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175K views 381 replies 86 participants last post by  HokieKen 
#1 ·
Making the Hand Tool Commitment

So as I plan out my first "Real" workbench I have read dozens of articles, forum threads and blogs here and around the internet about the different bench styles and the build process for them. One common theme stood out and that was they all were made using mostly if not only hand tools.

While I am still relatively young at 35 I am pretty old fashioned. I love the thought that even in this day and age of instant gratification and robot workers we still have craftsmen out there creating quality products with their hands. This is how I approach everything I do and have decided that is the direction I want to go in with wood working.

Now first let me just say that I am a bit of a hobby whore (can I say that here?) I have always (since childhood) found creating things myself out of raw materials to be far more gratifying than buying something at a store so I have a number of hobbies that cater to that drive of creation. Wood working is new to me mainly due to being a suburban apartment dweller for most of my adult life and not having the space for any equipment or dust making.

I now have a garage and live in a small Navy town in Washington State and can finally explore this new avenue with.

Initially I had written out a list of needed equipment for my garage shop. All of which were power tools most of which are large bench or floor units. This would lead to needing a dust collector plus air filtration unit. Explaining to my neighbors what all the noise is about and trying to fit myself in there once all this is in place. I have come to the realization that what i was planning is a factory and not a quiet stress releasing wood working shop that I really wanted. Then I realized that all of those large units could be replaced with the correct hand tools and I would take up MUCH less space in the garage, make less noise and would only need a broom/dustpan and yes an air filtration unit (that can be a box fan with a furnace filter strapped to it.. no biggie there).

Not only that but I would be learning a craft and not just learning to build stuff and that is what sold me.

SO.. now that that long winded prequel is done I have placed an order for my first "real" hand tool. I am considering this a beginner/learning tool and for $18 and some change I don't mind if it shows up needing a lot of work. Re working planes is something I will need to know how to do so no better time than the present to start learning.

Here is the Stanley No. 4 Adjustable Bench Plane I ordered.



Yes, I do realize it is not the same Stanley as the old vintage ones but like I said for the price it is bound to be better than my Bucks Brothers 6" plane which is a whole 'nother blog entry. I started re working it tonight and I'm not sure if it will be useful for anything but holding down papers when I am done but we shall see. It's already a turd so if it stays that way no loss.

So now, I am building a new list of "must haves" which will include the basic tool kit of hand tools to build on. To start I am going to keep them mid grade while learning and upgrade the ones that need it once I really get the hang of this. I can't even explain how excited I am to have come to this decision and can't wait to cut my first mortise and tenon joint with a mallet and chisel!

This series will be updated with new tool acquisitions and such. Thanks LJ for being here and finally pointing me in the right direction!
 
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1
#138 ·
New Mallet No. 1

A few months ago I made a simple mallet out of an oak cut off and a 1" dowel. It has done a good job but has always been a bit on the light side and has started splitting on the top from trying to use it to chop some mortises.

Well, last night it finally just gave up. One face is still usable but I think it's time for it to retire..

Wood Rectangle Wood stain Hardwood Natural material


I have been planning an upgrade ever since I finished the first one but never really had the motivation to put some other projects on hold long enough to do it. Well…. this was my motivation. It was time to make that upgrade.

Gathered up some hard maple, jatoba and grabbed some BB's from WallyWorld and got to work.

The head measures 7" x 3 3/4" x 2 1/2" . That will reduce some after final shaping but I want to keep it a bit on the biggish side of things…. I mean what can't be fixed with a bigger hammer?

In the center laminate on each end I drilled a 1 1/2" hole and filled them full of BB's to give it more weight. I have yet to actually weigh it but it feels good and heafty and makes my old mallet feel like it's made of styrofoam.

Wood Hand tool Tool Hardwood Flooring


Hand tool Tool Crosscut saw Metalworking hand tool Wrench


Wood Tool Tints and shades Font Metalworking hand tool


The handle is being made from more maple with some jatoba accents in the shoulder area and down in the grip to help round that part out a bit.

First was to cut the tenon to fit and then leave that part alone and focus on rough cutting it to shape.

Wood Floor Flooring Artifact Hardwood


Wood Beige Flooring Rectangle Hardwood


Attempted a resaw on some jatoba with my craptastic Ryobi band saw… it doesn't do that so well.

Wood Rectangle Hardwood Linens Hand tool


Used some double sided tape to secure the 2 halves onto some backer board and clamped that board to the bench so I could plane these flat (really need to finish THIS BENCH!)

Wood Flooring Gas Hardwood Machine


Wood Tints and shades Kitchen utensil Font Metal


Cut out the pieces and glued them up. BTW DonW's pointer on using some salt to keep the pieces from sliding around during glue up is boss! Works like a charm!

Tool Material property Wood Gas Tints and shades


The ovals will have a recess cut into them and some leather inserted for comfort and grip (that's the plan anyway).

Now just waiting on the glue to dry so final shaping can commence and final assembly. Stay tuned!
 

Attachments

#139 ·
New Mallet No. 1

A few months ago I made a simple mallet out of an oak cut off and a 1" dowel. It has done a good job but has always been a bit on the light side and has started splitting on the top from trying to use it to chop some mortises.

Well, last night it finally just gave up. One face is still usable but I think it's time for it to retire..

Wood Rectangle Wood stain Hardwood Natural material


I have been planning an upgrade ever since I finished the first one but never really had the motivation to put some other projects on hold long enough to do it. Well…. this was my motivation. It was time to make that upgrade.

Gathered up some hard maple, jatoba and grabbed some BB's from WallyWorld and got to work.

The head measures 7" x 3 3/4" x 2 1/2" . That will reduce some after final shaping but I want to keep it a bit on the biggish side of things…. I mean what can't be fixed with a bigger hammer?

In the center laminate on each end I drilled a 1 1/2" hole and filled them full of BB's to give it more weight. I have yet to actually weigh it but it feels good and heafty and makes my old mallet feel like it's made of styrofoam.

Wood Hand tool Tool Hardwood Flooring


Hand tool Tool Crosscut saw Metalworking hand tool Wrench


Wood Tool Tints and shades Font Metalworking hand tool


The handle is being made from more maple with some jatoba accents in the shoulder area and down in the grip to help round that part out a bit.

First was to cut the tenon to fit and then leave that part alone and focus on rough cutting it to shape.

Wood Floor Flooring Artifact Hardwood


Wood Beige Flooring Rectangle Hardwood


Attempted a resaw on some jatoba with my craptastic Ryobi band saw… it doesn't do that so well.

Wood Rectangle Hardwood Linens Hand tool


Used some double sided tape to secure the 2 halves onto some backer board and clamped that board to the bench so I could plane these flat (really need to finish THIS BENCH!)

Wood Flooring Gas Hardwood Machine


Wood Tints and shades Kitchen utensil Font Metal


Cut out the pieces and glued them up. BTW DonW's pointer on using some salt to keep the pieces from sliding around during glue up is boss! Works like a charm!

Tool Material property Wood Gas Tints and shades


The ovals will have a recess cut into them and some leather inserted for comfort and grip (that's the plan anyway).

Now just waiting on the glue to dry so final shaping can commence and final assembly. Stay tuned!
Tell the truth Eric, you did in the old mallet so you could make a bigger, badder basher, didn't you? Fess up.
Looks to be quite formidable. Do the BB's stay loose in the cavity, or will you lock them with epoxy?
 

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#143 ·
New Mallet No. 2

Spent the night in with the family last night. Which was fine because I wanted to let the glue set a bit longer before doing anything that might stress the joints.

So no progress made last night but got started early this morning.

Took the head out of the clamps and cleaned up and flattened the top and bottom. Then using the string trick I figured out the angle for the faces to be cut at.

Scored some nice deep lines for the cuts and got to cuttin'

Wood Plant Tool Material property Tints and shades


Wood Floor Flooring Tool Metal


Then turned my attention to the handle. Got out the weapons of choice and decided to try out the saw bench as a shaping bench. I have to say it works beautifully in the role. The hold fast keeps it steady but you can still scoot it side to side if needed and the V in the front allows for full access to all sides of it while working. Pretty snazzy. Again.. should have made one of these benches a long time ago lol.

Wood Automotive tire Flooring Hardwood Auto part


Tableware Wood Cutlery Hardwood Tints and shades


Well, I have a bit left to go on the handle but it's starting to get there. More to come soon.

Table Wood Wooden block Hardwood Wood stain
 

Attachments

#144 ·
New Mallet No. 2

Spent the night in with the family last night. Which was fine because I wanted to let the glue set a bit longer before doing anything that might stress the joints.

So no progress made last night but got started early this morning.

Took the head out of the clamps and cleaned up and flattened the top and bottom. Then using the string trick I figured out the angle for the faces to be cut at.

Scored some nice deep lines for the cuts and got to cuttin'

Wood Plant Tool Material property Tints and shades


Wood Floor Flooring Tool Metal


Then turned my attention to the handle. Got out the weapons of choice and decided to try out the saw bench as a shaping bench. I have to say it works beautifully in the role. The hold fast keeps it steady but you can still scoot it side to side if needed and the V in the front allows for full access to all sides of it while working. Pretty snazzy. Again.. should have made one of these benches a long time ago lol.

Wood Automotive tire Flooring Hardwood Auto part


Tableware Wood Cutlery Hardwood Tints and shades


Well, I have a bit left to go on the handle but it's starting to get there. More to come soon.

Table Wood Wooden block Hardwood Wood stain
That's gonna be sweeetttt!!! I like the walnut inlay move.
 

Attachments

#147 ·
New Mallet No. 3.. Advise Needed..

I had a bunch of errands to run today which have kept me out of the shop. I just now had a chance to get out there to maybe get some shaping done on the handle when I noticed an issue with the mallet head.

It looks like some hairline separation of the glue joints have appeared since yesterday (or maybe earlier but I haven't noticed them till just now). I am trying to figure out how to rectify this if it even needs rectifying.

Here are some pics of what I am talking about…

Top:

Brown Rectangle Wood Flooring Table


Brown Rectangle Wood Wood stain Flooring


Bottom:

Wood Rectangle Table Flooring Floor


Rectangle Wood Flooring Floor Wood stain


Now, since this portion will see a lot of impact force I imagine these need fixing if I expect this thing to last longer than a week I am just not sure how to proceed.

A couple options I am considering are bow tie's on the top and bottom or placing some brass dowels into the 8 corners of the joints.. each of these options would be glued in place with 2 part epoxy instead of wood glue for added strength.

What would you do here (besides start over..)
 

Attachments

#148 ·
New Mallet No. 3.. Advise Needed..

I had a bunch of errands to run today which have kept me out of the shop. I just now had a chance to get out there to maybe get some shaping done on the handle when I noticed an issue with the mallet head.

It looks like some hairline separation of the glue joints have appeared since yesterday (or maybe earlier but I haven't noticed them till just now). I am trying to figure out how to rectify this if it even needs rectifying.

Here are some pics of what I am talking about…

Top:

Brown Rectangle Wood Flooring Table


Brown Rectangle Wood Wood stain Flooring


Bottom:

Wood Rectangle Table Flooring Floor


Rectangle Wood Flooring Floor Wood stain


Now, since this portion will see a lot of impact force I imagine these need fixing if I expect this thing to last longer than a week I am just not sure how to proceed.

A couple options I am considering are bow tie's on the top and bottom or placing some brass dowels into the 8 corners of the joints.. each of these options would be glued in place with 2 part epoxy instead of wood glue for added strength.

What would you do here (besides start over..)
Id just drill some holes and jam some dowels in it. Or leave it as is. There's probably enough glue in there to hold things together.
 

Attachments

#162 ·
Carvers Vise #1

This is something I have been planning on building for a few months now. I have been putting it to the side until today when I realized I could really use it right now for my layout swap item.

While I was building my workbench I was searching the net for vises just to get some ideas and inspiration for the ones on the bench and I came across the Benchcrafted Carvers Vise.

Wood Hardwood Table Rectangle Font


It looked pretty nifty but like many of their products I simply cannot justify the price when it can be made from big box bought items save for the ACME rod. I ordered a 3 foot section of 3/4" ACME rod from MC along with 2 nuts for under $20 iirc.

I dug through my wood pile and I have a few left over oak laminations that were intended for use on my bench but weren't needed in the end. That plus a number of cutoffs and I think I have all I should need to build this.. I think lol.

So here is what I am working with..

Wood Yellow Engineering Rectangle Machine


Now I am only loosely following the build instructions found on BC's website. I also have a set of plans from Shop Notes which has slightly different dimensions and construction. Between the 2 I am going to cobble this together somehow.

First order of business is to make some small boards into larger boards for the 2 jaws. None of the pieces are large enough to make the jaws from so a pair of laminated oak jaws it is. Once these are glued I plan to sink some dowels through them across the grain to add some strength. I have my fingers crossed this will be strong enough.. should be fine.

The front longer jaw in work..

Wood Tool Gas Machine Auto part


Wood Floor Flooring Rectangle Wood stain


And then the shorter rear jaw and glue up..

Wood Hand tool Tool Office ruler Metalworking hand tool


Brush Gas Tints and shades Wood Electric blue


And that is just about where we end for tonight. The only thing worse than waiting for paint to dry is waiting for glue to dry lol.

Stay tuned for more..
 

Attachments

#163 ·
Carvers Vise #1

This is something I have been planning on building for a few months now. I have been putting it to the side until today when I realized I could really use it right now for my layout swap item.

While I was building my workbench I was searching the net for vises just to get some ideas and inspiration for the ones on the bench and I came across the Benchcrafted Carvers Vise.

Wood Hardwood Table Rectangle Font


It looked pretty nifty but like many of their products I simply cannot justify the price when it can be made from big box bought items save for the ACME rod. I ordered a 3 foot section of 3/4" ACME rod from MC along with 2 nuts for under $20 iirc.

I dug through my wood pile and I have a few left over oak laminations that were intended for use on my bench but weren't needed in the end. That plus a number of cutoffs and I think I have all I should need to build this.. I think lol.

So here is what I am working with..

Wood Yellow Engineering Rectangle Machine


Now I am only loosely following the build instructions found on BC's website. I also have a set of plans from Shop Notes which has slightly different dimensions and construction. Between the 2 I am going to cobble this together somehow.

