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49K views 107 replies 27 participants last post by  BB1 
#1 ·
In the begining


In the beginning chaos reigned.


Yep, that about sums up my "shop". Or to quote my wife: "What a mess"! Easily 50% of my time is spent searching for a tool or hardware I know I have and dancing around everything trying not to knock over wood piles or tools.

I had a decent shop once but after several moves and life changes I've never been able to actually pull together another organized workspace. Now I'm staring at another move in 18 to 24 months and I want to be prepared.

After working with toolboxes, drawers, and now piles on flat shelves I've decide that I hate rummaging around for stuff, opening drawers, staring into bins and move something just to get at the item I want.

I really want to be organized in a way that supports my methods of work too. I would like to see/find/reach/pick/replace in an easy and seamless way that doesn't interrupt my workflow and thought process or result in my leaving things piled up so they fall to the floor in cascades of disaster.

Yes, we all want to be organized - who doesn't want something like H. O. Studley's cabinet, a repository for personal treasures that is a work of art too. In executing this project I expect to at least give a nod to Studley and his craftsmanship.

Brown Wood Wood stain Machine Varnish


So this is a chronicle of my journey to towards order. I hope in the end to have completed a tool cabinet that will carry 90% of my tools (probably overly optimistic - I have a lot), be easy to work from and support my methods of work, and will be fairly easily movable/transportable so I am prepared for our next journey.
 

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#2 ·
Well that didn't take long

Of course not - I've been thinking about this for about 6 months. And like most have done a LOT of internet searches on "Tool Cabinets"; "Toolboxes"; "Tool Chests" (Yes I have the book); "Hanging Tool Cabinets"; "Tool Hanging"; "Tool Storage" and several more permutations. If you think I may have missed one let me know.

There are hundreds of solutions, as many as there are Woodworkers, and so many great ideas. These are a few:

Building Shelving Wood Dollhouse Font


Which got me to ask, what do I really want in a cabinet. Several things it seems:
- I want a place for my hand tools and a place for my power tools (Yes, I use them - sorry if you find that offensive)
- I want to be able to actually see 60% to 70% of my tools
- I want to be able to remove and replace oft used tools without having to dig behind something.
- I want tools to hang securely or be able to be secured easily, I hate things that rattle and bang around.
- I want the cabinet to be mobile so 2 years from now I can roll it onto a moving truck.
- I want it to look good! Maybe not H.O.Studley good but at least showcase some of my experience and technique.

This has led me to a Chest on Chest design with the upper chest for hand tools and the lower with doors and slide out trays for power tools

Cabinetry Furniture Drawer Product Wood


And I think I've decided on a multi-door approach for the upper cabinet

Property Product Building Wood Interior design


I think I'll do some hand sketching
 

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#3 ·
Well that didn't take long

Of course not - I've been thinking about this for about 6 months. And like most have done a LOT of internet searches on "Tool Cabinets"; "Toolboxes"; "Tool Chests" (Yes I have the book); "Hanging Tool Cabinets"; "Tool Hanging"; "Tool Storage" and several more permutations. If you think I may have missed one let me know.

There are hundreds of solutions, as many as there are Woodworkers, and so many great ideas. These are a few:

Building Shelving Wood Dollhouse Font


Which got me to ask, what do I really want in a cabinet. Several things it seems:
- I want a place for my hand tools and a place for my power tools (Yes, I use them - sorry if you find that offensive)
- I want to be able to actually see 60% to 70% of my tools
- I want to be able to remove and replace oft used tools without having to dig behind something.
- I want tools to hang securely or be able to be secured easily, I hate things that rattle and bang around.
- I want the cabinet to be mobile so 2 years from now I can roll it onto a moving truck.
- I want it to look good! Maybe not H.O.Studley good but at least showcase some of my experience and technique.

This has led me to a Chest on Chest design with the upper chest for hand tools and the lower with doors and slide out trays for power tools

Cabinetry Furniture Drawer Product Wood


And I think I've decided on a multi-door approach for the upper cabinet

Property Product Building Wood Interior design


I think I'll do some hand sketching
Bill, first and foremost a heart-felt Good Luck on your upcoming build. Aside from that, the biggest caution (if it could be called that) I can offer concerns size. Having recently completed my 'Not Wall Hung' tool cabinet, I'd suggest it met all of my needs BUT only after extra-deliberate consideration was paid as to what would fit into it AFTER it was completed.

