut, mortises needed chopped..another full dry fit..

This is actually about the third try. Corner post at the top doesn't even have the mortises done, yet. Nothing wanted to fit where I wanted it to….got to checking those raised panels…..1/8" too wide, 1/8" too long, about the same out of square…Grrrrrr. Ok, got that problem fixed, and the edges re-beveled….then stopped for the night.

In the next episode, things were much better…stay tuned….there was glue ups done!

xt day…..

Click to expand...

bandit571 said:

Getting assembled...

Not moving the best, this week, forced to take things a bit easy…..
Ok, to get caught up with this project….

Got the fourth panel all glued up….and even did a test fit…

Which left the problem of the glue joints at the corners….took yesterday off…wasn't feeling too good..

Today, after a decent rest, went SLOWLY to the shop…trying to keep the trips up and down the stairs as low as I can…..Set up an end panel in the vise…

I thought that shelf had a reason to be sticking out so far…..helps support stuff….. Reason for the vise was to check for square …

Which this wasn't. We have ways…

Of getting things "squared away". Millers Falls #14 Jack plane seemed to be about the right size for this job. Needed this square, for the next item on the list..

I WAS going to use this 3/16" Match cutter, to mill a tongue along the edges of the end panels….wood was a tad too wide, would have left a whisker along the edges…...there is another cutter…

I have the 1/4" Match cutter for the Stanley No. 45….it at least is wider than the boards I was going over..

I wanted to keep the skates ON the wood. Once I had the skates set, and the depth set, I could add the fence.
Ok, once I figured out which way the grain was actually going….I could start at the far end..

And work my way back. Once a bit of the tongue appeared, I rubbed the "new" candle along the sides of the tongue. I figure the cutter will remove almost all the wax, after a few trips..

Finally got four tongues milled…but, I wanted them to fit into stopped grooves, which meant they needed trimmed back a bit…around 1-1/2" or so..

Backsaw to make a saw cut, chisel to pare away the waste….set these aside, clear the top of the bench, and lay one of the front/back panels on the bench. With the "inside" facing up. Dug up a 1/4" router bit. And the rest of the contraption's parts..

Noisey, messy thing. Still, about the easiest way to make a stopped groove. Once I marked a stop/start line, and remembered which way to run the router along an edge…..and set the fence for where the groove needed to be..

Groove is also "stopped" about the same at the top. First groove was easy…second groove….not so much, got about an inch or so ploughed out…..

Never heard a sound. Hate when that happens. Dug out a few more 1/4" bits….(I would pick the dullest one first)

second, third , and fourth cuts…tried to burn a bit….gave each a second pass to clean them out. Dry fits as I went along..

They were a might tight…..decided to go ahead and glue the mess up…

Diagonal to pull things square…well, a little past square, so it "springs back" into square, when I remove the clamp.

Will let this set awhile….i went upstairs, and took the rest of the day off, other than peeling dried glue off of my fingers. Tomorrow? Might try either to build the bottom, make a small box, or work on the lid.

Stay tuned…..

Click to expand...

bandit571 said:

Getting assembled...

Not moving the best, this week, forced to take things a bit easy…..
Ok, to get caught up with this project….

Got the fourth panel all glued up….and even did a test fit…

Which left the problem of the glue joints at the corners….took yesterday off…wasn't feeling too good..

Today, after a decent rest, went SLOWLY to the shop…trying to keep the trips up and down the stairs as low as I can…..Set up an end panel in the vise…

I thought that shelf had a reason to be sticking out so far…..helps support stuff….. Reason for the vise was to check for square …

Which this wasn't. We have ways…

Of getting things "squared away". Millers Falls #14 Jack plane seemed to be about the right size for this job. Needed this square, for the next item on the list..

I WAS going to use this 3/16" Match cutter, to mill a tongue along the edges of the end panels….wood was a tad too wide, would have left a whisker along the edges…...there is another cutter…

I have the 1/4" Match cutter for the Stanley No. 45….it at least is wider than the boards I was going over..