First order of business is to make some small boards into larger boards for the 2 jaws. None of the pieces are large enough to make the jaws from so a pair of laminated oak jaws it is. Once these are glued I plan to sink some dowels through them across the grain to add some strength. I have my fingers crossed this will be strong enough.. should be fine.

The front longer jaw in work..

Wood Tool Gas Machine Auto part


Wood Floor Flooring Rectangle Wood stain


And then the shorter rear jaw and glue up..

Wood Hand tool Tool Office ruler Metalworking hand tool


Brush Gas Tints and shades Wood Electric blue


And that is just about where we end for tonight. The only thing worse than waiting for paint to dry is waiting for glue to dry lol.

Stay tuned for more..
This will be great to follow. I am really looking forward to the time when you find that you are in need of a space shuttle and you construct it from items you buy at the $0.99 store.
 

Attachments

#174 ·
Carvers Vise #2

Late last night I ended with some small boards getting glued into larger boards.

Well this morning while the little guy was sleeping I was able to get those out of the clamps and start getting them to final dimensions.

I purposefully made the glue ups larger than needed to I can trim them to size and make up for any irregularities encountered during the glueup.

First order was to simply clean them up 4 square..

Wood Tool Machine Saw Metal


Wood Rectangle Hardwood Wood stain Flooring


Then I ripped the sides to get to final width (did a little off both sides so a solid lamination would be centered instead of a glue line) and then measure and cut to length..

Wood Floor Flooring Hardwood Tints and shades


And now I have 2 jaws ready for the front to get dovetails cut and the rear to be assembled.

Wood Flooring Art Hardwood Gas


Wood Yellow Handheld power drill Floor Tool


Wood Floor Flooring Hardwood Wood stain


Then I turned my attention to the base board. Again I needed to laminate this one up from the same stock as before. I had to wait on this due to the lack of clampage (on my Christmas list lol)

Cut then glue and then we wait..

Hand tool Ruler Office ruler Metalworking hand tool Tool


Wood Tool Gas Slide rule Tints and shades


Once that comes out of the clamps I'll dimension it the same way and start marking out the dovetail that holds the front jaw onto the base.

Now I have a question… I am thinking a hand wheel would be more convenient on this vise so it can be operated easily if the crank was turned over the bench top but every version of this vise I have seen has a handle.

Any reason a wheel would not be optimal?
 

Attachments

#175 ·
Carvers Vise #2

Late last night I ended with some small boards getting glued into larger boards.

Well this morning while the little guy was sleeping I was able to get those out of the clamps and start getting them to final dimensions.

I purposefully made the glue ups larger than needed to I can trim them to size and make up for any irregularities encountered during the glueup.

First order was to simply clean them up 4 square..

Wood Tool Machine Saw Metal


Wood Rectangle Hardwood Wood stain Flooring


Then I ripped the sides to get to final width (did a little off both sides so a solid lamination would be centered instead of a glue line) and then measure and cut to length..

Wood Floor Flooring Hardwood Tints and shades


And now I have 2 jaws ready for the front to get dovetails cut and the rear to be assembled.

Wood Flooring Art Hardwood Gas


Wood Yellow Handheld power drill Floor Tool


Wood Floor Flooring Hardwood Wood stain


Then I turned my attention to the base board. Again I needed to laminate this one up from the same stock as before. I had to wait on this due to the lack of clampage (on my Christmas list lol)

Cut then glue and then we wait..

Hand tool Ruler Office ruler Metalworking hand tool Tool


Wood Tool Gas Slide rule Tints and shades


Once that comes out of the clamps I'll dimension it the same way and start marking out the dovetail that holds the front jaw onto the base.

Now I have a question… I am thinking a hand wheel would be more convenient on this vise so it can be operated easily if the crank was turned over the bench top but every version of this vise I have seen has a handle.

Any reason a wheel would not be optimal?
Eric a couple of considerations as to the handle. 1 can you get enough torque? And 2 will the wheel be in the way of a tool needEd to do work on what is held in the vise. The tee handle at least can slide from side to side to avoid work in progress if need be. You could make a cardboard representation of the wheel and see how obtrusive it really is.
Jim
 

Attachments

#181 ·
Carvers Vise #3

OK. Been a bit since I did some work on this but today I FINALLY found some shop time to get more work done.

I managed to get the bulk of the joinery completed today which meant my first try at half blind dovetails and a second attempt at giant condor tails.

Neither went masterfully but they all fit and hold nice and tight (despite how they look) and now I can start laying out and drilling for the screw and the glide rails.

Gonna leave you with some pics.. they tell the story better than I can really….

Hand tool Wood Tool Metalworking hand tool Metal


Wood Serveware Hardwood Wooden block Lumber


Wood Wood stain Plank Flooring Hardwood


Wood Machine Metal Motor vehicle Automotive tire


Wood Urban design Engineering Scale model Hardwood


Wood Wood stain Hardwood Font Art


Wood Tool Metalworking hand tool Table Kitchen utensil


Wood Table Hardwood Font Tints and shades


Wood Table Wood stain Material property Varnish


Wood Hardwood Engineering Wooden block Rectangle


Wood Wooden block Rectangle Hardwood Composite material


Wood Wooden block Rectangle Wood stain Natural material


Wood Hardwood Lumber Metal Machine


Up next.. MetalJocks! (which begs the question of why there isn't one… just sayin'..)

Building Wood Rectangle Tower block Tints and shades


Stay tuned and thanks for following along!
 

Attachments

#182 ·
Carvers Vise #3

OK. Been a bit since I did some work on this but today I FINALLY found some shop time to get more work done.

I managed to get the bulk of the joinery completed today which meant my first try at half blind dovetails and a second attempt at giant condor tails.

Neither went masterfully but they all fit and hold nice and tight (despite how they look) and now I can start laying out and drilling for the screw and the glide rails.

Gonna leave you with some pics.. they tell the story better than I can really….

Hand tool Wood Tool Metalworking hand tool Metal


Wood Serveware Hardwood Wooden block Lumber


Wood Wood stain Plank Flooring Hardwood


Wood Machine Metal Motor vehicle Automotive tire


Wood Urban design Engineering Scale model Hardwood


Wood Wood stain Hardwood Font Art


Wood Tool Metalworking hand tool Table Kitchen utensil


Wood Table Hardwood Font Tints and shades


Wood Table Wood stain Material property Varnish


Wood Hardwood Engineering Wooden block Rectangle


Wood Wooden block Rectangle Hardwood Composite material


Wood Wooden block Rectangle Wood stain Natural material


Wood Hardwood Lumber Metal Machine


Up next.. MetalJocks! (which begs the question of why there isn't one… just sayin'..)

Building Wood Rectangle Tower block Tints and shades


Stay tuned and thanks for following along!
What are you talking about? They look just fine. Nice work Eric!

A really cool project, I am enjoying it. Thanks.
 

Attachments

#186 ·
Repairing my Stanley #19 Block Plane No.1..

This week I started restoring my what I thought was a Stanley #18 block plane that turned out to be a #19. That's a good thing considering how hard to find they are and the fact I got this for under $20. Here is how it ended up..

Wood Telephony Communication Device Hardwood Wood stain


The bad news is that while cleaning it up I needed to touch up the threads on the adjustable mouth. Luckily they are 1/4-20 so I got my tap out and started threading it in. I meat a bit of resistance and beyond my better judgement I decided to give it one more twist to see if it bottomed out or needed to cut new threads. Well it kept going right through the bottom of the plate!

Wood Gadget Bumper Rectangle Communication Device


So now I have an expensive plane with a hole in it.. piss.. what to do about this. I tried to find a replacement but this being a #19 the ones I found didn't work. I pondered using JB Weld which would work fine but I have been warned that it can leave marks on your wood. That left clear epoxy. The only trouble with that is.. you could see the hole after the repair was finished.

So I continued scratching my brain for a solution when it hit me.. since it is 1/4-20 I could epoxy a 1/4-20 rod into the sole and after it all gets lapped flat should be just as strong and almost invisible to the surrounding area.

So here goes nothing..

I finished tapping the hole all the way through and inserted the filler screw and then assembled the plane to see how deep to thread it in.

Table Tableware Drinkware Wood Serveware


Then I got out the epoxy

Gas Font Metal Cylinder Label


and marked a line on the screw.. added epoxy to it and re-threaded it back in. Again I re-assembled the plane to make sure it was where it should be then placed the plate in my "kiln" to cure overnight.

Wood Door Wood stain Hardwood Musical instrument


That is how it sits for now. Tomorrow I'll cut it flush and start lapping the sole and fingers crossed this should work out.

Stay tuned for more!
 

Attachments

#187 ·
Repairing my Stanley #19 Block Plane No.1..

This week I started restoring my what I thought was a Stanley #18 block plane that turned out to be a #19. That's a good thing considering how hard to find they are and the fact I got this for under $20. Here is how it ended up..

Wood Telephony Communication Device Hardwood Wood stain


The bad news is that while cleaning it up I needed to touch up the threads on the adjustable mouth. Luckily they are 1/4-20 so I got my tap out and started threading it in. I meat a bit of resistance and beyond my better judgement I decided to give it one more twist to see if it bottomed out or needed to cut new threads. Well it kept going right through the bottom of the plate!

Wood Gadget Bumper Rectangle Communication Device


So now I have an expensive plane with a hole in it.. piss.. what to do about this. I tried to find a replacement but this being a #19 the ones I found didn't work. I pondered using JB Weld which would work fine but I have been warned that it can leave marks on your wood. That left clear epoxy. The only trouble with that is.. you could see the hole after the repair was finished.

So I continued scratching my brain for a solution when it hit me.. since it is 1/4-20 I could epoxy a 1/4-20 rod into the sole and after it all gets lapped flat should be just as strong and almost invisible to the surrounding area.

So here goes nothing..

I finished tapping the hole all the way through and inserted the filler screw and then assembled the plane to see how deep to thread it in.

Table Tableware Drinkware Wood Serveware


Then I got out the epoxy

Gas Font Metal Cylinder Label


and marked a line on the screw.. added epoxy to it and re-threaded it back in. Again I re-assembled the plane to make sure it was where it should be then placed the plate in my "kiln" to cure overnight.

Wood Door Wood stain Hardwood Musical instrument


That is how it sits for now. Tomorrow I'll cut it flush and start lapping the sole and fingers crossed this should work out.

Stay tuned for more!
That repair should work fine. One other idea would have been to weld the rod in, but that also runs the risk of over heating and warping the part. Your solution is probably the best one.

Doc
 

Attachments

#197 ·
Hand Tool Journey #25: Repairing my Stanley #19 Block Plane No.2..

This morning I checked and the epoxy was cured so I went about cutting off the rod..

Wood Vise Gas Wheel Engineering


Then it was down to lapping the sole. I started with my XCourse DMT to get the rod flat to the sole..
Wood Gas Vise Engineering Machine


Then I got one of my aluminum sanding bars and using spray adheisive attched some 100 grit sand paper then went to town on the sole till it was flat..

Rectangle Wood Ruler Font Flooring


Rectangle Wood Font Ruler Material property


Wood Armrest Tints and shades Chair Electric blue


Wood Rectangle Hardwood Communication Device Wood stain


She ain't pretty but she is smooth and flat. Then some rust preventative (love this stuff!)

Drinkware Liquid Bottle Fluid Plastic bottle


And now my #19 is no longer holy :D

Wood Audio equipment Gadget Hardwood Auto part


I do plan to keep an eye out for a replacement mouth still. This works but I would like to get one that doesn't have a repair and get the plane back to original condition if I can.

Thanks for looking!
 

Attachments

#198 ·
Hand Tool Journey #25: Repairing my Stanley #19 Block Plane No.2..

This morning I checked and the epoxy was cured so I went about cutting off the rod..

Wood Vise Gas Wheel Engineering


Then it was down to lapping the sole. I started with my XCourse DMT to get the rod flat to the sole..
Wood Gas Vise Engineering Machine


Then I got one of my aluminum sanding bars and using spray adheisive attched some 100 grit sand paper then went to town on the sole till it was flat..

Rectangle Wood Ruler Font Flooring


Rectangle Wood Font Ruler Material property


Wood Armrest Tints and shades Chair Electric blue


Wood Rectangle Hardwood Communication Device Wood stain


She ain't pretty but she is smooth and flat. Then some rust preventative (love this stuff!)

Drinkware Liquid Bottle Fluid Plastic bottle


And now my #19 is no longer holy :D

Wood Audio equipment Gadget Hardwood Auto part


I do plan to keep an eye out for a replacement mouth still. This works but I would like to get one that doesn't have a repair and get the plane back to original condition if I can.

Thanks for looking!
That is my favorite block…aside from a no name block that I own that happens to work better than i feel it should.

Love your machine vise set up.
 

Attachments

#202 ·
Stanley SW #246 Miter Box Restoration #1.. What have we got here?

Just received a Sweetheart era #246 Miter Box. It is in decent working order but really needs a good cleaning to get everything moving like it should again. My original plan was to clean and be done with it but… like usual I can't just leave well enough alone.

Here is the state it arrived in..

Wood Engineering Hardwood Machine Machine tool


Complete with the trip mechanism!

Wood Motor vehicle Gas Machine Metal


Wood Gas Motor vehicle Sculpture Metal


Motor vehicle Font Wood Tints and shades Metal


Saw is in great shape with no obvious signs of pitting.. only the tote needs help.

Wood Gas Engineering Machine tool Machine


It also arrived with one of the 2 stop rods and both hold down clamps for the holding bars..

Wood Wood stain Hardwood Household hardware Varnish


Wood Automotive tire Bumper Automotive exterior Rim


The plan is to bring it back to "near new" condition as best as possible and put it to work. This will include some fabricating of the missing hard to find parts but that will all get covered later.

Up next is tear down and get the parts into some evaporust and get this party started.

Thanks for reading and Stay Tuned!
 

Attachments

#203 ·
Stanley SW #246 Miter Box Restoration #1.. What have we got here?

Just received a Sweetheart era #246 Miter Box. It is in decent working order but really needs a good cleaning to get everything moving like it should again. My original plan was to clean and be done with it but… like usual I can't just leave well enough alone.