The dimensions of my cabinet were based on the dimensions of material I intended to use in construction vs. a more thoughtful analysis of how things would fit. It ended fine, but I'm suggesting it could have gone better. Especially in deciding the depth of the cabinet overall (for nested doors, block plane cubbies, etc.). Books and illustrations don't really give you a sense of scale that's needed, so take some time and play with dimensional layouts to get a true idea of the space needed for your key tools in context of your intended cabinet design.

Looking forward to a blog series of your build!
 

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#9 ·
Some Initial Sketches

I did a bit of sketching to capture my thoughts - far easier to change lines than recut wood. Here's a start. apologies for the curvature. Apparently my Cell has a 26 or 28 mm fl equivalent lens.

Handwriting Rectangle Font Schematic Parallel


Font Parallel Handwriting Office supplies Pattern


I can also see that my talents as a sketch artist are sadly lacking so I think I'll take a tip from the previous post and start learning SketchUp.
 

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#10 ·
Some Initial Sketches

I did a bit of sketching to capture my thoughts - far easier to change lines than recut wood. Here's a start. apologies for the curvature. Apparently my Cell has a 26 or 28 mm fl equivalent lens.

Handwriting Rectangle Font Schematic Parallel


Font Parallel Handwriting Office supplies Pattern


I can also see that my talents as a sketch artist are sadly lacking so I think I'll take a tip from the previous post and start learning SketchUp.
Your sketches look fine to me - they don't take long and you can try out new ideas quickly. Once you move to CAD find changes come more slowly.
 

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#14 ·
Thoughts in SketchUp

Temps dropped, cold in the shop so refocused to more indoor activities. Friday (November 10th), of course, was the U.S. Marine Corps 242nd Birthday - Semper Fi Brothers past, present, and future, and may we serve 300 more with honor. Did the Vets day thing too on Saturday served breakfast to a host of Korea and Vietnam Vets and some of the few remaining WWII Vets too. I have to say that I met a guy who was on the USN Nautilus. The first nuclear sub and the first to sail under the polar ice cap. As a kid I went to sleep with a book on the Nautilus almost every night - the stuff of dreams. It was nice to be able to shake his hand.

Finally made some headway with SketchUp. The eBook, "SketchUp: A Design Guide for Woodworkers" by Joe Zeh has been an invaluable companion. I do have some CAD experience (though old) so it wasn't brand new and it really is pretty easy to use.

All that said I created an initial model that is generally equivalent to what I would sketch in my project book (but looks way nicer and has more accurate dimensions). I have to say that based on my methods of work and tools I think this is exactly what I want and what I had envisioned.

The Outer doors are my Saw Tills left and right with about 2" of usable depth and 5 sqft of usable surface. They are for light weight tools that need big areas . And, I'm really not much of a sawyer but I'm working on it.

The Mid-doors have 5" of usable depth and about 7 sqft (including the sides). I'm thinking chisels on the lower half of one door and marking tools and screwdrivers above and Files and drill and auger bits on the lower half of the other door then hand braces and mallets on top.

The main cabinet is 8 1/2" deep and about 10 sqft of area. There is, of course, a plane rack for my #6, #5, #4 1/2, #4, #3 and 3 block planes as well as several rounders, rabbet, and shoulder planes.

There will also be a spot for scraper cards, drawknives, spoke shaves, inshaves, hammers, punches, drifts, a few wrenches, pliers, and the miscellany that collect in any shop.

Furniture Chair Table Rectangle Parallel


Table Line Machine Rectangle Technology


I'm hoping it warms up a bit next week so I can start breaking down the plywood.
 

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#15 ·
Thoughts in SketchUp

Temps dropped, cold in the shop so refocused to more indoor activities. Friday (November 10th), of course, was the U.S. Marine Corps 242nd Birthday - Semper Fi Brothers past, present, and future, and may we serve 300 more with honor. Did the Vets day thing too on Saturday served breakfast to a host of Korea and Vietnam Vets and some of the few remaining WWII Vets too. I have to say that I met a guy who was on the USN Nautilus. The first nuclear sub and the first to sail under the polar ice cap. As a kid I went to sleep with a book on the Nautilus almost every night - the stuff of dreams. It was nice to be able to shake his hand.

Finally made some headway with SketchUp. The eBook, "SketchUp: A Design Guide for Woodworkers" by Joe Zeh has been an invaluable companion. I do have some CAD experience (though old) so it wasn't brand new and it really is pretty easy to use.

