seven hours in the shop?

Plus a road trip to get a couple 1×12s for shelves..and a quart of stain….might take today off….kind of sore.

Ok, this is going to be a LONG post….I started at 10:00 am and finished the main part by 4:00pm….then the road trip, then another hour in the shop….picture heavy day, too…

On the way to the Dungeon Shop, looked out the backdoor of the house….NOT ready for leaves to be turning….

Cleared the benchtop off, then cleaned out the tool well, again..all sorts of goodies were found. The main part was making a jig, as I needed grooves done..

Stiles needed a groove made. not a whole lot of room left under the Stanley 45's fence….needed a way to hold things in place..

Jig was moved a tad closer to the edge of the bench….screw & washer is then a tight fit….mallet to set a part in place tight. Both stiles were done..

But, the rest of the parts that needed a groove (or two) were a lot shorter…some I could c clamp in place..

But the two narrow rails were a bit harder to do. That 1/4" piece of plywood does have a notch, to fit the end of a part….

Ok, all the grooves were done…Gatorade Break. Came back from that, used a wide chisel, bevel down, to trim the installed plugs off flush…will hit them with a block plane later…..top of door #1 was….gappy. cut and fitted a filler strip and glue and clamped it in place, for a while….also adjusted the bottom hinge, to stop the squeaks the Boss doesn't like…size 11 shoe helped…
Ok, back to the bench..

laid out the tenons on the rails….top and bottom rails use a haunched tenon….the others just a normal one…jig is to cut the tenons on the bandsaw…too crowded to use the mitre box…

Made a bunch of "Dominoes". Once all the tenons were milled..

I got out the mortise jig…had 10 holes to dig..

usual suspects….dry fitted as I went along one stile..

Once these five were done, laid the two stiles together, and transferred marks to show where the mortises need to be..

Once those five were done, a dry fit of the completed frame was attempted…..hammer to adjust….frame was a hair of of square….got that adjusted….all the rails then sat nice and tight, and square…

Set this aside, out of the way….Panels? Had two already rough cut….rough being the word here..

Cut the to the final size needed…and made the ends square, too. That plank behind them, with that ugly knot?

Was trying to be a Knot Farm…was just enough room to cut two panels out, between the knots.

This is from the last trip of the day to the shop..was down there to take a few pictures…that WAS the plan..

Top of fixed door. Those plugs have a burnt ring around them may leave that as is…frame was moved out, for a better picture..

But, those 4 blanks did need a little "prep work" before I could actually raise them…

Beltsander to flatten the end grain…just to get it close. Then edge grain?

Was visited by a jack plane, until they were all alike….at least close enough to sit in a groove. I also made a jig..

So I can plane a bevel onto the end grain ends….Then change the jig for the sides to be beveled…same jig for adding a rebate around the inside edges…
About 7-1/2 hours IN the shop..plus a few Gatorade Breaks. Somehow missed lunch…drat.

Resting up, today..might try again tomorrow?
Stay tuned…

 

seven hours in the shop?

Plus a road trip to get a couple 1×12s for shelves..and a quart of stain….might take today off….kind of sore.

Ok, this is going to be a LONG post….I started at 10:00 am and finished the main part by 4:00pm….then the road trip, then another hour in the shop….picture heavy day, too…

On the way to the Dungeon Shop, looked out the backdoor of the house….NOT ready for leaves to be turning….

Cleared the benchtop off, then cleaned out the tool well, again..all sorts of goodies were found. The main part was making a jig, as I needed grooves done..

Stiles needed a groove made. not a whole lot of room left under the Stanley 45's fence….needed a way to hold things in place..

Jig was moved a tad closer to the edge of the bench….screw & washer is then a tight fit….mallet to set a part in place tight. Both stiles were done..

But, the rest of the parts that needed a groove (or two) were a lot shorter…some I could c clamp in place..

But the two narrow rails were a bit harder to do. That 1/4" piece of plywood does have a notch, to fit the end of a part….