Here is the state it arrived in..

Wood Engineering Hardwood Machine Machine tool


Complete with the trip mechanism!

Wood Motor vehicle Gas Machine Metal


Wood Gas Motor vehicle Sculpture Metal


Motor vehicle Font Wood Tints and shades Metal


Saw is in great shape with no obvious signs of pitting.. only the tote needs help.

Wood Gas Engineering Machine tool Machine


It also arrived with one of the 2 stop rods and both hold down clamps for the holding bars..

Wood Wood stain Hardwood Household hardware Varnish


Wood Automotive tire Bumper Automotive exterior Rim


The plan is to bring it back to "near new" condition as best as possible and put it to work. This will include some fabricating of the missing hard to find parts but that will all get covered later.

Up next is tear down and get the parts into some evaporust and get this party started.

Thanks for reading and Stay Tuned!
Eric, That 246 is an outstanding shape. And I'm sure you'll get it to like new. Great score!
 

Attachments

#211 ·
Stanley SW #246 Miter Box Restoration #2.. Tear Down..

Late last night while waiting for Game of Thrones to come on (don't judge me!) I spend a couple hours taking this apart and separating all the parts in labeled bags.

Motor vehicle Bumper Gas Automotive exterior Automotive tire


Automotive lighting Automotive design Hood Auto part Metalworking hand tool


The 2 up rights were frozen in their bases and this is where everything went horribly wrong when I was taking apart my 358 so I wanted to be careful not to snap off the threaded end. Off to WallyWorld I went and returned with some Marvel Mystery Oil. Cut it 50/50 with some mineral spirits in a spray bottle, sprayed the part and waited about 5 mins.. that did the trick!

Bottle Liquid Fluid Solution Glass bottle


Hand tool Wrench Ratchet Air gun Musical instrument


In the process I took pics of everything before/during and after it came off paying particular attention to orientation of the part on the box so when i go to put everything back together I have a reference if I get stuck. If any of you have ever replaced drum brakes before you know what I am talking about.

Then this morning I placed everything in their own tubs and soaked it all in Evaporust.

Tableware Musical instrument accessory Rectangle Metal Cuisine


Everything fit except for the main base it's self. I would need about 10 gallons of ER to completely submerge it so I am sticking to Citri Strip for that which it is currently covered in that orange goo as we speak. Any major rust pockets will get hit with navel jelly after the stripper bath is done.

Now it is just the waiting game for the parts I have… now it is time to start planning out the fabricated parts..

Supplies so far..

Automotive tire Wood Asphalt Road surface Gas


And I have a block of aluminum on it's way to mill out the tree part as seen in this pic..

Wood Automotive exterior Gas Tool Metal


That will probably be a couple of blog entries just that part alone so stay tuned!
 

Attachments

#212 ·
Stanley SW #246 Miter Box Restoration #2.. Tear Down..

Late last night while waiting for Game of Thrones to come on (don't judge me!) I spend a couple hours taking this apart and separating all the parts in labeled bags.

Motor vehicle Bumper Gas Automotive exterior Automotive tire


Automotive lighting Automotive design Hood Auto part Metalworking hand tool


The 2 up rights were frozen in their bases and this is where everything went horribly wrong when I was taking apart my 358 so I wanted to be careful not to snap off the threaded end. Off to WallyWorld I went and returned with some Marvel Mystery Oil. Cut it 50/50 with some mineral spirits in a spray bottle, sprayed the part and waited about 5 mins.. that did the trick!

Bottle Liquid Fluid Solution Glass bottle


Hand tool Wrench Ratchet Air gun Musical instrument


In the process I took pics of everything before/during and after it came off paying particular attention to orientation of the part on the box so when i go to put everything back together I have a reference if I get stuck. If any of you have ever replaced drum brakes before you know what I am talking about.

Then this morning I placed everything in their own tubs and soaked it all in Evaporust.

Tableware Musical instrument accessory Rectangle Metal Cuisine


Everything fit except for the main base it's self. I would need about 10 gallons of ER to completely submerge it so I am sticking to Citri Strip for that which it is currently covered in that orange goo as we speak. Any major rust pockets will get hit with navel jelly after the stripper bath is done.

Now it is just the waiting game for the parts I have… now it is time to start planning out the fabricated parts..

Supplies so far..

Automotive tire Wood Asphalt Road surface Gas


And I have a block of aluminum on it's way to mill out the tree part as seen in this pic..

Wood Automotive exterior Gas Tool Metal


That will probably be a couple of blog entries just that part alone so stay tuned!
Nicely done. Orderly and systematic. Looking forward to the fabrication.

Is Game of Thrones viewing a bad thing to be associated with?
 

Attachments

#219 ·
Stanley SW #246 Miter Box Restoration #3.. Deck is good to go..

Progress today was slow but eventful. I mainly only have time in the morning during the boys morning nap to work on anything but luckily he decided on a long one today.

Everything started out last night when I soaked the deck in some spray on CitriStrip in a tub.

If you have never used this stuff before it rocks! Spray it on and let it do it's thing overnight.. scrub with a wire brush and rinse.. Boom! Rust and paint free!

Liquid Tints and shades Cylinder Magenta Paint


HOWEVER.. after the rinse you need to work fast to dry it off or you do get flash rusting pretty quick. Not a big deal as it comes off pretty easily but we are trying to get the rust off not add more so be careful. I also didn't want to use any oil to prevent the flash rust as I need to paint this next and oily surface + paint don't usually make for a good end result.

Once it was rinsed and clean I got my tools of torture out and carefully but thoroughly scrubbed the entire piece with a brass wheel in my grinder then a fine steel brush to get in some hard to get to spots. You can't get to everything with these but they knock out the bulk of the surface.

Tread Flooring Floor Automotive tire Audio equipment


After that was all done I went at it with a green scrubby/wire brush/abrasive bottle brushes and Q-Tips to get the rest of the spots that nothing else would reach.. whatever works lol.

Now I needed to make sure the surface was free of oils and detergents before it is painted.. and this step will also take care of any left over flash rusting that you may have missed. I always wipe down metal surfaces with Naphtha before paint.

Liquid Guitar accessory Fluid Musical instrument accessory Solution


And here is where we ended today.

Automotive tire Bumper Automotive wheel system Gas Rim


Next step is to mask off the areas that don't see any paint and get the rest of the parts out of their baths and cleaned up. I am waiting till everything that gets paint is ready and they will all get done at the same time.

Hopefully I'll have more to show for myself tomorrow… maybe if the boy says it's ok lol.
 

Attachments

#220 ·
Stanley SW #246 Miter Box Restoration #3.. Deck is good to go..

Progress today was slow but eventful. I mainly only have time in the morning during the boys morning nap to work on anything but luckily he decided on a long one today.

Everything started out last night when I soaked the deck in some spray on CitriStrip in a tub.

If you have never used this stuff before it rocks! Spray it on and let it do it's thing overnight.. scrub with a wire brush and rinse.. Boom! Rust and paint free!

Liquid Tints and shades Cylinder Magenta Paint


HOWEVER.. after the rinse you need to work fast to dry it off or you do get flash rusting pretty quick. Not a big deal as it comes off pretty easily but we are trying to get the rust off not add more so be careful. I also didn't want to use any oil to prevent the flash rust as I need to paint this next and oily surface + paint don't usually make for a good end result.

Once it was rinsed and clean I got my tools of torture out and carefully but thoroughly scrubbed the entire piece with a brass wheel in my grinder then a fine steel brush to get in some hard to get to spots. You can't get to everything with these but they knock out the bulk of the surface.

Tread Flooring Floor Automotive tire Audio equipment


After that was all done I went at it with a green scrubby/wire brush/abrasive bottle brushes and Q-Tips to get the rest of the spots that nothing else would reach.. whatever works lol.

Now I needed to make sure the surface was free of oils and detergents before it is painted.. and this step will also take care of any left over flash rusting that you may have missed. I always wipe down metal surfaces with Naphtha before paint.

Liquid Guitar accessory Fluid Musical instrument accessory Solution


And here is where we ended today.

Automotive tire Bumper Automotive wheel system Gas Rim


Next step is to mask off the areas that don't see any paint and get the rest of the parts out of their baths and cleaned up. I am waiting till everything that gets paint is ready and they will all get done at the same time.

Hopefully I'll have more to show for myself tomorrow… maybe if the boy says it's ok lol.
Huffer.

That looks t!ts.
 

Attachments

#223 ·
Stanley SW #246 Miter Box Restoration #4.. Watching Paint Dry and Other Things..

I have been lucky the last couple days with a few hours of shop time and good weather (a combo that nearly never happens lol).

So I took full advantage of it and got to work again on the mitre box.

Fist thing on the list was to get everything out of their respective Evaporust baths, rinsed and brushed clean. This took what felt like a week to get done due to the shear amount of parts but really it only took about 4 hours yesterday morning.

Fresh out of the bath and rinsed with fresh water (a very important step in the Evaporust process!)
Musical instrument Hood Automotive lighting Bumper Trunk


Automotive lighting Automotive design Trunk Motor vehicle Gas


Everything took a trip to my wire wheel chucked into my drill press and got a good scrubbing. Shines everything up real nice like..

Gas Air gun Auto part Trigger Metal


Wood Composite material Road surface Gas Tints and shades


Then this morning during my kids unusually long morning nap I was able to get everything masked off and ready for paint.

Air gun Trigger Gas Gun accessory Auto part


At that point I figured I was done for the day. It was cold and rainy while I was masking and we had a Carnival to get to in town but… the weather broke after we got back home and rushing around to not miss the opportunity I got a "paint booth" setup and started spraying.

First thing I painted was the back fence with Rustoleum Metalic Silver paint..
Liquid Fluid Font Drink Solvent


Seems to be a nearly perfect match to the original paint there.

A couple coats later and when it was dry to the touch I fliped the box over letting the wall hang off the 2Ă—6 it was sitting on I sprayed the bottom with Duplicolor Semi-Gloss Engine Enamel.
Liquid Ingredient Drink Fluid Packaging and labeling


I didn't spend too much time here making it pretty.. I just wanted it covered with some rust protection.

That done and again dry to touch I flipped it back over and laid a scrap of 1/2" ply against the fence and sprayed the rest of the box.

Not bad for a rush job while the kid screamed at me through the sliding door lol..

Asphalt Wood Gas Engineering Composite material


Automotive tire Wood Motor vehicle Gas Automotive exterior


I let them sit outside for a bit then into the shop they went and now they just need the tape peeled and reassembled.

Wood Hand tool Tool Engineering Metal


Wood Hardwood Gas Machine Metal


Up next is a new wood deck and turn one of these into a new stop rod tree..

Wood Table Office supplies Flooring Desk


Thanks for reading and Stay Tuned!
 

Attachments

#224 ·
Stanley SW #246 Miter Box Restoration #4.. Watching Paint Dry and Other Things..

I have been lucky the last couple days with a few hours of shop time and good weather (a combo that nearly never happens lol).

So I took full advantage of it and got to work again on the mitre box.

Fist thing on the list was to get everything out of their respective Evaporust baths, rinsed and brushed clean. This took what felt like a week to get done due to the shear amount of parts but really it only took about 4 hours yesterday morning.

Fresh out of the bath and rinsed with fresh water (a very important step in the Evaporust process!)
Musical instrument Hood Automotive lighting Bumper Trunk


Automotive lighting Automotive design Trunk Motor vehicle Gas


Everything took a trip to my wire wheel chucked into my drill press and got a good scrubbing. Shines everything up real nice like..

Gas Air gun Auto part Trigger Metal


Wood Composite material Road surface Gas Tints and shades


Then this morning during my kids unusually long morning nap I was able to get everything masked off and ready for paint.

Air gun Trigger Gas Gun accessory Auto part


At that point I figured I was done for the day. It was cold and rainy while I was masking and we had a Carnival to get to in town but… the weather broke after we got back home and rushing around to not miss the opportunity I got a "paint booth" setup and started spraying.

First thing I painted was the back fence with Rustoleum Metalic Silver paint..
Liquid Fluid Font Drink Solvent


Seems to be a nearly perfect match to the original paint there.

A couple coats later and when it was dry to the touch I fliped the box over letting the wall hang off the 2Ă—6 it was sitting on I sprayed the bottom with Duplicolor Semi-Gloss Engine Enamel.
Liquid Ingredient Drink Fluid Packaging and labeling


I didn't spend too much time here making it pretty.. I just wanted it covered with some rust protection.

That done and again dry to touch I flipped it back over and laid a scrap of 1/2" ply against the fence and sprayed the rest of the box.

Not bad for a rush job while the kid screamed at me through the sliding door lol..

Asphalt Wood Gas Engineering Composite material


Automotive tire Wood Motor vehicle Gas Automotive exterior


I let them sit outside for a bit then into the shop they went and now they just need the tape peeled and reassembled.

Wood Hand tool Tool Engineering Metal


Wood Hardwood Gas Machine Metal


Up next is a new wood deck and turn one of these into a new stop rod tree..

Wood Table Office supplies Flooring Desk


Thanks for reading and Stay Tuned!
I can't believe no one has commented, everyone else must be out partying.
Nice saw,
Great organization and logical work plan (no lost parts)
If those are solid aluminum pieces it will be interesting seeing what you make.
Can one still buy this type saw new?
 

Attachments

#230 ·
Stanley SW #246 Miter Box Restoration #5.. All Cleaned Up Just Waiting On Missing Parts..

I spent the day yesterday putting Humpty Dumpty back together again. I brought everything inside so I could referance my pics if needed and yes… it was very needed. Quite the jigsaw puzzle this thing is.

Liquid Bottle Fluid Solution Plastic bottle


Then I remembered I had forgotten to shine the brass bits. I had to kinda hurry through this because.. again.. Game of Thrones was coming on in half an hour lol.

Left hasn't been polished and the right is after a quick trip to the buffer..

Gas Audio equipment Auto part Fashion accessory Cylinder


I made sure to coat every inch of bare metal (including fasteners) with T-9 and then a coat of Renaissance Wax just for good measure. I want this thing to last another 80+ years if I can help it. I also made sure that any areas that moved got oiled before reassembly. I might still add some grease to some of the areas such as the arm swivel joint and the registration tab area. Otherwise it moves like new now.