I wanted to keep the skates ON the wood. Once I had the skates set, and the depth set, I could add the fence.
Ok, once I figured out which way the grain was actually going….I could start at the far end..

And work my way back. Once a bit of the tongue appeared, I rubbed the "new" candle along the sides of the tongue. I figure the cutter will remove almost all the wax, after a few trips..

Finally got four tongues milled…but, I wanted them to fit into stopped grooves, which meant they needed trimmed back a bit…around 1-1/2" or so..

Backsaw to make a saw cut, chisel to pare away the waste….set these aside, clear the top of the bench, and lay one of the front/back panels on the bench. With the "inside" facing up. Dug up a 1/4" router bit. And the rest of the contraption's parts..

Noisey, messy thing. Still, about the easiest way to make a stopped groove. Once I marked a stop/start line, and remembered which way to run the router along an edge…..and set the fence for where the groove needed to be..

Groove is also "stopped" about the same at the top. First groove was easy…second groove….not so much, got about an inch or so ploughed out…..

Never heard a sound. Hate when that happens. Dug out a few more 1/4" bits….(I would pick the dullest one first)

second, third , and fourth cuts…tried to burn a bit….gave each a second pass to clean them out. Dry fits as I went along..

They were a might tight…..decided to go ahead and glue the mess up…

Diagonal to pull things square…well, a little past square, so it "springs back" into square, when I remove the clamp.

Will let this set awhile….i went upstairs, and took the rest of the day off, other than peeling dried glue off of my fingers. Tomorrow? Might try either to build the bottom, make a small box, or work on the lid.

Stay tuned…..

Click to expand...

bandit571 said:

A bottom framed, a puppy died, a lid done...

Had a little 3 month old puppy in the house…..she came down sick the other day….the next morning she passed away, before we could even get her to the vet…..thinking something poisoned her out in the yard….

Ok, I wasn't in a very good mood when I returned to the shop…

Hammer and chisel to shape the feet a bit, to at least blend them together….
Ripped a bunch of maple scraps into 1×1s…and made a frame of sorts..

To support the plywood bottom. Had to "toe-nail a few spots…

Otherwise, just nails and glue to hold the frame in place…..

No matter how well I marked this panel for size, I still had to trim it down to fit…..glue and screws to attach it to the frame….was getting a bit fed up….then tried the lid…

Too long, and not wide enough….trip to Menards for one more plank of Maple….and even found a deal!

Got this for $5. the plank was $2 less than the last one I bought, and a foot longer! Cut off a 31" long chunk from the plank. Check to see IF I needed to joint and edge…

Not really needed. I did need a few cauls, to keep it halfway flat….This morning, the clamps came off..

Hmm…still too long, and now a tad too wide….we have ways..

Hey, it IS a vintage saw…a framer square to mark each end, then trimmed for length….When I first tried to rip for width…one end was wider? Ok, measure from one edge, make a mark..go to the other end, and do the same…then dig out a straightedge..

Called a Tinner's Rule. Marked a new line. and ripped that.

Dug out the old router table….then another chunk of maple was rough cut to length, and then ripped down the center. I had two breadboard ends. Needed to mill a dovetail along one edge..

Got both done….Then I needed to remove the bit, and install it in another router, sooo (we like to move it, move it…) and set up a fence…a few times..

First time was a hair off. After ripping the mess off, I re-checked WHERE it was cutting, and made a adjustment…
I also clamped a bit of scrap along the far side, to help support the router's fat …bottom..

Slid one of the bread boards in place….pulled it back out, a few dabs of glue, and drive the board through. Flip the lid around, and repeat. sat it on the case..

Kind of plain jane…breadboards are a tad long..
Got bored this evening, no puppy to play with…meander back to the shop. Picked up a pint can of varnish (empty) and laid out a few curves. Bandsaw was fun to cut the curves….

