Wooden Return Vents for Air Conditioning

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Blog series by Bertha updated 07-05-2011 01:59 PM 4 parts 15592 reads 50 comments total

Part 1: Choosing a wood and making a plan

06-15-2011 08:19 PM by Bertha | 10 comments »

I need help with a project. A little background; I promise the end will involve me cutting wood:I had right at 4000 square feet of 3/4” figured hard maple installed in my house about six months ago. It took about two months to be delivered, a month to acclimate, and about 2 months for them to install. I also had the stairs and bannister re-done at the same time. At the start of the job, I had enough flush-mount figured maple floor vents made, as well as a number of 3 foot wide or so ...

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Part 2: making a jig for the slat support

07-02-2011 12:17 PM by Bertha | 7 comments »

Once I planed the hickory stock to the thickness of my baseboards, I needed a jig to route angled slat support grooves into the stiles. I’m going to be making several of these, after all. The slats are at 30 degrees. “H” is for Hickory. I sandwiched a piece of MDF b/w plywood with Titebond III and a nailer. The guides and stop are scrap hickory, as are the test pieces below. It’s made for the venerable PC690 with a clear base. I considered making it for t...

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Part 3: Assembly and finishing

07-04-2011 03:33 AM by Bertha | 6 comments »

Out of the clamps and ready for slat installation. I notched both fronts of each slat so that the leading edge meets the face; I just nibbled on the TS, too lazy to make another jig, but I might for the next few. I made them about 1/32 too thick & I’ll knock the width down with a block plane. I want snug, but not tight enough to fracture the supports. Got them all in. Seal coat of 1lb. amber shellac I’ll knock it down with 400 then a couple coats of wipe ...

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Part 4: Done and installed; Four more to go

07-05-2011 01:59 PM by Bertha | 27 comments »

Before and After: Installed. It’s a little dressier than the baseboards but those will eventually be upgraded.

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