Wood Wheel Engineering Gas Machine


Then on tap for this morning was to get a new wood deck made for this. I found a piece of 1/2" Red Oak that has some nice straight grain on it to use. Plopped the old deck on top and traced the template onto it. Then I started to use a 1 1/4" Forstner bit to cut the half rounds with but discovered that one of the motor mount welds has broken loose making my drill press useless so…. Galooting it up we went!

Floor Drilling Milling Jig grinder Gas


Then made the short cuts with my Dovetail Saw..

Wood Musical instrument accessory Musical instrument Electronic instrument Machine


Ripped it roughly to width with my bandsaw (I really need to sharpen up a rip panel saw!) and brought it to the line with my No 4 then cleaned up the curves with a rasp then file.

Wood Hand tool Engineering Metal Machine


Flipped it and planed a bevel on the back edge and checked the fit..

Wood Table Hardwood Audio equipment Idiophone


Next up was to chop out the hold back dados. I Married the two boards up and marked the line and chopped them out with a chisel followed by my routah plane.

Wood Tool Hardwood Wood stain Flooring


Hand tool Wood Tool Musical instrument Metalworking hand tool


Then I lined it up on the box, flipped it over and marked for the screws then pre drilled slightly with my GP eggbeater..

Wood Floor Flooring Mallet Automotive tire


Gave the whole board a nice coat of Danish Oil and whallah! She's brand new ready to go back to work!

Musical instrument Wood Plucked string instruments Folk instrument Bench


Musical instrument Tire Wood Wheel Flooring


Plant Musical instrument Wood Outdoor furniture Street furniture


Plant Road surface Asphalt Wood Rolling


Musical instrument Wheel Road surface Asphalt Wood


Musical instrument Wood Folk instrument Flooring Hardwood


Musical instrument Sports equipment Wood Rolling Human leg


I took it outside to take those pics because the sun was out and I thought I would get better lighting that way but… a cloud rolled in as soon as I was out the door so my "Glamour Pics" aren't as nice as I had hoped lol. Oh well.

Now what is left is to fabricate all the missing parts such as.. The Hold Backs, The second rod and coupler and the stop rod tree.

Then the part I am actually dreading quite a bit.. the saw. I am extremely nervous about that part but I don't drive a Prius (Tony) so no pussing out now lol.

Stay Tuned!
 

Attachments

#231 ·
Stanley SW #246 Miter Box Restoration #5.. All Cleaned Up Just Waiting On Missing Parts..

I spent the day yesterday putting Humpty Dumpty back together again. I brought everything inside so I could referance my pics if needed and yes… it was very needed. Quite the jigsaw puzzle this thing is.

Liquid Bottle Fluid Solution Plastic bottle


Then I remembered I had forgotten to shine the brass bits. I had to kinda hurry through this because.. again.. Game of Thrones was coming on in half an hour lol.

Left hasn't been polished and the right is after a quick trip to the buffer..

Gas Audio equipment Auto part Fashion accessory Cylinder


I made sure to coat every inch of bare metal (including fasteners) with T-9 and then a coat of Renaissance Wax just for good measure. I want this thing to last another 80+ years if I can help it. I also made sure that any areas that moved got oiled before reassembly. I might still add some grease to some of the areas such as the arm swivel joint and the registration tab area. Otherwise it moves like new now.

Wood Wheel Engineering Gas Machine


Then on tap for this morning was to get a new wood deck made for this. I found a piece of 1/2" Red Oak that has some nice straight grain on it to use. Plopped the old deck on top and traced the template onto it. Then I started to use a 1 1/4" Forstner bit to cut the half rounds with but discovered that one of the motor mount welds has broken loose making my drill press useless so…. Galooting it up we went!

Floor Drilling Milling Jig grinder Gas


Then made the short cuts with my Dovetail Saw..

Wood Musical instrument accessory Musical instrument Electronic instrument Machine


Ripped it roughly to width with my bandsaw (I really need to sharpen up a rip panel saw!) and brought it to the line with my No 4 then cleaned up the curves with a rasp then file.

Wood Hand tool Engineering Metal Machine


Flipped it and planed a bevel on the back edge and checked the fit..

Wood Table Hardwood Audio equipment Idiophone


Next up was to chop out the hold back dados. I Married the two boards up and marked the line and chopped them out with a chisel followed by my routah plane.

Wood Tool Hardwood Wood stain Flooring


Hand tool Wood Tool Musical instrument Metalworking hand tool


Then I lined it up on the box, flipped it over and marked for the screws then pre drilled slightly with my GP eggbeater..

Wood Floor Flooring Mallet Automotive tire


Gave the whole board a nice coat of Danish Oil and whallah! She's brand new ready to go back to work!

Musical instrument Wood Plucked string instruments Folk instrument Bench


Musical instrument Tire Wood Wheel Flooring


Plant Musical instrument Wood Outdoor furniture Street furniture


Plant Road surface Asphalt Wood Rolling


Musical instrument Wheel Road surface Asphalt Wood


Musical instrument Wood Folk instrument Flooring Hardwood


Musical instrument Sports equipment Wood Rolling Human leg


I took it outside to take those pics because the sun was out and I thought I would get better lighting that way but… a cloud rolled in as soon as I was out the door so my "Glamour Pics" aren't as nice as I had hoped lol. Oh well.

Now what is left is to fabricate all the missing parts such as.. The Hold Backs, The second rod and coupler and the stop rod tree.

Then the part I am actually dreading quite a bit.. the saw. I am extremely nervous about that part but I don't drive a Prius (Tony) so no pussing out now lol.

Stay Tuned!
Wow! Restoring a miter saw has been low on my list of priorities. You're changing my mind. Old tools have a beauty that is missing in so many modern tools. Your work reflects that. Very well done.

I'm betting we'll see a few more full restores after this.
 

Attachments

#246 ·
Stanley SW #246 Miter Box Restoration #6..Metal Fabbin it Up in Here..

So yesterday we left off with a clean and reassembled mitre box with a few missing accompaniments. I was also left with a broken drill press (piss.. damn you HF!!!!!!)..

Anyhoo.. the drill press saga will come into play in a bit but first I needed to draw up some plans for the missing tree from a photo provided by a fellow LJ.

Rectangle Font Wood Religious item Cross


I blew it up on my computer screen till it was scale to my ruler and started mapping it out on some graph paper ending up with this..

Handwriting Font Rectangle Pattern Parallel


Now…. I hear a lot of folks on here talk about working with metal as if it is a foreign subject but really it is not much different than working with wood and in some respects it's a bit easier. No grain direction to contend with, no seasonal movement to consider and nearly anything can be fixed with some filing lol. If you own old tools you should own a few metal working tools imho.. but anyhoo.. where were we.. oh yes..

Just like if I was to cut this out of a chunk of wood I attach the plan to the aluminum block with spray adhesive.

Handwriting Rectangle Wood Font Packing materials


Now I cut off the excess on the side (gonna hang onto it and use it for the flat base portion)

I put a course toothed blade on my hack saw and cut just outside the line.. NEVER CUT THE LINE!!. You want to cut just outside it and file to the line. This goes just like cutting a dovetail. Start the cut and watch the line. It will seem like you are getting nowhere at first but in no time your done!

Wood Gas Engineering Electrical wiring Machine


Wood Rectangle Flooring Floor Font


Then I file to the line. For those who don't know, files cut in one direction only. Don't use it like a saw.. push lift reset push. If it starts squeaking that means it's filled with shavings and needs a quick cleaning.

Wood Engineering Vise Machine Metal


Now here is where I wish I had my drill press. I need to drill 2 5/16" holes for the rods to pass through. Would be an easy task with a drill press but.. I must have left my easy button at work or something.

I decided on a dowel jig and my corded drill for this task.

Hand tool Wood Tool Paint brush Metalworking hand tool


When drilling in metal faster gets you nowhere.. slow and even pressure will actually drill faster.. keep that in mind.

I drilled both holes.. Not bad..

Pneumatic tool Drill Handheld power drill Hammer drill Wood


Wood Wood stain Hardwood Plank Flooring


Then flipped it over and.. well piss.. Again DAMN YOU HF!!!!

Wood Wood stain Floor Flooring Hardwood


Oh well.. that one will have to be filled and redrilled when I get to braising this together. Live and learn right?

At least they line up with the base..

Wood Wood stain Flooring Rectangle Hardwood


Next I laid out my cut lines and started cutting the rest of the rough shape out.

Wood Hardwood Font Rectangle Gas


Wood Vise Machine tool Gas Engineering


Wood Engineering Font Machine Art


Wood Engineering Machine Metal Rectangle


And this is what I have ended with for today…

Wood Gas Engineering Machine tool Auto part


Next will be hogging out the rest of the waste with some carbide cutters in my dremel, fixing a hole (darnnit) and working on the base. Hang in there.. playing with fire is coming up soon!
 

Attachments

#247 ·
Stanley SW #246 Miter Box Restoration #6..Metal Fabbin it Up in Here..

So yesterday we left off with a clean and reassembled mitre box with a few missing accompaniments. I was also left with a broken drill press (piss.. damn you HF!!!!!!)..

Anyhoo.. the drill press saga will come into play in a bit but first I needed to draw up some plans for the missing tree from a photo provided by a fellow LJ.

Rectangle Font Wood Religious item Cross


I blew it up on my computer screen till it was scale to my ruler and started mapping it out on some graph paper ending up with this..

Handwriting Font Rectangle Pattern Parallel


Now…. I hear a lot of folks on here talk about working with metal as if it is a foreign subject but really it is not much different than working with wood and in some respects it's a bit easier. No grain direction to contend with, no seasonal movement to consider and nearly anything can be fixed with some filing lol. If you own old tools you should own a few metal working tools imho.. but anyhoo.. where were we.. oh yes..

Just like if I was to cut this out of a chunk of wood I attach the plan to the aluminum block with spray adhesive.

Handwriting Rectangle Wood Font Packing materials


Now I cut off the excess on the side (gonna hang onto it and use it for the flat base portion)

I put a course toothed blade on my hack saw and cut just outside the line.. NEVER CUT THE LINE!!. You want to cut just outside it and file to the line. This goes just like cutting a dovetail. Start the cut and watch the line. It will seem like you are getting nowhere at first but in no time your done!

Wood Gas Engineering Electrical wiring Machine


Wood Rectangle Flooring Floor Font


Then I file to the line. For those who don't know, files cut in one direction only. Don't use it like a saw.. push lift reset push. If it starts squeaking that means it's filled with shavings and needs a quick cleaning.

Wood Engineering Vise Machine Metal


Now here is where I wish I had my drill press. I need to drill 2 5/16" holes for the rods to pass through. Would be an easy task with a drill press but.. I must have left my easy button at work or something.

I decided on a dowel jig and my corded drill for this task.

Hand tool Wood Tool Paint brush Metalworking hand tool


When drilling in metal faster gets you nowhere.. slow and even pressure will actually drill faster.. keep that in mind.

I drilled both holes.. Not bad..

Pneumatic tool Drill Handheld power drill Hammer drill Wood


Wood Wood stain Hardwood Plank Flooring


Then flipped it over and.. well piss.. Again DAMN YOU HF!!!!

Wood Wood stain Floor Flooring Hardwood


Oh well.. that one will have to be filled and redrilled when I get to braising this together. Live and learn right?

At least they line up with the base..

Wood Wood stain Flooring Rectangle Hardwood


Next I laid out my cut lines and started cutting the rest of the rough shape out.

Wood Hardwood Font Rectangle Gas


Wood Vise Machine tool Gas Engineering


Wood Engineering Font Machine Art


Wood Engineering Machine Metal Rectangle


And this is what I have ended with for today…

Wood Gas Engineering Machine tool Auto part


Next will be hogging out the rest of the waste with some carbide cutters in my dremel, fixing a hole (darnnit) and working on the base. Hang in there.. playing with fire is coming up soon!
Fun stuff AF. Thanks.
 

Attachments

#255 ·
Stanley SW #246 Miter Box Restoration #6.. Well Frack..

So…. yesterday we stopped short of filling the stray hole and redrilling. Today I went about doing just that and well… The brazing rod is harder then the parent material and you know how drill bits want to follow the path of least resistance? Yeah…....

So the new hole is wanting to wander and blow out the side and I called it quits. If I had a functional drill press this would not be an issue and I stand by my previous statement about working with metal… it's really not that difficult.

So what do I do now? Well what does any other completionist do when they are REALLY desperate for a hard to find part? Buy another box just to get the one part they need off of it of course! Duh!

Yep, I did it. I was so peeved by the result of today's endeavors that I pulled the trigger on another box on fleebay to get the second rod and tree off of it lol. It wasn't an enormous amount but more than that single part is worth. The upside is the second box has the bearing style saw guides and I am tempted to clean them up and installing them on this box which has the friction slide saw guides. Looking at the spine on the backsaw I think it could use a break from rubbing against the angled "slide points". It seems that Stanley used both types during the SW era of these boxes because my SW 358 has the bearings installed. Hmm.. decisions.

The next question is what to do with the rest of the second box.. part it out? Keep it as a parts store? I'll figure that out.

So now I need to go and deal with some buyers remorse and start planning out the guide stops for this guy.. Stay tuned!
 
#261 ·
Stanley SW #246 Miter Box Restoration #7.. Done Finally..

I finally finished my SW #246 Mitre Box. I still need to sharpen the saw up but everything is clean and ready to go so I am calling this done. I spent a lot of time trolling for the hard to find accessories and I was finally able to get this box 100% complete and am pretty excited about that.

I tried to get a pic of the etch but it is too light to get on camera but it does have a SW etch still!

Table Wood Hardwood Audio equipment Bicycle part


Wood Flooring Building Floor Hardwood


Sewing machine Wood Office equipment Machine Household appliance accessory


Wood Interior design Flooring Floor Hardwood


Wood Tool Hardwood Wood stain Musical instrument accessory


Wood Wheel Machine Hardwood Flooring


Wood Hardwood Wood stain Circle Metal


Grey Font Audio equipment Electric blue Wood


Wood Gas Hardwood Flooring Metal


Musical instrument Wood Hardwood Musical instrument accessory Gas


Wood Wheel Floor Flooring Hardwood


Building Floor Flooring Musical instrument Guitar
 

Attachments

#262 ·
Stanley SW #246 Miter Box Restoration #7.. Done Finally..