Sander to remove the saw marks, and fair the curve a bit. Laid the lid on the bench..

And found a lot of "high" spots where two boards didn't quite match. The center of the lid had also cupped a bit…we have ways..

a cambered Jack plane, to remove the worst of the spots. Had to do this to both faces. A smooth plane was run along the edge grain areas, to remove saw marks. Finally was able to use the smooth plane on the faces..

To clean things up. set the lid back on the case..

Looks much better, now? need to do the same things to the case, to get it all nice and finish ready. Might even install the hinges. Un-decided about a little box on the inside….may do without it, and use some hardware, instead…..stay tuned….

Click to expand...

bandit571 said:

A bottom framed, a puppy died, a lid done...

Had a little 3 month old puppy in the house…..she came down sick the other day….the next morning she passed away, before we could even get her to the vet…..thinking something poisoned her out in the yard….

Ok, I wasn't in a very good mood when I returned to the shop…

Hammer and chisel to shape the feet a bit, to at least blend them together….
Ripped a bunch of maple scraps into 1×1s…and made a frame of sorts..

To support the plywood bottom. Had to "toe-nail a few spots…

Otherwise, just nails and glue to hold the frame in place…..

No matter how well I marked this panel for size, I still had to trim it down to fit…..glue and screws to attach it to the frame….was getting a bit fed up….then tried the lid…

Too long, and not wide enough….trip to Menards for one more plank of Maple….and even found a deal!

Got this for $5. the plank was $2 less than the last one I bought, and a foot longer! Cut off a 31" long chunk from the plank. Check to see IF I needed to joint and edge…

Not really needed. I did need a few cauls, to keep it halfway flat….This morning, the clamps came off..

Hmm…still too long, and now a tad too wide….we have ways..

Hey, it IS a vintage saw…a framer square to mark each end, then trimmed for length….When I first tried to rip for width…one end was wider? Ok, measure from one edge, make a mark..go to the other end, and do the same…then dig out a straightedge..

Called a Tinner's Rule. Marked a new line. and ripped that.

Dug out the old router table….then another chunk of maple was rough cut to length, and then ripped down the center. I had two breadboard ends. Needed to mill a dovetail along one edge..

Got both done….Then I needed to remove the bit, and install it in another router, sooo (we like to move it, move it…) and set up a fence…a few times..

First time was a hair off. After ripping the mess off, I re-checked WHERE it was cutting, and made a adjustment…
I also clamped a bit of scrap along the far side, to help support the router's fat …bottom..

Slid one of the bread boards in place….pulled it back out, a few dabs of glue, and drive the board through. Flip the lid around, and repeat. sat it on the case..

Kind of plain jane…breadboards are a tad long..
Got bored this evening, no puppy to play with…meander back to the shop. Picked up a pint can of varnish (empty) and laid out a few curves. Bandsaw was fun to cut the curves….

Sander to remove the saw marks, and fair the curve a bit. Laid the lid on the bench..

And found a lot of "high" spots where two boards didn't quite match. The center of the lid had also cupped a bit…we have ways..

a cambered Jack plane, to remove the worst of the spots. Had to do this to both faces. A smooth plane was run along the edge grain areas, to remove saw marks. Finally was able to use the smooth plane on the faces..

To clean things up. set the lid back on the case..

Looks much better, now? need to do the same things to the case, to get it all nice and finish ready. Might even install the hinges. Un-decided about a little box on the inside….may do without it, and use some hardware, instead…..stay tuned….

Click to expand...

bandit571 said:

A bottom framed, a puppy died, a lid done...

Had a little 3 month old puppy in the house…..she came down sick the other day….the next morning she passed away, before we could even get her to the vet…..thinking something poisoned her out in the yard….

Ok, I wasn't in a very good mood when I returned to the shop…

Hammer and chisel to shape the feet a bit, to at least blend them together….
Ripped a bunch of maple scraps into 1×1s…and made a frame of sorts..