All that said I created an initial model that is generally equivalent to what I would sketch in my project book (but looks way nicer and has more accurate dimensions). I have to say that based on my methods of work and tools I think this is exactly what I want and what I had envisioned.

The Outer doors are my Saw Tills left and right with about 2" of usable depth and 5 sqft of usable surface. They are for light weight tools that need big areas . And, I'm really not much of a sawyer but I'm working on it.

The Mid-doors have 5" of usable depth and about 7 sqft (including the sides). I'm thinking chisels on the lower half of one door and marking tools and screwdrivers above and Files and drill and auger bits on the lower half of the other door then hand braces and mallets on top.

The main cabinet is 8 1/2" deep and about 10 sqft of area. There is, of course, a plane rack for my #6, #5, #4 1/2, #4, #3 and 3 block planes as well as several rounders, rabbet, and shoulder planes.

There will also be a spot for scraper cards, drawknives, spoke shaves, inshaves, hammers, punches, drifts, a few wrenches, pliers, and the miscellany that collect in any shop.

Furniture Chair Table Rectangle Parallel


Table Line Machine Rectangle Technology


I'm hoping it warms up a bit next week so I can start breaking down the plywood.
I see you are making friends with Sketchup. Nicely done. When you get into a 3D controller you will be really fast.
 

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#18 ·
Lower Cabinet Design - Tool Packing

SktechUp - what a great tool! I can change things much easier, explore design options, and visualize architectures far easier. After a couple false starts a bit of learning on how SketchUp works compared to its big brothers the lower cabinet literally came together.

The lower cabinet is expressly to house most of my power tools - the ones I reach for regularly. The multi-tool and biscuit joiner will stay in their respective cases because they just don't get used much. The rest will have a sweet new home.

Getting the drawers right is always a challenge for me and this was no different. Originally it was 3 equally spaced pull out trays behind each door. Locating and dropping in similar tools from the SketchUp Warehouse (Thanks to all the makers and creators out there) showed me that I had a lot of "crashes" where tools just wouldn't fit. Because of groups and components moving things around was very easy and in about 30 minutes I had it down.

The result is a 24"D x 33"H x 42"W case with a face frame on 3 1/2" casters. With two drawers over two doors and 6 full extension pullout trays give me just over 20sqft of storage space. I'm thinking I can probably squeeze a couple more feet out of it too.

Table Output device Rectangle Technology Diagram


Next will be to layout my actual power tools on cardboard and see if the theory of the design will work in practice.
 

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#19 ·
Lower Cabinet Design - Tool Packing

SktechUp - what a great tool! I can change things much easier, explore design options, and visualize architectures far easier. After a couple false starts a bit of learning on how SketchUp works compared to its big brothers the lower cabinet literally came together.

The lower cabinet is expressly to house most of my power tools - the ones I reach for regularly. The multi-tool and biscuit joiner will stay in their respective cases because they just don't get used much. The rest will have a sweet new home.

Getting the drawers right is always a challenge for me and this was no different. Originally it was 3 equally spaced pull out trays behind each door. Locating and dropping in similar tools from the SketchUp Warehouse (Thanks to all the makers and creators out there) showed me that I had a lot of "crashes" where tools just wouldn't fit. Because of groups and components moving things around was very easy and in about 30 minutes I had it down.

The result is a 24"D x 33"H x 42"W case with a face frame on 3 1/2" casters. With two drawers over two doors and 6 full extension pullout trays give me just over 20sqft of storage space. I'm thinking I can probably squeeze a couple more feet out of it too.

Table Output device Rectangle Technology Diagram


Next will be to layout my actual power tools on cardboard and see if the theory of the design will work in practice.
Cabinet doors above table hight is fine but having them below table hight in addition to drawers behind them is questionable. It is just one more unnecessary layer to open between you and the tool you need. 2 cents.

Look how far you have come along with Sketchup!
 

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#24 ·
Lower Case Assembly

Ok - It's been awhile since I had the chance to work on my Tool Cabinet. Last November to be exact. But, the project is underway once again. Getting back into any long shelved project is always a challenge, time passes, things are forgotten, pieces are mislaid, and parts are used for other purposes. No different on this project but after a week of excavating, rooting, and cleaning I managed to identify and collect all of the critical parts and pieces.

As I stood staring at the pile of lumber wondering what went where and what specific joints did I intend to use I realized two things. First is that I actually labeled the parts!! (Wahoo!!!) And not with my usual cryptic RHLCDF (Right Hand Lower Center Divider Front) but with plain English Yipee! And two, I had a pretty good Sketchup Model too. Not totally complete but a really good start.