I finally finished my SW #246 Mitre Box. I still need to sharpen the saw up but everything is clean and ready to go so I am calling this done. I spent a lot of time trolling for the hard to find accessories and I was finally able to get this box 100% complete and am pretty excited about that.

I tried to get a pic of the etch but it is too light to get on camera but it does have a SW etch still!

Table Wood Hardwood Audio equipment Bicycle part


Wood Flooring Building Floor Hardwood


Sewing machine Wood Office equipment Machine Household appliance accessory


Wood Interior design Flooring Floor Hardwood


Wood Tool Hardwood Wood stain Musical instrument accessory


Wood Wheel Machine Hardwood Flooring


Wood Hardwood Wood stain Circle Metal


Grey Font Audio equipment Electric blue Wood


Wood Gas Hardwood Flooring Metal


Musical instrument Wood Hardwood Musical instrument accessory Gas


Wood Wheel Floor Flooring Hardwood


Building Floor Flooring Musical instrument Guitar
Inspires me to fix up mine like I initially planned. You should be proud.
 

Attachments

#283 ·
Stanley SW #358 Miter Box Restoration #1.. Here we go again..

This is a project that has been waiting long enough. I actually started tearing down this one months before I got my #246 in but had to wait on some replacement parts before continuing on.

Here is what we have to work with.. a very rusty (as in every single freakin' screw/bolt whatever is rusted frozen on the darn thing) Sweetheart No 358 Mitre Box with a broken and "fixed" swing arm assembly.

Wood Engineering Gas Machine Motor vehicle


Wood Electronic instrument Font Audio equipment Metal


Wood Engineering Gas Machine Metal


Wood Machine tool Gas Motor vehicle Engineering


Wood Hardwood Wood stain Flooring Gas


During my initial attempt to tear this thing apart I broke off the threaded portion of one of the uprights on the back side so that almost sealed it's fate. After some trolling of fleeBay I was able to find a cheap"ish" newer #358 that had a usuable swing arm and uprights along with all the accessories that would be needed to get this thing complete including another Trip!

So today it was off to the races so to speak.

First thing after finishing the teardown was to remove the nameplate to protect it from the restoration process. If you have a box with the name plate on the degree arch this is pretty simple… if it's on the side of the box it is not coming off and you just have to be careful with it.

The name plate is held on with 2 blind twist rivets that can be popped out from the backside with a hammer and a small punch.

Automotive tire Motor vehicle Asphalt Hand tool Road surface


Gas Wood Auto part Metal Automotive wheel system


Hand tool Wood Metalworking hand tool Tool Automotive tire


Next was to give the base a good scrubbing with a wire brush and some Simple Green just to remove all the years of crud off it so the stripper can do it's job.

Bottle Fluid Hood Automotive tire Glass bottle


Wheel Tire Automotive tire Vehicle Hood


Strangely after it's cleaning I discovered that what I though was black japanning is actually a very dark blue!

Plumbing fixture Wood Gas Automotive exterior Composite material


I had played briefly with the thought of trying to color match it but have decided to go with black and call it good.

Then everything went into tubs and the base was coated liberally with Citristrip and the rest got an Evaporust bath. I wasn't as careful separating everything this time around. I have taken apart 3 of these now and am pretty intimate with where everything goes now. If it is your first.. bag and tag everything with photos! trust me.. it is a bit of a jig saw puzzle.

Automotive lighting Hood Motor vehicle Grille Automotive tire


Shotgun Air gun Office equipment Automotive exterior Gas


Cuisine Gas Auto part Plastic Metal


Tin Fluid Cylinder Liquid Gas


Rectangle Automotive exterior Bumper Gas Tints and shades


Product Motor vehicle Tin Gas Bumper


Netbook Rectangle Tin Gas Bumper


There are actually 2.5 boxes worth of parts in there. I decided to go ahead and clean EVERYTHING I had this time around just in case lol. Hopefully that doesn't come back to haunt me later.

Stay tuned!
 

Attachments

#284 ·
Stanley SW #358 Miter Box Restoration #1.. Here we go again..

This is a project that has been waiting long enough. I actually started tearing down this one months before I got my #246 in but had to wait on some replacement parts before continuing on.

Here is what we have to work with.. a very rusty (as in every single freakin' screw/bolt whatever is rusted frozen on the darn thing) Sweetheart No 358 Mitre Box with a broken and "fixed" swing arm assembly.

Wood Engineering Gas Machine Motor vehicle


Wood Electronic instrument Font Audio equipment Metal


Wood Engineering Gas Machine Metal


Wood Machine tool Gas Motor vehicle Engineering


Wood Hardwood Wood stain Flooring Gas


During my initial attempt to tear this thing apart I broke off the threaded portion of one of the uprights on the back side so that almost sealed it's fate. After some trolling of fleeBay I was able to find a cheap"ish" newer #358 that had a usuable swing arm and uprights along with all the accessories that would be needed to get this thing complete including another Trip!

So today it was off to the races so to speak.

First thing after finishing the teardown was to remove the nameplate to protect it from the restoration process. If you have a box with the name plate on the degree arch this is pretty simple… if it's on the side of the box it is not coming off and you just have to be careful with it.

The name plate is held on with 2 blind twist rivets that can be popped out from the backside with a hammer and a small punch.

Automotive tire Motor vehicle Asphalt Hand tool Road surface


Gas Wood Auto part Metal Automotive wheel system


Hand tool Wood Metalworking hand tool Tool Automotive tire


Next was to give the base a good scrubbing with a wire brush and some Simple Green just to remove all the years of crud off it so the stripper can do it's job.

Bottle Fluid Hood Automotive tire Glass bottle


Wheel Tire Automotive tire Vehicle Hood


Strangely after it's cleaning I discovered that what I though was black japanning is actually a very dark blue!

Plumbing fixture Wood Gas Automotive exterior Composite material


I had played briefly with the thought of trying to color match it but have decided to go with black and call it good.

Then everything went into tubs and the base was coated liberally with Citristrip and the rest got an Evaporust bath. I wasn't as careful separating everything this time around. I have taken apart 3 of these now and am pretty intimate with where everything goes now. If it is your first.. bag and tag everything with photos! trust me.. it is a bit of a jig saw puzzle.

Automotive lighting Hood Motor vehicle Grille Automotive tire


Shotgun Air gun Office equipment Automotive exterior Gas


Cuisine Gas Auto part Plastic Metal


Tin Fluid Cylinder Liquid Gas


Rectangle Automotive exterior Bumper Gas Tints and shades


Product Motor vehicle Tin Gas Bumper


Netbook Rectangle Tin Gas Bumper


There are actually 2.5 boxes worth of parts in there. I decided to go ahead and clean EVERYTHING I had this time around just in case lol. Hopefully that doesn't come back to haunt me later.

Stay tuned!
That looks like a lot of work Eric. Can't wait to see the finished assembly once you've got her back together again. Good luck!
 

Attachments

#289 ·
Stanley SW #358 Miter Box Restoration #2... Partapalooza!

Well it took a week to get to it but I finally have everything clean and ready for masking and paint.

First up was the main base it's self. This thing was too rusty for the Citristrip to even make a dent in but it did clean up with a steel wire wheel and my angle grinder well enough.

Table Tints and shades Wood Tableware Serveware


Automotive tire Hood Automotive lighting Motor vehicle Wheel


Any left over rust spots (mostly in those hard to get to crevasses) will get treated with some Rustoleum rust reformer before paint just to avoid any cancer from forming and spreading. The point here is to get another 100+ years out of this and leaving rust under paint is a recipe for disaster.

Then yesterday I started on all the other parts (what seemed like thousands lol). It all started out well enough until the motor mount on my drill press finally fully let go thus killing my preferred method of scrubbing parts clean.

I got about this far..

Tool Wood Musical instrument Hand tool Metal


When this happened..

Wood Gas Gadget Office equipment Machine


Automotive lighting Gas Automotive exterior Personal protective equipment Bumper


So after throwing a small fit and searching every store on the island that would sell a drill press i finally found the only one in stock on my small island (yes the only one as in singular) at my local tiny Sears.

It is a Crapsman but miles better than my HF was..

Gas Publication Flooring Machine Engineering


Drilling Drill presses Tool Electrical wiring Jig grinder


That burned up all my shop time for that day so I got back at it first thing this morning and was at it for nearly 8 hours! Keep in mind I am cleaning 2 and a half boxes worth of parts (I only need one but had these extras and figured I would clean everything all at once while I was at it).

At the end of it all I now have this..

Wood Musical instrument accessory Gas Engineering Machine


Engineering Musical instrument accessory Metal Machine Audio equipment


I still need to buff the brass bits and properly clean the stock guide rods but holy hell that was a lot of parts.. Note to self.. one at a time from now on!

Next up is masking and painting then re-assembly which I plan to take LOTS of pics for as a referance on how to assemble one of these so stay tuned!
 

Attachments

#290 ·
Stanley SW #358 Miter Box Restoration #2... Partapalooza!

Well it took a week to get to it but I finally have everything clean and ready for masking and paint.

First up was the main base it's self. This thing was too rusty for the Citristrip to even make a dent in but it did clean up with a steel wire wheel and my angle grinder well enough.

Table Tints and shades Wood Tableware Serveware


Automotive tire Hood Automotive lighting Motor vehicle Wheel


Any left over rust spots (mostly in those hard to get to crevasses) will get treated with some Rustoleum rust reformer before paint just to avoid any cancer from forming and spreading. The point here is to get another 100+ years out of this and leaving rust under paint is a recipe for disaster.

Then yesterday I started on all the other parts (what seemed like thousands lol). It all started out well enough until the motor mount on my drill press finally fully let go thus killing my preferred method of scrubbing parts clean.

I got about this far..

Tool Wood Musical instrument Hand tool Metal


When this happened..

Wood Gas Gadget Office equipment Machine


Automotive lighting Gas Automotive exterior Personal protective equipment Bumper


So after throwing a small fit and searching every store on the island that would sell a drill press i finally found the only one in stock on my small island (yes the only one as in singular) at my local tiny Sears.

It is a Crapsman but miles better than my HF was..

Gas Publication Flooring Machine Engineering


Drilling Drill presses Tool Electrical wiring Jig grinder


That burned up all my shop time for that day so I got back at it first thing this morning and was at it for nearly 8 hours! Keep in mind I am cleaning 2 and a half boxes worth of parts (I only need one but had these extras and figured I would clean everything all at once while I was at it).

At the end of it all I now have this..

Wood Musical instrument accessory Gas Engineering Machine


Engineering Musical instrument accessory Metal Machine Audio equipment


I still need to buff the brass bits and properly clean the stock guide rods but holy hell that was a lot of parts.. Note to self.. one at a time from now on!

Next up is masking and painting then re-assembly which I plan to take LOTS of pics for as a referance on how to assemble one of these so stay tuned!
Eric, do all of your boxes have threaded posts? My 246 has all smooth posts so only two of the four clamps you sent me fit. I just assumed they were all the same. Is mine a newer type maybe?
 

Attachments

#300 ·
Stanley SW #358 Miter Box Restoration #3... Tape Bending and Paint

We found out this week that Grandma is not going to be in town next week so we arranged for her to take the boy for the night to spend some time with him before she leaves. So with the boy not at home, beautiful weather (mid 70's and lots of sun) and the fact that the sun is up till after 10pm nowadays it was the perfect storm to get this guy painted before the weekend.

First thing up was to tape off the parts that will be painted. I neglected to get any pics of the taped parts pre-paint (whoops) but basically the spots you want to hit are any machined surfaces, the front degree arc (and the inside track) and the machined hinge rings.

Then I brought them outside and set up my "paint booth" again.

Wood Automotive tire Bicycle tire Bicycle part Bumper


Flip the box over allowing the fence to hang off the support board and spray the bottom side with some Duplocolor Black Semi-Gloss Engine Enamel. That stuff dries to the touch pretty quick so once you can touch it go ahead and flip it over and we start on the top side.

Like last time I started with the lighter color first (you can go darker but it is much harder to go lighter). I sprayed the back fence with Rustoleum Metallic Silver. This color is a very close match to the original paint used on the back wall.

Wood Bottle Gas Urban design Roof


Then it is as simple as propping a board up against the back wall and spraying the same black as the bottom. Be sure to get all the other parts too.

Automotive tire Bumper Wood Automotive exterior Motor vehicle


Remove the board and whalla! Ready for some curing time!

Automotive tire Grille Bumper Wood Motor vehicle


Annnnnnd here is where we end for today.

Wood Hardwood Wood stain Engineering Flooring


Yellow Bumper Wood Automotive exterior Gas


Tableware Wood Kitchen utensil Tool Hand tool


Household hardware Hand tool Tool Font Metal


Slated for this weekend will be pealing the tape and cutting out the new deck board. Then possibly another week of cure time and the re-assembly.

Stay tuned!
 

Attachments

#301 ·
Stanley SW #358 Miter Box Restoration #3... Tape Bending and Paint

We found out this week that Grandma is not going to be in town next week so we arranged for her to take the boy for the night to spend some time with him before she leaves. So with the boy not at home, beautiful weather (mid 70's and lots of sun) and the fact that the sun is up till after 10pm nowadays it was the perfect storm to get this guy painted before the weekend.

First thing up was to tape off the parts that will be painted. I neglected to get any pics of the taped parts pre-paint (whoops) but basically the spots you want to hit are any machined surfaces, the front degree arc (and the inside track) and the machined hinge rings.

Then I brought them outside and set up my "paint booth" again.

Wood Automotive tire Bicycle tire Bicycle part Bumper


Flip the box over allowing the fence to hang off the support board and spray the bottom side with some Duplocolor Black Semi-Gloss Engine Enamel. That stuff dries to the touch pretty quick so once you can touch it go ahead and flip it over and we start on the top side.