To support the plywood bottom. Had to "toe-nail a few spots…

Otherwise, just nails and glue to hold the frame in place…..

No matter how well I marked this panel for size, I still had to trim it down to fit…..glue and screws to attach it to the frame….was getting a bit fed up….then tried the lid…

Too long, and not wide enough….trip to Menards for one more plank of Maple….and even found a deal!

Got this for $5. the plank was $2 less than the last one I bought, and a foot longer! Cut off a 31" long chunk from the plank. Check to see IF I needed to joint and edge…

Not really needed. I did need a few cauls, to keep it halfway flat….This morning, the clamps came off..

Hmm…still too long, and now a tad too wide….we have ways..

Hey, it IS a vintage saw…a framer square to mark each end, then trimmed for length….When I first tried to rip for width…one end was wider? Ok, measure from one edge, make a mark..go to the other end, and do the same…then dig out a straightedge..

Called a Tinner's Rule. Marked a new line. and ripped that.

Dug out the old router table….then another chunk of maple was rough cut to length, and then ripped down the center. I had two breadboard ends. Needed to mill a dovetail along one edge..

Got both done….Then I needed to remove the bit, and install it in another router, sooo (we like to move it, move it…) and set up a fence…a few times..

First time was a hair off. After ripping the mess off, I re-checked WHERE it was cutting, and made a adjustment…
I also clamped a bit of scrap along the far side, to help support the router's fat …bottom..

Slid one of the bread boards in place….pulled it back out, a few dabs of glue, and drive the board through. Flip the lid around, and repeat. sat it on the case..

Kind of plain jane…breadboards are a tad long..
Got bored this evening, no puppy to play with…meander back to the shop. Picked up a pint can of varnish (empty) and laid out a few curves. Bandsaw was fun to cut the curves….

Sander to remove the saw marks, and fair the curve a bit. Laid the lid on the bench..

And found a lot of "high" spots where two boards didn't quite match. The center of the lid had also cupped a bit…we have ways..

a cambered Jack plane, to remove the worst of the spots. Had to do this to both faces. A smooth plane was run along the edge grain areas, to remove saw marks. Finally was able to use the smooth plane on the faces..

To clean things up. set the lid back on the case..

Looks much better, now? need to do the same things to the case, to get it all nice and finish ready. Might even install the hinges. Un-decided about a little box on the inside….may do without it, and use some hardware, instead…..stay tuned….

Click to expand...

bandit571 said:

A bottom framed, a puppy died, a lid done...

Had a little 3 month old puppy in the house…..she came down sick the other day….the next morning she passed away, before we could even get her to the vet…..thinking something poisoned her out in the yard….

Ok, I wasn't in a very good mood when I returned to the shop…

Hammer and chisel to shape the feet a bit, to at least blend them together….
Ripped a bunch of maple scraps into 1×1s…and made a frame of sorts..

To support the plywood bottom. Had to "toe-nail a few spots…

Otherwise, just nails and glue to hold the frame in place…..

No matter how well I marked this panel for size, I still had to trim it down to fit…..glue and screws to attach it to the frame….was getting a bit fed up….then tried the lid…

Too long, and not wide enough….trip to Menards for one more plank of Maple….and even found a deal!

Got this for $5. the plank was $2 less than the last one I bought, and a foot longer! Cut off a 31" long chunk from the plank. Check to see IF I needed to joint and edge…

Not really needed. I did need a few cauls, to keep it halfway flat….This morning, the clamps came off..

Hmm…still too long, and now a tad too wide….we have ways..

Hey, it IS a vintage saw…a framer square to mark each end, then trimmed for length….When I first tried to rip for width…one end was wider? Ok, measure from one edge, make a mark..go to the other end, and do the same…then dig out a straightedge..

Called a Tinner's Rule. Marked a new line. and ripped that.

Dug out the old router table….then another chunk of maple was rough cut to length, and then ripped down the center. I had two breadboard ends. Needed to mill a dovetail along one edge..