Ok, all the grooves were done…Gatorade Break. Came back from that, used a wide chisel, bevel down, to trim the installed plugs off flush…will hit them with a block plane later…..top of door #1 was….gappy. cut and fitted a filler strip and glue and clamped it in place, for a while….also adjusted the bottom hinge, to stop the squeaks the Boss doesn't like…size 11 shoe helped…
Ok, back to the bench..

laid out the tenons on the rails….top and bottom rails use a haunched tenon….the others just a normal one…jig is to cut the tenons on the bandsaw…too crowded to use the mitre box…

Made a bunch of "Dominoes". Once all the tenons were milled..

I got out the mortise jig…had 10 holes to dig..

usual suspects….dry fitted as I went along one stile..

Once these five were done, laid the two stiles together, and transferred marks to show where the mortises need to be..

Once those five were done, a dry fit of the completed frame was attempted…..hammer to adjust….frame was a hair of of square….got that adjusted….all the rails then sat nice and tight, and square…

Set this aside, out of the way….Panels? Had two already rough cut….rough being the word here..

Cut the to the final size needed…and made the ends square, too. That plank behind them, with that ugly knot?

Was trying to be a Knot Farm…was just enough room to cut two panels out, between the knots.

This is from the last trip of the day to the shop..was down there to take a few pictures…that WAS the plan..

Top of fixed door. Those plugs have a burnt ring around them may leave that as is…frame was moved out, for a better picture..

But, those 4 blanks did need a little "prep work" before I could actually raise them…

Beltsander to flatten the end grain…just to get it close. Then edge grain?

Was visited by a jack plane, until they were all alike….at least close enough to sit in a groove. I also made a jig..

So I can plane a bevel onto the end grain ends….Then change the jig for the sides to be beveled…same jig for adding a rebate around the inside edges…
About 7-1/2 hours IN the shop..plus a few Gatorade Breaks. Somehow missed lunch…drat.

Resting up, today..might try again tomorrow?
Stay tuned…

There was a long break (Supper) and a trip to Home Depot….a spare heater insert was returned. The Boss picked out the flavour of stain she wants…at least it will NOT be paint. I also sorted through a rack of 1×12 x 4' boards..to find two that were worth buying. Those will be the three fixed shelves behind door#2.

Even saw a Funnel Cloud on the way home! About halfway to the ground, it gave up, and returned to the clouds.

Fought Honda Rush Hour Traffic on the way to the BORG….they were all gone on the way home….we were getting passed, while going 75-80mph! was too slow for some?

 

Lazy day?

Well, after that LONG Tuesday work session….decided to stay out of the shop, yesterday…....

Last night….got tired of looking at the two 1×12s that were still sitting in the kitchen (why?) so I thought i would just haul those to the shop…Boss wanted the dryer checked, as well….what could go wrong with this plan?

Two boards..about 4 bf a piece….Home Depot wanted $8.96 + tax a piece…Dug around until I found these two keepers….meh…will do for shelves.

Dryer needed restarted…what to do while I wait?

Rounded up the Usual Suspects….that blank sitting in the jig…thought I would at least try the jig out, to see if it would work….plane a simple bevel….one thing led to another…

Soon ran out of end grain bevels to do…rebuilt the jig….and again did a test drive..

Jack plane did most of this bevel, then cleaned things up with the #3c…...was making a mess on the floor..

Well, jig works, clothes are dry….replaced with clothes from the washer, restart. Had just enough fun for today…

Should have known better than to go down to the shop, something always seems to get done…
Maybe after Lunch, today..I can finish making the raised panels…and after Supper, do a glue-up?

Stay tuned…

 

Lazy day?

Well, after that LONG Tuesday work session….decided to stay out of the shop, yesterday…....

Last night….got tired of looking at the two 1×12s that were still sitting in the kitchen (why?) so I thought i would just haul those to the shop…Boss wanted the dryer checked, as well….what could go wrong with this plan?

Two boards..about 4 bf a piece….Home Depot wanted $8.96 + tax a piece…Dug around until I found these two keepers….meh…will do for shelves.