Like last time I started with the lighter color first (you can go darker but it is much harder to go lighter). I sprayed the back fence with Rustoleum Metallic Silver. This color is a very close match to the original paint used on the back wall.

Wood Bottle Gas Urban design Roof


Then it is as simple as propping a board up against the back wall and spraying the same black as the bottom. Be sure to get all the other parts too.

Automotive tire Bumper Wood Automotive exterior Motor vehicle


Remove the board and whalla! Ready for some curing time!

Automotive tire Grille Bumper Wood Motor vehicle


Annnnnnd here is where we end for today.

Wood Hardwood Wood stain Engineering Flooring


Yellow Bumper Wood Automotive exterior Gas


Tableware Wood Kitchen utensil Tool Hand tool


Household hardware Hand tool Tool Font Metal


Slated for this weekend will be pealing the tape and cutting out the new deck board. Then possibly another week of cure time and the re-assembly.

Stay tuned!
Wow, that's really nuts, good job. So many parts.
 

Attachments

#305 ·
Stanley SW #358 Miter Box Restoration #4... Made Some Sawdust Today..

I finally got off my arse and bagged up and labeled all the parts to clear off the bench top. Next up was to make a new wooden deck for the box.

Musical instrument Automotive exterior Bumper Auto part Wind instrument


1/2" Red Oak again. No clue what the old board is but it's brittle as all hell now so it's toast.

Wood Rectangle Flooring Floor Stairs


Crosscut saw Wood Saw Tool Hand tool


And I got this far yesterday when 1/4 of the way through drilling the curved corners the board split along the grain…. Had to start from scratch with a new board. Oh well. Got to spend some time at the wood store with the boy so not a wasted afternoon ;-)

Hand tool Wood Tool Auto part Metal


Skipping ahead a bit (it really is as simple as cutting out a shape.. I don't really have to explain that do I? )

Felt good to get some shavings on the benchtop again finally!

Plane Smoothing plane Hand tool Tool Rebate plane


Brown Wood Flooring Beige Tints and shades


Then to layout the dados.. Tip of the day.. Don't use the old board as a guide for depth of these. Lay your new board on the box and register a chisel on the guide clamp plate and mark the depth from there.. Ask me how I know.

Hood Wood Table Tire Automotive tire


Knife and cut.. LOVE this saw!

Hand tool Wood Tool Metalworking hand tool Household hardware


Wood Hardwood Wood stain Rectangle Tints and shades


Then the ol' routah plane trick..

Wood Hand tool Gas Tool Hardwood


Annnnnd Boom! Ready for some danish oil and wax.

Wood Rectangle Beige Fashion accessory Leather


That leaves only one thing to do (aside from tackling the saw it's self).. Assembly! Hope to get to that tomorrow but no actual promises.. Stay Tuned!
 

Attachments

#306 ·
Stanley SW #358 Miter Box Restoration #4... Made Some Sawdust Today..

I finally got off my arse and bagged up and labeled all the parts to clear off the bench top. Next up was to make a new wooden deck for the box.



1/2" Red Oak again. No clue what the old board is but it's brittle as all hell now so it's toast.





And I got this far yesterday when 1/4 of the way through drilling the curved corners the board split along the grain…. Had to start from scratch with a new board. Oh well. Got to spend some time at the wood store with the boy so not a wasted afternoon ;-)



Skipping ahead a bit (it really is as simple as cutting out a shape.. I don't really have to explain that do I? )

Felt good to get some shavings on the benchtop again finally!





Then to layout the dados.. Tip of the day.. Don't use the old board as a guide for depth of these. Lay your new board on the box and register a chisel on the guide clamp plate and mark the depth from there.. Ask me how I know.



Knife and cut.. LOVE this saw!



Wood Hardwood Wood stain Rectangle Tints and shades


Then the ol' routah plane trick..

Wood Hand tool Gas Tool Hardwood


Annnnnd Boom! Ready for some danish oil and wax.

Wood Rectangle Beige Fashion accessory Leather


That leaves only one thing to do (aside from tackling the saw it's self).. Assembly! Hope to get to that tomorrow but no actual promises.. Stay Tuned!
Very nice work. This helps motivate me to get my own goin'
 

Attachments

#312 ·
Stanley SW #358 Miter Box Restoration #5... Final Touches Before Assembly..

I might have had time today to completely assemble this but I wouldn't have had time to take the detailed assembly pics I promised. That said there were a couple of things left to do pre-assembly that I was able to take care of this morning. I am hoping for an assembly day tomorrow so stay tuned for that.

The first thing on tap this morning was to get my bench and parts/supplies organized for tomorrow.

Wood Flooring Engineering Machine Toolroom


I got out only this boxes parts ao it brings the part count down a bit.

Hand tool Tool Wood Metalworking hand tool Metal


Then the usual assembly corrosion prevention tools and detritus..

Bottle Drinkware Gas Barware Water bottle


I'll go over each of these in more detail in the next entry when we start using them.

Next I needed to sand the back fence flat and remove the paint from the ridges. I have no idea if these remained painted originally but I prefer to leave them bare metal just to avoid any rubbing off on the stock being cut.

Got my sander ready.. (using 80 grit here probably would have been better off with 60).. You want to use a sanding block or something similar for this. Nothing that will conform to contours. You want sand this flat not round off the ridges.

Rectangle Wood Flooring Wood stain Hardwood


Wood Table Rectangle Flooring Wood stain


Then I covered a 4Ă—6 with some paper towels to keep from scratching the new paint and propped my box on top and went to town. Don't linger in one spot just full strokes and work from top to bottom till all the paint is gone and you get even scratches across the wall.

Hood Automotive tire Motor vehicle Automotive design Wood


Wood Tool Musical instrument accessory Rectangle Kitchen utensil


And this is why I use a scrap instead of my bench.. makes an awful mess (the towel had been changed twice already)

Wood Road surface Floor Rectangle Flooring


With that done I needed to mark and predrill the mounting holes for the wood deck. Alignment of the stock guides is a bit critical for this stage so I use a couple 1/2"x1/8" metal cutoffs as place holders to align and clamp the board in place during the process.

Brown Wood Wood stain Table Hardwood


Wood Bumper Hood Automotive exterior Musical instrument accessory


Flip and mark the holes with an awl (got to use my new hammer.. thanks DaddyZ!)

Crankset Bicycle tire Automotive tire Wood Bicycle part


Automotive tire Tire Crankset Bumper Wood


Then pre drilled part way and it is ready to be installed when needed.

Wood Hardwood Wood stain Flooring Mallet


Wood Table Line Hardwood Flooring


So there we go. Ready for assembly finally and like I said I hope to get that done tomorrow (Sunday). While there are a lot of little parts the assembly is pretty straight forward as you will see and I hope you stay tuned for that.

Thanks for reading!
 

Attachments

#313 ·
Stanley SW #358 Miter Box Restoration #5... Final Touches Before Assembly..

I might have had time today to completely assemble this but I wouldn't have had time to take the detailed assembly pics I promised. That said there were a couple of things left to do pre-assembly that I was able to take care of this morning. I am hoping for an assembly day tomorrow so stay tuned for that.

The first thing on tap this morning was to get my bench and parts/supplies organized for tomorrow.

Wood Flooring Engineering Machine Toolroom


I got out only this boxes parts ao it brings the part count down a bit.

Hand tool Tool Wood Metalworking hand tool Metal


Then the usual assembly corrosion prevention tools and detritus..

Bottle Drinkware Gas Barware Water bottle


I'll go over each of these in more detail in the next entry when we start using them.

Next I needed to sand the back fence flat and remove the paint from the ridges. I have no idea if these remained painted originally but I prefer to leave them bare metal just to avoid any rubbing off on the stock being cut.

Got my sander ready.. (using 80 grit here probably would have been better off with 60).. You want to use a sanding block or something similar for this. Nothing that will conform to contours. You want sand this flat not round off the ridges.

Rectangle Wood Flooring Wood stain Hardwood


Wood Table Rectangle Flooring Wood stain


Then I covered a 4Ă—6 with some paper towels to keep from scratching the new paint and propped my box on top and went to town. Don't linger in one spot just full strokes and work from top to bottom till all the paint is gone and you get even scratches across the wall.

Hood Automotive tire Motor vehicle Automotive design Wood


Wood Tool Musical instrument accessory Rectangle Kitchen utensil


And this is why I use a scrap instead of my bench.. makes an awful mess (the towel had been changed twice already)

Wood Road surface Floor Rectangle Flooring


With that done I needed to mark and predrill the mounting holes for the wood deck. Alignment of the stock guides is a bit critical for this stage so I use a couple 1/2"x1/8" metal cutoffs as place holders to align and clamp the board in place during the process.

Brown Wood Wood stain Table Hardwood


Wood Bumper Hood Automotive exterior Musical instrument accessory


Flip and mark the holes with an awl (got to use my new hammer.. thanks DaddyZ!)

Crankset Bicycle tire Automotive tire Wood Bicycle part


Automotive tire Tire Crankset Bumper Wood


Then pre drilled part way and it is ready to be installed when needed.

Wood Hardwood Wood stain Flooring Mallet


Wood Table Line Hardwood Flooring


So there we go. Ready for assembly finally and like I said I hope to get that done tomorrow (Sunday). While there are a lot of little parts the assembly is pretty straight forward as you will see and I hope you stay tuned for that.

Thanks for reading!
Very deliberate and proper. Great pics and dialog too. Well done, a fine post and even finer Box!
 

Attachments

#319 ·
Stanley SW #358 Miter Box Restoration #6... Assembly! Long Winded and A Ton of Pics..

(Inhales deeply)

OK, lets get this going. Warning up front to anyone NOT curious about how one of these goes together you might want to scroll a bit to get to the money shots otherwise hang in there we have a bit to go over first.

First things first here are what I typically use in any tool restoration during assembly. Nearly all of these deal with corrosion prevention in some form or another and that folks is the name of the game from this point on. We just spent a lot of sweat equity REMOVING years of corrosion from this tool and we should be willing to spend a few extra moments to ensure that never happens again (or at least happens slower).

Wax: I like Renaissance Wax and you can normally find it for a decent price on Amazon if you search for it. A large(200ml) can will last long enough to make the price worth while. Otherwise any other wax product will work but I have just found this to be the easiest to work with and it doesn't color the metal.

Drinkware Wood Writing implement Pen Office supplies


Oil/Lubes: Moving parts need to stay mobile and the best way to ensure that happens without metal wear is oil and lube(giggity). 3 in 1 is pretty much the standard and I also use some general axle grease in certain high motion areas.

Tire Liquid Automotive tire Bottle cap Bottle


Liquid Fluid Kitchen utensil Dishware Drink


General Corrosion Prevention: T9 is the bees knees guys. I can't speak highly enough about this stuff! We use the Mil Spec version of this product at work and it works wonderfully. The handplanes I treated with T9 over a year ago still show no signs of tarnish or rust and the fasteners all turn easily and freely. It works by drying to a lubricated film creating a barrier against water and the atmosphere. One word of caution.. it WILL slightly darken older metals. Just keep that in mind when using it.

Tin Aluminum can Ingredient Font Gas


Other items needed are rags, paper towels, some q-tips, a small parts tray and a variety of slotted screwdrivers..

Bottle Drinkware Gas Barware Water bottle


NOW.. first thing on the list is to give the entire main body of the box a good coating of wax. It is much easier to do this now then after assembly. Make sure you pay attention to any areas that will be covered and forgotten about for years.. that is where rust likes to form first and you won't even know about it.

Dishware Wood Tableware Tin can Safety glove


Wood Safety glove Gesture Finger Glove


Buff with a soft cloth and done..

Wood Finger Musical instrument accessory Bumper Set tool


Next we will install the name plate. The plate has 2 small twist blind rivets that simply tap into place.

Brown Wood Flooring Hardwood Wood stain


Place them in either a bag or on your plastic tray and give them a spritz of T9. EVERY fastener on this box will get a coating of T9 pre assembly.

Brown Wood Flooring Fashion accessory Cuisine


Next using a ball peen hammer and tapping LIGHTLY! Tap them into place. Lightly is the key here folks. If it takes 300 light taps it is better than 4 hard whacks that breaks the cast iron making this thing a boat anchor again.

Hand tool Metalworking hand tool Tool Musical instrument accessory Wood


Wood Tool Measuring instrument Bumper Font


Next is the wood base. Clamp it to the box same as when you marked your holes and give the wood screws a good spray of T9 (I use the bag, spray, toss then dump method from here out.)

Fluid Drinkware Wood Liquid Bottle


Asphalt Wood Road surface Tints and shades Automotive lighting


Hood Table Eyewear Tablecloth Linens


Then.. install!

Automotive tire Bicycle part Wood Rim Auto part


Crankset Bicycle tire Wood Automotive tire Bicycle part


What it all looks like at this stage..

Musical instrument accessory Wood Electronic instrument Audio equipment Bumper


Now the legs. Here is a look at these parts.. Remember Bag and T9 before installing! Don't get lazy on me now!

Wood Musical instrument Hardwood Household hardware Metal


Wood Household hardware Gas Fastener Hardwood


Bicycle part Wood Gun accessory Gun barrel Metal


Looking more like a mitre box now..

Wood Musical instrument accessory Musical instrument Hardwood Automotive exterior


Now the "dun Dun DUNNNN" Swing arm…

Give ALL the machined areas inside and out a good coating of T9 using a q-tip soaked in it.

Textile Wood Electric blue Metal Denim


Hood Goggles Sunglasses Bag Eyewear


Next find these bits here.. this is your degree clamp mechanism. (bag, T9.. dump. Seriously.. seeing a pattern here?)

Hand tool Wood Bullet Metal Household hardware


Here is how it is positioned within the arm. You have to kinda fiddle with it to get the axle to slip into place but you will figure that out.

Household hardware Tool Metal Bullet Electric blue


Then flip it over (careful nothing falls out on the way.. Not that I know because I had to chase these 2 bits down about a hundred times while doing this lol.. nope not at all) and fill the inside with some 3 in 1 and grease.

Musical instrument String instrument Guitar accessory String instrument Guitar


And then install the plug. The plug also acts as a clamp force adjustment. You loosen it to decrease force and tighten to increase. Play with it a bit and you will see what I mean. That is what i love about these boxes.. Every bit of the mechanics is adjustable.