After about an hour I got the entire lower cabinet dry assembled and it went together like a charm.

Wood Shelving Water bottle Floor Hardwood


I went back to the drawings and decided to modify the drawer spacing a bit then disassembled everything.

Wood Floor Hardwood Engineering Shelving


Final assembly of the carcass complete including installation of the drawer slides.

And installation of 4" double locking casters.

Wood Handheld power drill Gas Hardwood Table


Next up is the Drawers.

Table Wood Flooring Workbench Hardwood


Wood Table Hardwood Plank Gas
 

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#25 ·
Other Projects - Outfeed Cart

Life isn't linear. Nothing, at least in my life, follows a straight line or well-marked path. On the way to working on the Tool cabinet several other projects happened. I'll start with the Outfeed Cart.

I've had all of my sanding supplies just stuffed in a box - actually three boxes and I've long wanted a place for everything so I can find it, get it, and store it. Because of my situation I need a couple of features 1) it had to be mobile. 2) it has two slip under my Table Saw wing and 3) it needed some kind of easily adjustable outfeed support.

I've made a lot of general casework so I didn't really bother with a drawing. I started the stack with the 3" double locking casters and knew I wanted a 2Ă—4 top the basically filled in the gap to make the end result 31". Then for it to fit where I needed it to I made it 22" and 24" deep.

Wood Natural material Rectangle Wood stain Varnish


Four Drawers with full extension slides and the drawer fronts are some Costa Rican plywood that's been laying around forever. No idea what it is but it look pretty!!

Wood Rectangle Plank Varnish Wood stain


The supports are based on a Woodsmith Magazine design with several mods. The "Rollers" aren't. They are fixed Sched40 pipe which is plenty slick for the wood to slide.

Furniture Table Wood Outdoor table Wood stain


Overall it turned out pretty well.

Oh - here's a link to the Woodsmith Plans. Not really the cart I built but I took the outfeed supports from it. https://www.woodsmithplans.com/plan/roll-around-shop-cart/
 

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#26 ·
Other Projects - Outfeed Cart

Life isn't linear. Nothing, at least in my life, follows a straight line or well-marked path. On the way to working on the Tool cabinet several other projects happened. I'll start with the Outfeed Cart.

I've had all of my sanding supplies just stuffed in a box - actually three boxes and I've long wanted a place for everything so I can find it, get it, and store it. Because of my situation I need a couple of features 1) it had to be mobile. 2) it has two slip under my Table Saw wing and 3) it needed some kind of easily adjustable outfeed support.

I've made a lot of general casework so I didn't really bother with a drawing. I started the stack with the 3" double locking casters and knew I wanted a 2Ă—4 top the basically filled in the gap to make the end result 31". Then for it to fit where I needed it to I made it 22" and 24" deep.

Wood Natural material Rectangle Wood stain Varnish


Four Drawers with full extension slides and the drawer fronts are some Costa Rican plywood that's been laying around forever. No idea what it is but it look pretty!!

Wood Rectangle Plank Varnish Wood stain


The supports are based on a Woodsmith Magazine design with several mods. The "Rollers" aren't. They are fixed Sched40 pipe which is plenty slick for the wood to slide.

Furniture Table Wood Outdoor table Wood stain


Overall it turned out pretty well.

Oh - here's a link to the Woodsmith Plans. Not really the cart I built but I took the outfeed supports from it. https://www.woodsmithplans.com/plan/roll-around-shop-cart/
Sweet set-up. Too pretty for my shop. The "rollers" are a nice extra too.
 

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#28 ·
Other projects - Lathe cart

So along the way I built a Lathe cart. My lathe isn't big so I had it sitting on a garage sale table without casters so it was always where ai didn't want or need it. In keeping with building things with leftover and scrap wood I created it in two parts an upper and a lower. Never to be separated - I just didn't have any big pieces. I made the top long enough to accommodate a small grinder and when it is not in use I can hang the grinder on the end.

Table Cabinetry Wood Desk Shelving


The cart has two full with drawers faced with leftover Ecaudoran plywood and stainless steel hands in keeping with the Sand cart I finish up earlier.

Table Wood Workbench Reflex camera Machine


In addition to the drawers I put in a pencil till to make pencil and paper easy to find

Wood Musical instrument Musical instrument accessory Hardwood Wood stain


The bottom I left open to allow for wood storage.

Wood Table Workbench Cabinetry Machine tool


So far it is working out great - though I need to get in a bit more time on actual turning.
 