Dryer needed restarted…what to do while I wait?

Rounded up the Usual Suspects….that blank sitting in the jig…thought I would at least try the jig out, to see if it would work….plane a simple bevel….one thing led to another…

Soon ran out of end grain bevels to do…rebuilt the jig….and again did a test drive..

Jack plane did most of this bevel, then cleaned things up with the #3c…...was making a mess on the floor..

Well, jig works, clothes are dry….replaced with clothes from the washer, restart. Had just enough fun for today…

Should have known better than to go down to the shop, something always seems to get done…
Maybe after Lunch, today..I can finish making the raised panels…and after Supper, do a glue-up?

Stay tuned…

Whew!

 

Door #2 done

Started in just after Lunch….about 12:20 pm, or so…..quitting time was about 3:30 or so…
First up? Had the last of the plugs to install..
.

Maybe tomorrow, I can plane these down flush? Next, long grain bevels needed done..after I cleaned the floor up..had issues walking around on all those shavings….started out with a clean floor..

I was using a Millers Falls No.14 Jack plane for the long grain work….was a bit heavy..changed over to the smaller No. 11…..that is the No. 3c behind it. Made a decent enough shaving in the Ash..

Wound up with all four panels having the bevels done..

Time to re-do the jig, set up the Wards #78 for some end grain rebates..

Same parts as the other jig, just moved around a bit..the plane?

Then check for a fit..

Got all the end grain ones done, re-arrange the jig again..

Wasn't going to change the 78…had a the stanley 45 handy. The 78 was using a spur to cut across the grain, the 45 was going with the grain, and didn't need a spur/nicker…

The Auburn #181 plane helped clean things up….

Got the rebates all done…laid the panels out, to arrange how the grain would wind up….got the frame out of the clamps, and started to install the panels…..had a problem…some of these panels did NOT fit! All four are the same exact size…...it would seem that the rails were wrong…..went through and custom fitted each of the panels to the sizes needed to fit between the rails….hate when that happens….better than IF they had been too small, though….re-cut the rebates, re-planed the bevels….added the glue, and started the clamps…..one rail ( the middle one, again) wasn't going along with the plan…..finally got it to go….cheater bar on the pipe clamp…

Will let this thing sit overnight, and then some….it was one of them days..

Still had leg and toe cramps….hauled the load of dry clothes from the dryer upstairs, and called it a day.

Maybe tomorrow, I can get a few other things done?
Stay tuned….(will need a bit of help to move this project around)

 

Door #2 done

Started in just after Lunch….about 12:20 pm, or so…..quitting time was about 3:30 or so…
First up? Had the last of the plugs to install..
.

Maybe tomorrow, I can plane these down flush? Next, long grain bevels needed done..after I cleaned the floor up..had issues walking around on all those shavings….started out with a clean floor..

I was using a Millers Falls No.14 Jack plane for the long grain work….was a bit heavy..changed over to the smaller No. 11…..that is the No. 3c behind it. Made a decent enough shaving in the Ash..

Wound up with all four panels having the bevels done..

Time to re-do the jig, set up the Wards #78 for some end grain rebates..

Same parts as the other jig, just moved around a bit..the plane?

Then check for a fit..

Got all the end grain ones done, re-arrange the jig again..

Wasn't going to change the 78…had a the stanley 45 handy. The 78 was using a spur to cut across the grain, the 45 was going with the grain, and didn't need a spur/nicker…

The Auburn #181 plane helped clean things up….

Got the rebates all done…laid the panels out, to arrange how the grain would wind up….got the frame out of the clamps, and started to install the panels…..had a problem…some of these panels did NOT fit! All four are the same exact size…...it would seem that the rails were wrong…..went through and custom fitted each of the panels to the sizes needed to fit between the rails….hate when that happens….better than IF they had been too small, though….re-cut the rebates, re-planed the bevels….added the glue, and started the clamps…..one rail ( the middle one, again) wasn't going along with the plan…..finally got it to go….cheater bar on the pipe clamp…

Will let this thing sit overnight, and then some….it was one of them days..