Got both done….Then I needed to remove the bit, and install it in another router, sooo (we like to move it, move it…) and set up a fence…a few times..

First time was a hair off. After ripping the mess off, I re-checked WHERE it was cutting, and made a adjustment…
I also clamped a bit of scrap along the far side, to help support the router's fat …bottom..

Slid one of the bread boards in place….pulled it back out, a few dabs of glue, and drive the board through. Flip the lid around, and repeat. sat it on the case..

Kind of plain jane…breadboards are a tad long..
Got bored this evening, no puppy to play with…meander back to the shop. Picked up a pint can of varnish (empty) and laid out a few curves. Bandsaw was fun to cut the curves….

Sander to remove the saw marks, and fair the curve a bit. Laid the lid on the bench..

And found a lot of "high" spots where two boards didn't quite match. The center of the lid had also cupped a bit…we have ways..

a cambered Jack plane, to remove the worst of the spots. Had to do this to both faces. A smooth plane was run along the edge grain areas, to remove saw marks. Finally was able to use the smooth plane on the faces..

To clean things up. set the lid back on the case..

Looks much better, now? need to do the same things to the case, to get it all nice and finish ready. Might even install the hinges. Un-decided about a little box on the inside….may do without it, and use some hardware, instead…..stay tuned….

Click to expand...

bandit571 said:

A bottom framed, a puppy died, a lid done...

Had a little 3 month old puppy in the house…..she came down sick the other day….the next morning she passed away, before we could even get her to the vet…..thinking something poisoned her out in the yard….

Ok, I wasn't in a very good mood when I returned to the shop…

Hammer and chisel to shape the feet a bit, to at least blend them together….
Ripped a bunch of maple scraps into 1×1s…and made a frame of sorts..

To support the plywood bottom. Had to "toe-nail a few spots…

Otherwise, just nails and glue to hold the frame in place…..

No matter how well I marked this panel for size, I still had to trim it down to fit…..glue and screws to attach it to the frame….was getting a bit fed up….then tried the lid…

Too long, and not wide enough….trip to Menards for one more plank of Maple….and even found a deal!

Got this for $5. the plank was $2 less than the last one I bought, and a foot longer! Cut off a 31" long chunk from the plank. Check to see IF I needed to joint and edge…

Not really needed. I did need a few cauls, to keep it halfway flat….This morning, the clamps came off..

Hmm…still too long, and now a tad too wide….we have ways..

Hey, it IS a vintage saw…a framer square to mark each end, then trimmed for length….When I first tried to rip for width…one end was wider? Ok, measure from one edge, make a mark..go to the other end, and do the same…then dig out a straightedge..

Called a Tinner's Rule. Marked a new line. and ripped that.

Dug out the old router table….then another chunk of maple was rough cut to length, and then ripped down the center. I had two breadboard ends. Needed to mill a dovetail along one edge..

Got both done….Then I needed to remove the bit, and install it in another router, sooo (we like to move it, move it…) and set up a fence…a few times..

First time was a hair off. After ripping the mess off, I re-checked WHERE it was cutting, and made a adjustment…
I also clamped a bit of scrap along the far side, to help support the router's fat …bottom..

Slid one of the bread boards in place….pulled it back out, a few dabs of glue, and drive the board through. Flip the lid around, and repeat. sat it on the case..

Kind of plain jane…breadboards are a tad long..
Got bored this evening, no puppy to play with…meander back to the shop. Picked up a pint can of varnish (empty) and laid out a few curves. Bandsaw was fun to cut the curves….

Sander to remove the saw marks, and fair the curve a bit. Laid the lid on the bench..

And found a lot of "high" spots where two boards didn't quite match. The center of the lid had also cupped a bit…we have ways..

a cambered Jack plane, to remove the worst of the spots. Had to do this to both faces. A smooth plane was run along the edge grain areas, to remove saw marks. Finally was able to use the smooth plane on the faces..