Next is the positioning pin assembly.

Household hardware Wood Metal Fashion accessory Fastener


Assembled it looks like this.. (note the tear drop shaped item.. it goes with this guy..) (You used T9 right?)

Wood Musical instrument Household hardware Bullet Gas


Slip it into the arm like this and lock the brass portion into place with the 2 set/adjustment screws.

Tire Wood Sleeve Bicycle part Jewellery


Then press the spring loaded pin down and install the teardrop actuator into the hole in the right side till it fully seats and holds the pin in place..

Wood Musical instrument Folk instrument Metal Electric blue


Then we install the actuating arm. Watch the positioning.. there is a tab that sticks out on one side.. that needs to be on the right so it bumps the teardrop and actuates everything. Install it into the axle with the 2 screws.

Wood Motor vehicle Automotive exterior Artifact Metal


Now is the time to check that everything moves like it should. When the arm is down the clamp should drop and the pin raises.

Wood Air gun Trigger Shotgun Gun barrel


When it is lifted the clamp should raise and the pin drops..

Wood Wood stain Gun accessory Hardwood Metal


If it doesn't or nothing happens backtrack till you find the culprit (not going to teach trouble shooting procedures here.. they are pretty universal)

Next is the hold back screws and springs..

Household hardware Wood Gas Screw Fastener


Collar Material property Cross Religious item Jewellery


Bicycle tire Tire Automotive tire Hood Wood


Then the third hand (used when adjusting the arm.. this is often times missing and not really a critical component just a convenience)

Shoe Revolver Handgun holster Bicycle part Personal protective equipment


Wood Bullet Revolver Two-way radio Metal


Wood Metal Satellite phone Fashion accessory Ammunition


Then the main swivel joint. Insert the bushing from the bottom up..

Wood Gas Metal Button Household hardware


Automotive tire Wood Tire Auto part Metal


Automotive tire Wood Gas Audio equipment Vehicle door


LIBERALLY lube the joint on both the box and the arm and slip the clamp into the track.. lock into a positive position and screw down the swivel.

Automotive tire Crankset Wood Motor vehicle Steering wheel


Wheel Wood Automotive tire Bicycle part Bicycle tire


Now we can install the marking plate..

Road surface Asphalt Gas Wood Circle


Brown Wood Audio equipment Camera lens Camera accessory


Next up is the upright assemblies. The bases are normally marked "F" and "B" for front and back. Position them so that the 3 holes face outward and fasten into place from below with the large knurled screws. (You are still using the T9 right? Bare surfaces Get There!)

Household hardware Bullet Gas Wood Metal


Wood Metal Fashion accessory Rectangle Hardwood


The long screw is the center pivot bolt.. (note the position of the tapered side of the pivot plate. It should face the 2 screw holes)

Camera lens Cameras & optics Wood Camera accessory Automotive tire


Then install your adjustment screws.

Wood Bumper Camera lens Gadget Cable


Do this for both front and back and now we are cooking!

Wood Musical instrument accessory Gas Audio equipment Hardwood


Now.. this next part is my least favorite part mainly because of the exercise in frustration trying to shim these. I got lucky and the previous owner had already installed some shims and was able to reuse them but you may(read will) need to make your own. I have used aluminum foil with good results and have seen them made from a soda can which would probably work better. The thing is you want these to be tight and have the 2 tabs on top to go laterally across the top at the same time. Take your time and do it right and you won't have to worry about it again.

Shelf Wood Shelving Retail Hardwood


Tip: You can use one of the latch assemblies as a tool to tighten these.

Hand Bookcase Finger Electrical wiring Electrician


The position of these is typically found as follows.. threaded post on the right and smooth post on the left.. is that critical? No but that is how I have recieved them and how I install them.

Before installing any of the threaded posts thread on (from the bottom) the brass max depth stop. It only threads on from the bottom.

Wood Glove Gas Screw Auto part


Here is a look at the fasteners for the stops. Some older boxes came with a thumb screw on the smooth stop while others are slotted screws like these. Just make sure you position the stops so that the screws heads are facing outward otherwise you won't be able to get a tool in there to adjust these.

Font Gas Screw Symbol Asphalt


So now you have shimmed, tried again, shimmed and gotten close enough on all 4 posts (try the posts in different holes.. sometimes what doesn't work in one works better in the other)

Wood Gas Engineering Workbench Machine tool


Install your adjustable stops and cushion spring then we move onto the saw guides..

Bullet Gun accessory Nickel Auto part Metal


If you look at the slip tab you will find a machined divot in one spot.. this is positioned down and inboard to catch the hook on.

Wood Artifact Jewellery Fashion accessory Metal


Material property Artifact Wood Rose Metal


Slip the 2 halves together (you did treat all this with T9 right? Just checking) and with some fiddling and persuasion slip it over the upright rods.

Musical instrument Wood Floor Reed instrument Flooring


Then the hooks and cross bars are installed like so..

Gold Font Wood Body jewelry Jewellery


Artifact Metal Symbol Fashion accessory Household hardware


Front..

Wood Artifact Metal Jewellery Fashion accessory


Back..

Wood Hardwood Wood stain Plywood Varnish


Wood Bicycle part Bumper Gas Engineering


Wood Gas Engineering Machine Cylinder


Bookcase Shelf Publication Wood Gas


The back assembly..

Bicycle part Wood Household hardware Engineering Auto part


Check your catch and release works..

Drinkware Bicycle part Cylinder Engineering Barware


Then the cross member. This is installed UNDER the cross bars not on top of it like is seen in so many eBay photos.

Wood Material property Gas Household hardware Metal


Wood Musical instrument Engineering Machine Bumper


Then whatever accessories you may have..

Wood Automotive tire Household hardware Gas Engineering


Incidentally.. these screws are exactly the same as the rod holding screws on a Stanley 45.. if your are missing those will be easier to find..

Glasses Wood Eyewear Sunglasses Hardwood


Annnnd Boom.. a Mitre Box.

Wood Hardwood Gas Flooring Machine


Now I just need to see if I can make this shine and cut again and I can call this officially done..

Wood Rectangle Window Metal Composite material


Whats that? Oh you skipped all the way down here for the money shots.. well I'd hate to disappoint a slacker such as yourself.. here ya go!

Wood Building Gas Engineering Machine tool


Wood Hardwood Flooring Wood stain Plywood


Font Natural material Electric blue Metal Cleanliness


Wood Automotive tire Auto part Machine Metal


Wood Hardwood Machine Engineering Workbench


And sitting next to it's little brother..

Wood Gas Machine Office equipment Musical instrument accessory


Wood Engineering Machine Metal Factory


Now.. GO MAKE SOMETHING NEW AGAIN! Go on.. git!

Thanks for reading and stay tuned for the saw restoration..
 

Attachments

#320 ·
Stanley SW #358 Miter Box Restoration #6... Assembly! Long Winded and A Ton of Pics..

(Inhales deeply)

OK, lets get this going. Warning up front to anyone NOT curious about how one of these goes together you might want to scroll a bit to get to the money shots otherwise hang in there we have a bit to go over first.

First things first here are what I typically use in any tool restoration during assembly. Nearly all of these deal with corrosion prevention in some form or another and that folks is the name of the game from this point on. We just spent a lot of sweat equity REMOVING years of corrosion from this tool and we should be willing to spend a few extra moments to ensure that never happens again (or at least happens slower).

Wax: I like Renaissance Wax and you can normally find it for a decent price on Amazon if you search for it. A large(200ml) can will last long enough to make the price worth while. Otherwise any other wax product will work but I have just found this to be the easiest to work with and it doesn't color the metal.

Drinkware Wood Writing implement Pen Office supplies


Oil/Lubes: Moving parts need to stay mobile and the best way to ensure that happens without metal wear is oil and lube(giggity). 3 in 1 is pretty much the standard and I also use some general axle grease in certain high motion areas.

Tire Liquid Automotive tire Bottle cap Bottle


Liquid Fluid Kitchen utensil Dishware Drink


General Corrosion Prevention: T9 is the bees knees guys. I can't speak highly enough about this stuff! We use the Mil Spec version of this product at work and it works wonderfully. The handplanes I treated with T9 over a year ago still show no signs of tarnish or rust and the fasteners all turn easily and freely. It works by drying to a lubricated film creating a barrier against water and the atmosphere. One word of caution.. it WILL slightly darken older metals. Just keep that in mind when using it.

Tin Aluminum can Ingredient Font Gas


Other items needed are rags, paper towels, some q-tips, a small parts tray and a variety of slotted screwdrivers..

Bottle Drinkware Gas Barware Water bottle


NOW.. first thing on the list is to give the entire main body of the box a good coating of wax. It is much easier to do this now then after assembly. Make sure you pay attention to any areas that will be covered and forgotten about for years.. that is where rust likes to form first and you won't even know about it.

Dishware Wood Tableware Tin can Safety glove


Wood Safety glove Gesture Finger Glove


Buff with a soft cloth and done..

Wood Finger Musical instrument accessory Bumper Set tool


Next we will install the name plate. The plate has 2 small twist blind rivets that simply tap into place.

Brown Wood Flooring Hardwood Wood stain


Place them in either a bag or on your plastic tray and give them a spritz of T9. EVERY fastener on this box will get a coating of T9 pre assembly.

Brown Wood Flooring Fashion accessory Cuisine


Next using a ball peen hammer and tapping LIGHTLY! Tap them into place. Lightly is the key here folks. If it takes 300 light taps it is better than 4 hard whacks that breaks the cast iron making this thing a boat anchor again.

Hand tool Metalworking hand tool Tool Musical instrument accessory Wood


Wood Tool Measuring instrument Bumper Font


Next is the wood base. Clamp it to the box same as when you marked your holes and give the wood screws a good spray of T9 (I use the bag, spray, toss then dump method from here out.)

Fluid Drinkware Wood Liquid Bottle


Asphalt Wood Road surface Tints and shades Automotive lighting


Hood Table Eyewear Tablecloth Linens


Then.. install!

Automotive tire Bicycle part Wood Rim Auto part


Crankset Bicycle tire Wood Automotive tire Bicycle part


What it all looks like at this stage..

Musical instrument accessory Wood Electronic instrument Audio equipment Bumper


Now the legs. Here is a look at these parts.. Remember Bag and T9 before installing! Don't get lazy on me now!

Wood Musical instrument Hardwood Household hardware Metal


Wood Household hardware Gas Fastener Hardwood


Bicycle part Wood Gun accessory Gun barrel Metal


Looking more like a mitre box now..

Wood Musical instrument accessory Musical instrument Hardwood Automotive exterior


Now the "dun Dun DUNNNN" Swing arm…

Give ALL the machined areas inside and out a good coating of T9 using a q-tip soaked in it.

Textile Wood Electric blue Metal Denim


Hood Goggles Sunglasses Bag Eyewear


Next find these bits here.. this is your degree clamp mechanism. (bag, T9.. dump. Seriously.. seeing a pattern here?)

Hand tool Wood Bullet Metal Household hardware


Here is how it is positioned within the arm. You have to kinda fiddle with it to get the axle to slip into place but you will figure that out.

Household hardware Tool Metal Bullet Electric blue


Then flip it over (careful nothing falls out on the way.. Not that I know because I had to chase these 2 bits down about a hundred times while doing this lol.. nope not at all) and fill the inside with some 3 in 1 and grease.

Musical instrument String instrument Guitar accessory String instrument Guitar


And then install the plug. The plug also acts as a clamp force adjustment. You loosen it to decrease force and tighten to increase. Play with it a bit and you will see what I mean. That is what i love about these boxes.. Every bit of the mechanics is adjustable.

Next is the positioning pin assembly.

Household hardware Wood Metal Fashion accessory Fastener


Assembled it looks like this.. (note the tear drop shaped item.. it goes with this guy..) (You used T9 right?)

Wood Musical instrument Household hardware Bullet Gas


Slip it into the arm like this and lock the brass portion into place with the 2 set/adjustment screws.

Tire Wood Sleeve Bicycle part Jewellery


Then press the spring loaded pin down and install the teardrop actuator into the hole in the right side till it fully seats and holds the pin in place..

Wood Musical instrument Folk instrument Metal Electric blue


Then we install the actuating arm. Watch the positioning.. there is a tab that sticks out on one side.. that needs to be on the right so it bumps the teardrop and actuates everything. Install it into the axle with the 2 screws.

Wood Motor vehicle Automotive exterior Artifact Metal


Now is the time to check that everything moves like it should. When the arm is down the clamp should drop and the pin raises.

Wood Air gun Trigger Shotgun Gun barrel


When it is lifted the clamp should raise and the pin drops..

Wood Wood stain Gun accessory Hardwood Metal


If it doesn't or nothing happens backtrack till you find the culprit (not going to teach trouble shooting procedures here.. they are pretty universal)

Next is the hold back screws and springs..

Household hardware Wood Gas Screw Fastener


Collar Material property Cross Religious item Jewellery


Bicycle tire Tire Automotive tire Hood Wood


Then the third hand (used when adjusting the arm.. this is often times missing and not really a critical component just a convenience)

Shoe Revolver Handgun holster Bicycle part Personal protective equipment


Wood Bullet Revolver Two-way radio Metal


Wood Metal Satellite phone Fashion accessory Ammunition


Then the main swivel joint. Insert the bushing from the bottom up..

Wood Gas Metal Button Household hardware


Automotive tire Wood Tire Auto part Metal


Automotive tire Wood Gas Audio equipment Vehicle door


LIBERALLY lube the joint on both the box and the arm and slip the clamp into the track.. lock into a positive position and screw down the swivel.

Automotive tire Crankset Wood Motor vehicle Steering wheel


Wheel Wood Automotive tire Bicycle part Bicycle tire


Now we can install the marking plate..

Road surface Asphalt Gas Wood Circle


Brown Wood Audio equipment Camera lens Camera accessory


Next up is the upright assemblies. The bases are normally marked "F" and "B" for front and back. Position them so that the 3 holes face outward and fasten into place from below with the large knurled screws. (You are still using the T9 right? Bare surfaces Get There!)