Still had leg and toe cramps….hauled the load of dry clothes from the dryer upstairs, and called it a day.

Maybe tomorrow, I can get a few other things done?
Stay tuned….(will need a bit of help to move this project around)

Shavings on the floor…..hand planed raised panels is work….and very messy..

Had three piles like this to sweep up, today….

Took a piece of scrap Ash upstairs….gave on face of it a coat of the "Weathered Oak" stain….not much of a change in colour to the wood ( needs mixed better?) later, I added a coat of Amber Shellac…nice change of colour….looks like I'll be using the stain AND the shellac…..The Boss has approved.

May wait until this thing is upstairs, and up of the shop, first.

 

PIP time?

Weather was ugly outside….sun would peek out, the goes and hides while the next rain cloud comes by. Pulled up to the house today…van load of groceries, and a replacement TV…soon as we started to unload the van..it started to rain..hard. Finally get everything into the house, and THEN the sun comes out…grrr

Decided to see IF the door was ready to install….carefully removed the clamps…no creaks, no loud cracking noises..
Placed the door in the leg vise…one edge was a bit curved…was too wide for the door opening, anyway..

I have a steel straight edge handy….and used the jack plane to remove the worst of the curves..

Then the #7c to joint the entire edge…hopefully I get it square, too..

Checked with the door opening…top of the door was a bit out of square…and a hair too long…framing square to mark a line, circular saw to remove the line,,,beltsander to clean up saw marks..

Planed and sanded any other high spots….About time to add the hinges?

VIX bit to do pilot holes….then try to get the knob's location to match the other door..third try did it!..then move the case around a bit, in order to get ME to where I can install the door, and do the second task of the day..used a shim under the door, so the door won't rub as you open/close it…

Door didn't want to open….Finally got it open..found the bottom hinge had shifted things too far…hammer adjusted to cure that. Hammer also teamed up with a chisel. I trimmed all the plugs down flush…will sand them tomorrow. two jobs done…..had to move this case around again…needed to get ME into the back of the case.

had to slide the case over against the bandsaw..

Had the other three shelves to install…was a tight fit for this fat body…
Ok, those 1×12s planks from Home depot? I needed 4 pieces at 13-1/8" long cut…

Got three good boards from the first plank….the fourth was needed to provide filler strips at the back of the shelves..needed to be the same length, and then ripped for width..

Shelves sit on 1×1 cleats….had to trim the ends of the cleats a bit. Filler strips also needed trimmed a bit.
Will add the plywood panels to the back of the case, to enclose the shelf areas, when I get the case upstairs….easier to carry, that way. Same with the heater insert ( using it right now, in the livingroom)
Had to slide this thing back around..have a lot of sanding to do…

That trash can WAS empty, when this project started out…

Need to get this upstairs, too….and out to the firepit. Thought I might as well show off how the front is looking..so…how about a PIP?

That big open area is for the insert to go in…moved the camera a tad closer..

Lots of sanding, a "Weather Oak" oil stain, and a coat or two of Amber Shellac? And round up a crew to haul this thing upstairs? Stay tuned….

 

PIP time?

Weather was ugly outside….sun would peek out, the goes and hides while the next rain cloud comes by. Pulled up to the house today…van load of groceries, and a replacement TV…soon as we started to unload the van..it started to rain..hard. Finally get everything into the house, and THEN the sun comes out…grrr

Decided to see IF the door was ready to install….carefully removed the clamps…no creaks, no loud cracking noises..
Placed the door in the leg vise…one edge was a bit curved…was too wide for the door opening, anyway..

I have a steel straight edge handy….and used the jack plane to remove the worst of the curves..

Then the #7c to joint the entire edge…hopefully I get it square, too..

Checked with the door opening…top of the door was a bit out of square…and a hair too long…framing square to mark a line, circular saw to remove the line,,,beltsander to clean up saw marks..

Planed and sanded any other high spots….About time to add the hinges?