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#29 ·
Other projects - Evolution of a Shop Vac cart

And… I built a Dust Deputy based Shop Vac Cart. Like everyone I started with 1, 2, 3 Shop vacs. And like everyone I found they were great for general vacuuming but filled/clogged fast. I just HATED emptying these and knocking out the filter because invariable dust ended up everywhere. So reading through lots posts and articles (and being cheap) I tried the PVC pipe and bucket idea. It worked pretty well for big stuff but the fine dust still clogged the filter and frankly it was a pain to use - especially to empty.

Ingredient Fluid Gas Cup Drinkware


So - again more reading an ended up with a mini Dust Deputy ($150) stuck on a 5 gal pail ($3). The Dust Deputy definitely separated out way more of the fine dust. But it was still a pain to drag around and especially to empty. Disconnecting and then peeling the lid off was almost as much of a chore as popping the lid on the Vac.

Paint Drink Gas Cylinder Plastic


Looking for a better way I found several on Youtube but almost all invariably suffered from the same "Peel the top off the 5 gal bucket" issue. Then I stumbled on Check it out. Great idea.

My cart generally follows his design concept using Âľ" Plywood for all the components. The trick to the design is using the toggle clamps which lift the table the bucket sits on then compressing the seal at the top of the bucket. Slick design - just pop the toggles and slide out the bucket.

Wood Automotive tire Engineering Gas Machine


Adding my own modifications I built the system and … it sucked. Mostly because the 5 gal pail was just too small. When I'm actually working I make far too much dust and chips and over run the pail in a very short time. Oh, and the pail would collapse if anything clogged the pick-up nozzle. That led me to swap the 5 Gal pail for an Eagle 14 gallon drum ($34 and free shipping).

Here are some pic of the design details:
Automotive tire Gas Synthetic rubber Engineering Automotive exterior


Automotive tire Gas Cylinder Automotive wheel system Art


Gas Helmet Cable Personal protective equipment Electrical supply


Blue Automotive tire Cylinder Gas Tire


Automotive tire Wood Gas Shelf Wheel


Hood Gas Engineering Composite material Automotive tire


Automotive tire Plastic bottle Drinkware Gas Bottle
 

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#30 ·
Other projects - Evolution of a Shop Vac cart

And… I built a Dust Deputy based Shop Vac Cart. Like everyone I started with 1, 2, 3 Shop vacs. And like everyone I found they were great for general vacuuming but filled/clogged fast. I just HATED emptying these and knocking out the filter because invariable dust ended up everywhere. So reading through lots posts and articles (and being cheap) I tried the PVC pipe and bucket idea. It worked pretty well for big stuff but the fine dust still clogged the filter and frankly it was a pain to use - especially to empty.

Ingredient Fluid Gas Cup Drinkware


So - again more reading an ended up with a mini Dust Deputy ($150) stuck on a 5 gal pail ($3). The Dust Deputy definitely separated out way more of the fine dust. But it was still a pain to drag around and especially to empty. Disconnecting and then peeling the lid off was almost as much of a chore as popping the lid on the Vac.

Paint Drink Gas Cylinder Plastic


Looking for a better way I found several on Youtube but almost all invariably suffered from the same "Peel the top off the 5 gal bucket" issue. Then I stumbled on Check it out. Great idea.

My cart generally follows his design concept using Âľ" Plywood for all the components. The trick to the design is using the toggle clamps which lift the table the bucket sits on then compressing the seal at the top of the bucket. Slick design - just pop the toggles and slide out the bucket.

Wood Automotive tire Engineering Gas Machine


Adding my own modifications I built the system and … it sucked. Mostly because the 5 gal pail was just too small. When I'm actually working I make far too much dust and chips and over run the pail in a very short time. Oh, and the pail would collapse if anything clogged the pick-up nozzle. That led me to swap the 5 Gal pail for an Eagle 14 gallon drum ($34 and free shipping).

Here are some pic of the design details:
Automotive tire Gas Synthetic rubber Engineering Automotive exterior


Automotive tire Gas Cylinder Automotive wheel system Art


Gas Helmet Cable Personal protective equipment Electrical supply


Blue Automotive tire Cylinder Gas Tire


Automotive tire Wood Gas Shelf Wheel


Hood Gas Engineering Composite material Automotive tire


Automotive tire Plastic bottle Drinkware Gas Bottle
While I have a Laguna CFlux 1.5, the shop vac gets used A LOT. This is some serious food for thought on improving the shop vac performance. Interesting idea to set up a shop vac like a 2 stage DC. I'm not a big fan of having to empty the Shop Vac filter any more often than I have to. The worst part of the process is all of the fine dust on the filter. Plus, reusable filters, even though they last longer, are still not cheap.
 