To clean things up. set the lid back on the case..

Looks much better, now? need to do the same things to the case, to get it all nice and finish ready. Might even install the hinges. Un-decided about a little box on the inside….may do without it, and use some hardware, instead…..stay tuned….

Click to expand...

bandit571 said:

a PIP, and a tray?

Well, catching up….trying to get this project done..sometime…

Got this all sanded down to 120 grit…and added a coat of amber shellac….

Still needs to have the hinges installed….

All squared edges were rounded over, using a spokeshave, a block plane, and smoothed out with the sander..
Hinges?

Well…they did make it ON to the chest…in a way. The Maple 1×1 and the 1×4?

The skinny one is to be a rail. The one by is to supply a second rail, and sides for a tray to ride on those rails..

Found an old rip fence….I cut the 1×4 down to the length I needed with the D-8..

Cardio for the day…Anyway, the rip fence worked great for a rip cut…not so great for resaw. Wound up almost freehanding the NOW 1×3 through….trying for 3/8" thick slabs..

Which were then cut to lengths…I also cut a slab of Poplar…

Then the handplanes came out….Poplar was 1/2" along one edge….3/8" thick along the other….Maple parts had a bit of wave to them, and saw marks…we have ways..

To flatten the Poplar, a cambered jack brought the high side down to match the low side..then the smooth plane could clean up..

There are 4 drywall screws holding things in place…just the heads of them. Set a bit below the thickness of the panels, so I would miss them when a plane goes by. Screws are in the bench, NOT the panels. Maple parts were just planed with the smooth plane.

Dry fit….needs a bit of joinery to connect the corners….bottom will get a rebate around all four edges.

Ok, Doctor Visit…Biopsy from the right forearm….Decided to just putter around a bit..
Laid out a few tools.
.

There is a small dovetail bit laying there…used it to set the bevel gauge…one thing led to another…

Thought I do one corner, to see how these will look..

Will need a bit of fine tuning….maybe tomorrow, I can get the other three done? Arm was getting sore..time to quit

Maybe tomorrow, I can do a bit more? Stay tuned…

Click to expand...

bandit571 said:

a PIP, and a tray?

Well, catching up….trying to get this project done..sometime…

Got this all sanded down to 120 grit…and added a coat of amber shellac….

Still needs to have the hinges installed….

All squared edges were rounded over, using a spokeshave, a block plane, and smoothed out with the sander..
Hinges?

Well…they did make it ON to the chest…in a way. The Maple 1×1 and the 1×4?

The skinny one is to be a rail. The one by is to supply a second rail, and sides for a tray to ride on those rails..

Found an old rip fence….I cut the 1×4 down to the length I needed with the D-8..

Cardio for the day…Anyway, the rip fence worked great for a rip cut…not so great for resaw. Wound up almost freehanding the NOW 1×3 through….trying for 3/8" thick slabs..

Which were then cut to lengths…I also cut a slab of Poplar…

Then the handplanes came out….Poplar was 1/2" along one edge….3/8" thick along the other….Maple parts had a bit of wave to them, and saw marks…we have ways..

To flatten the Poplar, a cambered jack brought the high side down to match the low side..then the smooth plane could clean up..

There are 4 drywall screws holding things in place…just the heads of them. Set a bit below the thickness of the panels, so I would miss them when a plane goes by. Screws are in the bench, NOT the panels. Maple parts were just planed with the smooth plane.

Dry fit….needs a bit of joinery to connect the corners….bottom will get a rebate around all four edges.

Ok, Doctor Visit…Biopsy from the right forearm….Decided to just putter around a bit..
Laid out a few tools.
.

There is a small dovetail bit laying there…used it to set the bevel gauge…one thing led to another…

Thought I do one corner, to see how these will look..

Will need a bit of fine tuning….maybe tomorrow, I can get the other three done? Arm was getting sore..time to quit

Maybe tomorrow, I can do a bit more? Stay tuned…

Click to expand...