VIX bit to do pilot holes….then try to get the knob's location to match the other door..third try did it!..then move the case around a bit, in order to get ME to where I can install the door, and do the second task of the day..used a shim under the door, so the door won't rub as you open/close it…

Door didn't want to open….Finally got it open..found the bottom hinge had shifted things too far…hammer adjusted to cure that. Hammer also teamed up with a chisel. I trimmed all the plugs down flush…will sand them tomorrow. two jobs done…..had to move this case around again…needed to get ME into the back of the case.

had to slide the case over against the bandsaw..

Had the other three shelves to install…was a tight fit for this fat body…
Ok, those 1×12s planks from Home depot? I needed 4 pieces at 13-1/8" long cut…

Got three good boards from the first plank….the fourth was needed to provide filler strips at the back of the shelves..needed to be the same length, and then ripped for width..

Shelves sit on 1×1 cleats….had to trim the ends of the cleats a bit. Filler strips also needed trimmed a bit.
Will add the plywood panels to the back of the case, to enclose the shelf areas, when I get the case upstairs….easier to carry, that way. Same with the heater insert ( using it right now, in the livingroom)
Had to slide this thing back around..have a lot of sanding to do…

That trash can WAS empty, when this project started out…

Need to get this upstairs, too….and out to the firepit. Thought I might as well show off how the front is looking..so…how about a PIP?

That big open area is for the insert to go in…moved the camera a tad closer..

Lots of sanding, a "Weather Oak" oil stain, and a coat or two of Amber Shellac? And round up a crew to haul this thing upstairs? Stay tuned….

Looks awesome with the hardware applied!

 

Final PIP..

Before this thing is brought upstairs, insert and backs installed, and posted as a Project…

Sanding was done. Then a coat of this stain was brushed on…I thought about using these latches for the doors..

As they match the rest of the hardware….

Was then informed by a Design Guru, that such latches are CHEAP, and the look sucks? One on every corner…..
Let the stain dry a while…..happened to remember I had a wee bit of Walnut scrap sitting around. First thought was to in-fill the latches…but they face the wrong way….Then I sawed a chunk off, resaw to make two thin pieces…then bandsaw to rough shape. Sander to smooth the curves out. Pilot hole and a countersink bit…to use the screws from the "Cheap" latches..( cheap screws, too?)

Something like this….

Nor does it matter which way you turn them…

Either way works. Let this sit a day ( Monday the shop is Closed) and then after the shop had cooled down today..

A coat of Clear Gloss varnish was brushed on….will rub it out tomorrow..

Then get the crew gathered up, and move this thing upstairs…need at least two, or three young, strong backs…may pay with a couple of "Cold Ones", if they want. have some things to move around in the living room, where this will be going….other than that…next posting will be as a Project.

Thanks for following along…

 

Final PIP..

Before this thing is brought upstairs, insert and backs installed, and posted as a Project…

Sanding was done. Then a coat of this stain was brushed on…I thought about using these latches for the doors..

As they match the rest of the hardware….

Was then informed by a Design Guru, that such latches are CHEAP, and the look sucks? One on every corner…..
Let the stain dry a while…..happened to remember I had a wee bit of Walnut scrap sitting around. First thought was to in-fill the latches…but they face the wrong way….Then I sawed a chunk off, resaw to make two thin pieces…then bandsaw to rough shape. Sander to smooth the curves out. Pilot hole and a countersink bit…to use the screws from the "Cheap" latches..( cheap screws, too?)

Something like this….

Nor does it matter which way you turn them…

Either way works. Let this sit a day ( Monday the shop is Closed) and then after the shop had cooled down today..

A coat of Clear Gloss varnish was brushed on….will rub it out tomorrow..

Then get the crew gathered up, and move this thing upstairs…need at least two, or three young, strong backs…may pay with a couple of "Cold Ones", if they want. have some things to move around in the living room, where this will be going….other than that…next posting will be as a Project.

Thanks for following along…

Well I think the original latches were fine. Growing up, they were the defacto latch for any cupboard door.

Looking forward to seeing the insert in place.