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#33 ·
Marking Tool Swap Fall 2018

Still not focusing on the Tool Cabinet, I joined the LJ Fall Swap. My first one and let me tell you the guys in the swap are expert. Knowing the everyone has most of the standard marking tools I looked around the shop and my eyes landed on a set of pinch sticks.

Wood Table Wood stain Rectangle Plank


Just poplar stained with Dychem (for metalworking) and coated with Wattco. The sliders are just 3/4" square steel tube drilled and tapped. But a great starting point because I figured that most people don't have/use them so it might be a good/useful tool.

My first design change was that I didn't like how the thumb screw dug into the wood. One solution would have been a pad and another would have been an inlay of metal. Following that thought I decided to use an aluminum sandwich. I epoxied Purpleheart and Aluminum together then trimmed/cut them on the table saw.

Bumper Automotive lighting Automotive exterior Motor vehicle Vehicle door


That created a lot of heat which the epoxy didn't like so the laminate failed. I finally figured out that I needed to wait 3 minutes between passes for the Aluminum to cool. I eventually got it right but … it burned the Purpleheart. I put my scraper to work pealing away burn marks, wood, and Aluminum.

Table Crosscut saw Wood Tableware Wood stain


Then sanded with 220, 320, and 600. I have to say the wagon vise was perfect for this kind of work. Add on 4 coats of Wattco, some wax and buffing and the sticks were done.

Wood Wood stain Bumper Automotive exterior Hardwood


Next were the keepers. Square steel tube didn't seem to be keeping with the spirit of the Swap and while not a competition I preferred to give some of my "best work". Again looking around the shop I have a bunch of small scraps that I just can't bear to toss.

Wood Table Automotive design Flooring Engineering


Casting about in the scrap bin netted me Pink Ivory and Gaboon Ebony pieces and I pulled several brass plates that were originally slated for a dovetail plane (maybe later).

Wood Creative arts Flooring Art Hardwood


Some drilling

Automotive tire Milling Wood Machine tool Saw


Then cutting, trimming, filing,

Wood Metalworking hand tool Drill Tool Screwdriver


I decided that I REALLY hate those little brass screws. Ebony and Pink Ivory are really hard and I broke off multiple screws and had to re-fabricate parts several times.

Eventually I got to the sanding up through 3000grit then polishing and buffing,

Wood Hardwood Trophy Varnish Wood stain


And finally assembly - yippee!!

Musical instrument Wood Folk instrument Tool Flute


Wood Musical instrument Wood stain Hardwood Varnish


Overall they turned out pretty well. And thanks to the LJ'ers that encouraged me on my first attempt.
 

Attachments

#34 ·
Marking Tool Swap Fall 2018

Still not focusing on the Tool Cabinet, I joined the LJ Fall Swap. My first one and let me tell you the guys in the swap are expert. Knowing the everyone has most of the standard marking tools I looked around the shop and my eyes landed on a set of pinch sticks.

Wood Table Wood stain Rectangle Plank


Just poplar stained with Dychem (for metalworking) and coated with Wattco. The sliders are just 3/4" square steel tube drilled and tapped. But a great starting point because I figured that most people don't have/use them so it might be a good/useful tool.

My first design change was that I didn't like how the thumb screw dug into the wood. One solution would have been a pad and another would have been an inlay of metal. Following that thought I decided to use an aluminum sandwich. I epoxied Purpleheart and Aluminum together then trimmed/cut them on the table saw.

Bumper Automotive lighting Automotive exterior Motor vehicle Vehicle door


That created a lot of heat which the epoxy didn't like so the laminate failed. I finally figured out that I needed to wait 3 minutes between passes for the Aluminum to cool. I eventually got it right but … it burned the Purpleheart. I put my scraper to work pealing away burn marks, wood, and Aluminum.

Table Crosscut saw Wood Tableware Wood stain


Then sanded with 220, 320, and 600. I have to say the wagon vise was perfect for this kind of work. Add on 4 coats of Wattco, some wax and buffing and the sticks were done.

Wood Wood stain Bumper Automotive exterior Hardwood


Next were the keepers. Square steel tube didn't seem to be keeping with the spirit of the Swap and while not a competition I preferred to give some of my "best work". Again looking around the shop I have a bunch of small scraps that I just can't bear to toss.