Household hardware Bullet Gas Wood Metal


Wood Metal Fashion accessory Rectangle Hardwood


The long screw is the center pivot bolt.. (note the position of the tapered side of the pivot plate. It should face the 2 screw holes)

Camera lens Cameras & optics Wood Camera accessory Automotive tire


Then install your adjustment screws.

Wood Bumper Camera lens Gadget Cable


Do this for both front and back and now we are cooking!

Wood Musical instrument accessory Gas Audio equipment Hardwood


Now.. this next part is my least favorite part mainly because of the exercise in frustration trying to shim these. I got lucky and the previous owner had already installed some shims and was able to reuse them but you may(read will) need to make your own. I have used aluminum foil with good results and have seen them made from a soda can which would probably work better. The thing is you want these to be tight and have the 2 tabs on top to go laterally across the top at the same time. Take your time and do it right and you won't have to worry about it again.

Shelf Wood Shelving Retail Hardwood


Tip: You can use one of the latch assemblies as a tool to tighten these.

Hand Bookcase Finger Electrical wiring Electrician


The position of these is typically found as follows.. threaded post on the right and smooth post on the left.. is that critical? No but that is how I have recieved them and how I install them.

Before installing any of the threaded posts thread on (from the bottom) the brass max depth stop. It only threads on from the bottom.

Wood Glove Gas Screw Auto part


Here is a look at the fasteners for the stops. Some older boxes came with a thumb screw on the smooth stop while others are slotted screws like these. Just make sure you position the stops so that the screws heads are facing outward otherwise you won't be able to get a tool in there to adjust these.

Font Gas Screw Symbol Asphalt


So now you have shimmed, tried again, shimmed and gotten close enough on all 4 posts (try the posts in different holes.. sometimes what doesn't work in one works better in the other)

Wood Gas Engineering Workbench Machine tool


Install your adjustable stops and cushion spring then we move onto the saw guides..

Bullet Gun accessory Nickel Auto part Metal


If you look at the slip tab you will find a machined divot in one spot.. this is positioned down and inboard to catch the hook on.

Wood Artifact Jewellery Fashion accessory Metal


Material property Artifact Wood Rose Metal


Slip the 2 halves together (you did treat all this with T9 right? Just checking) and with some fiddling and persuasion slip it over the upright rods.

Musical instrument Wood Floor Reed instrument Flooring


Then the hooks and cross bars are installed like so..

Gold Font Wood Body jewelry Jewellery


Artifact Metal Symbol Fashion accessory Household hardware


Front..

Wood Artifact Metal Jewellery Fashion accessory


Back..

Wood Hardwood Wood stain Plywood Varnish


Wood Bicycle part Bumper Gas Engineering


Wood Gas Engineering Machine Cylinder


Bookcase Shelf Publication Wood Gas


The back assembly..

Bicycle part Wood Household hardware Engineering Auto part


Check your catch and release works..

Drinkware Bicycle part Cylinder Engineering Barware


Then the cross member. This is installed UNDER the cross bars not on top of it like is seen in so many eBay photos.

Wood Material property Gas Household hardware Metal


Wood Musical instrument Engineering Machine Bumper


Then whatever accessories you may have..

Wood Automotive tire Household hardware Gas Engineering


Incidentally.. these screws are exactly the same as the rod holding screws on a Stanley 45.. if your are missing those will be easier to find..

Glasses Wood Eyewear Sunglasses Hardwood


Annnnd Boom.. a Mitre Box.

Wood Hardwood Gas Flooring Machine


Now I just need to see if I can make this shine and cut again and I can call this officially done..

Wood Rectangle Window Metal Composite material


Whats that? Oh you skipped all the way down here for the money shots.. well I'd hate to disappoint a slacker such as yourself.. here ya go!

Wood Building Gas Engineering Machine tool


Wood Hardwood Flooring Wood stain Plywood


Font Natural material Electric blue Metal Cleanliness


Wood Automotive tire Auto part Machine Metal


Wood Hardwood Machine Engineering Workbench


And sitting next to it's little brother..

Wood Gas Machine Office equipment Musical instrument accessory


Wood Engineering Machine Metal Factory


Now.. GO MAKE SOMETHING NEW AGAIN! Go on.. git!

Thanks for reading and stay tuned for the saw restoration..
Wow. Just, wow…..

I'd feel bad letting it get dusty again if it were in my shop, I'd have to build a cabinet for it.

Beautiful tesults, excellent blog.
 

Attachments

#336 ·
Stanley SW #358 Miter Box Restoration #7... Cleaned Up The Saw Plate.. Is This Worth Saving?

I am going to present this question to the group. Saw restoration and sharpening is not an area I have really spent much time in yet so I am far from an expert. So I ask is this saw plate worth trying to sharpen up or should I explore other options?

I WOULD like to use the original plate if it is at all usable but like I said.. I'm hoping some folks who are much more knowledgeable on the subject will help me out here.

First some before pics…

Wood Rectangle Window Metal Composite material


Post Evaporust..

Wood Gas Motor vehicle Auto part Automotive exterior


And sanded from 80 grit up to 220 grit.. (I tried my best to get a good representation of it's current condition)

Wood Eyewear Office equipment Metal Fashion accessory


Wood Table Tire Floor Wood stain


Brown Rectangle Wood Amber Font


Wood Automotive exterior Wood stain Bumper Plank


Wood Floor Flooring Hardwood Water


Wood Bumper Automotive exterior Gas Metal


Rectangle Wood Shade Tints and shades Font


And just the faintest etch still visible..

Brown Rectangle Wood Beige Tints and shades


Brown Rectangle Wood Tints and shades Parallel


So what say you? Is this going to be usable or is it a lost cause?

Thanks for the help!
 

Attachments

#337 ·
Stanley SW #358 Miter Box Restoration #7... Cleaned Up The Saw Plate.. Is This Worth Saving?

I am going to present this question to the group. Saw restoration and sharpening is not an area I have really spent much time in yet so I am far from an expert. So I ask is this saw plate worth trying to sharpen up or should I explore other options?

I WOULD like to use the original plate if it is at all usable but like I said.. I'm hoping some folks who are much more knowledgeable on the subject will help me out here.

First some before pics…



Post Evaporust..



And sanded from 80 grit up to 220 grit.. (I tried my best to get a good representation of it's current condition)















And just the faintest etch still visible..





So what say you? Is this going to be usable or is it a lost cause?

Thanks for the help!
The pictures I see look perfectly usable to me. If the plate isn't bent and there are no teeth missing I think it will be fine. I don't see any deep rust pot marks either and even if there are a few it's not going to affect the usability as a miter box saw. It looks nicer than my Miter box saw plate from the pictures but I have not taken any sandpaper to mine.
 

Attachments

#345 ·
Stanley SW #358 Miter Box Restoration #8...Getting a handle on things..

Moving forward with the saw restoration..

The original tote on this saw is usable but ugly and pretty beat up so a new one is in order. TGIAG to the rescue!

Handwriting Wood Writing implement Office supplies Pen


I have some slightly thicker than 4/4 African Mahogany on hand and it should make for a fine looking handle so why the heck not.

The next few pics will be a "well duh" series for some of you but I have seen some questions asked around the forums about dimensioning wood with handplanes and I figured this was as good an example as any other. So if you already have a handle on this.. you can skip ahead a bit if you'd like.

The piece I have measures just slightly thicker than 1" and I need it to be closer to 7/8" for the handle.

First step is to plane a flat registration face. Don't worry about final thickness here we just want a flat face to measure from.

First plane a slight bevel on the front and back of the wood to prevent blowout and get your jack out and scrub across the grain till you are getting full width shavings from it (now "full width shavings is a bit of a misnomer. The shavings won't stay together cross grain but you can hear it cutting the full width.)

Wood Motor vehicle Table Flooring Automotive tire


Wood Hardwood Rectangle Flooring Automotive exterior


This ensures the board is flat from side to side. Now we go at it from the diagonals to get it flat from corner to corner.

Smoothing plane Plane Scrub plane Jack plane Shoulder plane


Again once you get a full shaving on each stroke across the board your good.

Now.. straight down the grain to get it finally flat.

Smoothing plane Plane Scrub plane Jack plane Block plane


Then I like to hit it with a smoother to get it nice and shiney.. over kill maybe but why not right?

Wood Tool Table Hardwood Household hardware


Now measuring from this face mark your desired final thickness all the way around the board.

Wood Tool Household hardware Varnish Mallet


Brown Wood Rectangle Publication Hardwood


Then this time when you plane a bevel on the front and back side take it all the way down to your line. This will give you a visual indication of when you have it thicknessed correctly without chasing your tail measuring every few strokes.

Smoothing plane Wood Plane Flooring Floor


Brown Wood Rectangle Table Wood stain


Now go about it just as you did flattening the other face keeping an eye on your bevel. You want it to disappear as close to the end of the process as possible so you don't over shoot your mark.

And then you should have a correctly dimensioned board and a happy pile of shavings when you are done!

Smoothing plane Plane Scrub plane Jack plane Rebate plane


Next was to cut out the handle..

Plant Wood Tree Rectangle Font


Plant Wood Tree Font Art


Automotive design Art Font Writing implement Office supplies


Gadget Automotive design Gas Computer hardware Circle


Wood Font Flooring Hardwood Art


Notice how I left the area where the blade enters square(ish)... I have found it is easier to cut the slot when the faces are flat than when they are rounded.

Then we mark half way and cut the kerfs

Wood Gas Rectangle Metal Machine


Wood Wood stain Flooring Floor Stairs


Wood Flooring Hardwood Wood stain Plank


Wood Table Wood stain Flooring Plank


Then I finished the cut with a saw who's kerf closest matched the thickness of the blade.

Saw Wood Hand tool Tool Machine tool


Test..

Wood Gas Flooring Hardwood Wood stain


Finish cutting it out and then we will start on the mortise for the back..

Wood Hand tool Wood stain Tool Gas


Wood Wood stain Flooring Hardwood Art


Wood Hardwood Mallet Wood stain Plywood


I had some help for this part today..

Wood Wood stain Art Hardwood Engineering


Wood Wood stain Plank Varnish Hardwood


Annnnnd it fits!

Hand tool Wood Tool Wood stain Hardwood


Wood String instrument accessory Wrench Tool Hardwood


Now to figure out how to mark the holes in an existing sawplate onto a new handle and we can start shaping this bad boy!

More to come and again thanks for reading!
 

Attachments

#346 ·
Stanley SW #358 Miter Box Restoration #8...Getting a handle on things..

Moving forward with the saw restoration..

The original tote on this saw is usable but ugly and pretty beat up so a new one is in order. TGIAG to the rescue!

Handwriting Wood Writing implement Office supplies Pen


I have some slightly thicker than 4/4 African Mahogany on hand and it should make for a fine looking handle so why the heck not.

The next few pics will be a "well duh" series for some of you but I have seen some questions asked around the forums about dimensioning wood with handplanes and I figured this was as good an example as any other. So if you already have a handle on this.. you can skip ahead a bit if you'd like.

The piece I have measures just slightly thicker than 1" and I need it to be closer to 7/8" for the handle.

First step is to plane a flat registration face. Don't worry about final thickness here we just want a flat face to measure from.

First plane a slight bevel on the front and back of the wood to prevent blowout and get your jack out and scrub across the grain till you are getting full width shavings from it (now "full width shavings is a bit of a misnomer. The shavings won't stay together cross grain but you can hear it cutting the full width.)

Wood Motor vehicle Table Flooring Automotive tire


Wood Hardwood Rectangle Flooring Automotive exterior


This ensures the board is flat from side to side. Now we go at it from the diagonals to get it flat from corner to corner.

Smoothing plane Plane Scrub plane Jack plane Shoulder plane


Again once you get a full shaving on each stroke across the board your good.

Now.. straight down the grain to get it finally flat.

Smoothing plane Plane Scrub plane Jack plane Block plane


Then I like to hit it with a smoother to get it nice and shiney.. over kill maybe but why not right?

Wood Tool Table Hardwood Household hardware


Now measuring from this face mark your desired final thickness all the way around the board.

Wood Tool Household hardware Varnish Mallet


Brown Wood Rectangle Publication Hardwood


Then this time when you plane a bevel on the front and back side take it all the way down to your line. This will give you a visual indication of when you have it thicknessed correctly without chasing your tail measuring every few strokes.

Smoothing plane Wood Plane Flooring Floor


Brown Wood Rectangle Table Wood stain


Now go about it just as you did flattening the other face keeping an eye on your bevel. You want it to disappear as close to the end of the process as possible so you don't over shoot your mark.

And then you should have a correctly dimensioned board and a happy pile of shavings when you are done!

Smoothing plane Plane Scrub plane Jack plane Rebate plane


Next was to cut out the handle..

Plant Wood Tree Rectangle Font


Plant Wood Tree Font Art


Automotive design Art Font Writing implement Office supplies


Gadget Automotive design Gas Computer hardware Circle


Wood Font Flooring Hardwood Art


Notice how I left the area where the blade enters square(ish)... I have found it is easier to cut the slot when the faces are flat than when they are rounded.

Then we mark half way and cut the kerfs

Wood Gas Rectangle Metal Machine


Wood Wood stain Flooring Floor Stairs


Wood Flooring Hardwood Wood stain Plank


Wood Table Wood stain Flooring Plank


Then I finished the cut with a saw who's kerf closest matched the thickness of the blade.

Saw Wood Hand tool Tool Machine tool


Test..

Wood Gas Flooring Hardwood Wood stain


Finish cutting it out and then we will start on the mortise for the back..

Wood Hand tool Wood stain Tool Gas


Wood Wood stain Flooring Hardwood Art


Wood Hardwood Mallet Wood stain Plywood


I had some help for this part today..

Wood Wood stain Art Hardwood Engineering


Wood Wood stain Plank Varnish Hardwood


Annnnnd it fits!

Hand tool Wood Tool Wood stain Hardwood


Wood String instrument accessory Wrench Tool Hardwood


Now to figure out how to mark the holes in an existing sawplate onto a new handle and we can start shaping this bad boy!

More to come and again thanks for reading!
Some help in the shop is always nice.

What do you use for cutting out the handle (after drilling)? A coping saw? Scroll saw?
 

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