Wood Table Automotive design Flooring Engineering


Casting about in the scrap bin netted me Pink Ivory and Gaboon Ebony pieces and I pulled several brass plates that were originally slated for a dovetail plane (maybe later).

Wood Creative arts Flooring Art Hardwood


Some drilling

Automotive tire Milling Wood Machine tool Saw


Then cutting, trimming, filing,

Wood Metalworking hand tool Drill Tool Screwdriver


I decided that I REALLY hate those little brass screws. Ebony and Pink Ivory are really hard and I broke off multiple screws and had to re-fabricate parts several times.

Eventually I got to the sanding up through 3000grit then polishing and buffing,

Wood Hardwood Trophy Varnish Wood stain


And finally assembly - yippee!!

Musical instrument Wood Folk instrument Tool Flute


Wood Musical instrument Wood stain Hardwood Varnish


Overall they turned out pretty well. And thanks to the LJ'ers that encouraged me on my first attempt.
Those little brass screws really are a pain. I always test drill pilot holes in a scrap of the same wood and then test them. I usually end up with holes that are ever so slightly over size, then put CA and sawdust into the hole, and screw in the screw before the CA sets.

Then when I realize I put the part on backwards, I get to refabricate the whole thing, rather than just part of it!

Great job, Bill!
 

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#43 ·
A home for my Stanley 45 Irons

When we last saw our hero… (oops wrong story). Well still no substantive progress on the tool cabinet - waylaid by surgery/recovery and weather. Unheated garage is not conducive to cutting/fitting/gluing/finishing at 10F. I do need to get busy soon 'cuz the house is going up for sale in a couple more weeks and packing has already started. But that is a another story.

I have managed a few smaller projects over the past month or so on warmer days and with the heater going and here is one. I have a Stanley 45 that I have brought back from the edge and it came with most of the cutters.



Long have I wanted to create a "safe space" for the irons. To that end I had acquired some Aspen and it's been sitting around aging.



I got started and completed the project in a day including printing the labels. By the way, I owe quite a bit to the Stanley #45 - 7 forms of fun in 1! Forum, Plane Restorations #1: Stanley No. 45 Boxes Reproduction Graphics Blog, and several other LJ'er that have restored 45s.

Rough box dimensions were determined by laying out the irons with a playing card width between the measuring. And over to the RAS to make the sticks



Fine tuning the dimensions by laying out the irons



Then gluing



I cut the tops from the bottoms and then laid out and cut the "window". A coat of wipe on poly then printed and glued the labels on.



These turned out better than I hope for. They look great and serve to protect the irons well.



I def owe those that preceded me in restoration a debt of gratitude. I would not have executed this project - small as it is - without them.
 

Attachments

#44 ·
Split nut screwdriver

Lots of projects as every other LJ'er but this Split nut screwdriver is (in my mind) a good looking success.

Air gun Wood Gun accessory Metal Gun barrel


Like every project I do there is always something else I need before I get started on the main event. The Split nut Screwdrivers started because 1) so many LJ'ers have made so many really cool saws and 2) I have a couple of old back saw plates and 3) I REALLY needed a project for the LJ Spring Swap… :)

Wood Wood stain Gas Hardwood Plywood


Casting about LJ and the net I came up wiith several ideas landing on modifying a spade bit.

Wood Machine Home appliance Metal Flooring


A bit of judicious filing with a Chain saw file created the gap.

Wood Gas Auto part Plywood Bumper


Hand Wood Hand tool Gesture Finger


A bit of grinding and polishing

Wood Circuit component Gas Wood stain Hardwood


and the blade was complete. Then on to the handles. My first try was Amazouke but it had a hidden defect that caused it to fail while turning.

Motor vehicle Wood Gas Auto part Engineering


Failing that I had a piece of "found" cherry from the firewood pile.

Wood Wood stain Bumper Automotive exterior Kitchen utensil


Some cutting, squaring, turning

Wood Gas Machine tool Engineering Machine


A a copper ferrule, a little assembling with epoxy, and some wipe-on poly

Wood Gas Font Tool Temperature


Wood Tool Metalworking hand tool Metal Electric blue


I made the second one in Osage Orange to match the additional accessories for the Swap
Wood Tool Hand tool Metalworking hand tool Metal


It's a great project but I think it might be a bit better if the overall blade length was about 1/2" to 3/4" shorter to put my hand a bit closer to the nut.
 

Attachments

#45 ·
Split nut screwdriver

Lots of projects as every other LJ'er but this Split nut screwdriver is (in my mind) a good looking success.

Air gun Wood Gun accessory Metal Gun barrel


Like every project I do there is always something else I need before I get started on the main event. The Split nut Screwdrivers started because 1) so many LJ'ers have made so many really cool saws and 2) I have a couple of old back saw plates and 3) I REALLY needed a project for the LJ Spring Swap… :)

Wood Wood stain Gas Hardwood Plywood


Casting about LJ and the net I came up wiith several ideas landing on modifying a spade bit.

Wood Machine Home appliance Metal Flooring


A bit of judicious filing with a Chain saw file created the gap.

Wood Gas Auto part Plywood Bumper


Hand Wood Hand tool Gesture Finger


A bit of grinding and polishing

Wood Circuit component Gas Wood stain Hardwood


and the blade was complete. Then on to the handles. My first try was Amazouke but it had a hidden defect that caused it to fail while turning.

Motor vehicle Wood Gas Auto part Engineering


Failing that I had a piece of "found" cherry from the firewood pile.

Wood Wood stain Bumper Automotive exterior Kitchen utensil


Some cutting, squaring, turning

Wood Gas Machine tool Engineering Machine


A a copper ferrule, a little assembling with epoxy, and some wipe-on poly

Wood Gas Font Tool Temperature


Wood Tool Metalworking hand tool Metal Electric blue


I made the second one in Osage Orange to match the additional accessories for the Swap
Wood Tool Hand tool Metalworking hand tool Metal


It's a great project but I think it might be a bit better if the overall blade length was about 1/2" to 3/4" shorter to put my hand a bit closer to the nut.
It seems to work ok to me. Good thinking using a spade bit!
 

Attachments

#48 ·
Saw jointer handle

Knocked out a second small project for the Swap to go with the Split Nut Screwdriver, a Saw Jointer Handle.

Wood Ruler Office ruler Wood stain Hardwood


Generally the antique Stanley's are in steel. This one is Osage Orange starting with a 1.5" x 1.5" x 12" chunk I cut squared and scraped a blank.

Wood Tool Gas Metalworking hand tool Hardwood


Wood Wood stain Rectangle Door Plank


Then it was a matter of cutting a relief file and clearence for the saw. Then I installed a brass insert (I'd go steel next time).

Wood Tableware Wood stain Flooring Serveware


Some sanding and some poly

Hand tool Wood Tool Hardwood Office ruler


A small brass thumb screw secures the file in place during use.

Wood Stonemason's hammer Wood stain Hardwood Plank


Looking back on it I think it would benefit aesthetically from some shaping. Another LJ'er boat tailed a plane in the manner of a 1935 Auburn (https://www.lumberjocks.com/projects/408989) It's pretty cool so maybe at some point I'll work at reshaping it.
 

Attachments

#49 ·
Saw jointer handle

Knocked out a second small project for the Swap to go with the Split Nut Screwdriver, a Saw Jointer Handle.



Generally the antique Stanley's are in steel. This one is Osage Orange starting with a 1.5" x 1.5" x 12" chunk I cut squared and scraped a blank.





Then it was a matter of cutting a relief file and clearence for the saw. Then I installed a brass insert (I'd go steel next time).



Some sanding and some poly



A small brass thumb screw secures the file in place during use.



Looking back on it I think it would benefit aesthetically from some shaping. Another LJ'er boat tailed a plane in the manner of a 1935 Auburn (https://www.lumberjocks.com/projects/408989) It's pretty cool so maybe at some point I'll work at reshaping it.
Hey, I know the guy who did that! Turned out ok, I hear. I would suggest sacrificing a tubafor or two to make test shapes. When I realized I'd cut my prototype plane too short, the pressure was really on for shaping the real one. No mistakes!

Thanks for the file holder. I think the brass is fine, but steel might look nice against the Osage orange.
 

Attachments

#51 ·
Stanley #45 Chest

Like many LJ'ers I've felt the tug of vintage hand tools. I discovered and acquired a Stanley #45 almost complete for a very reasonable price and got it mostly cleaned and sharpened and it's been laid out on a side bench. Finally found time to make a chest.

Table Wood Rectangle Hardwood Wood stain


I wanted to make a chest similar to the original ones with finger joints. So to get started I made a simple box joint jig.

Rectangle Wood Flooring Floor Wood stain


Then I thicknessed Red Oak stock to 1/2" for the sides/ends/top and I also thicknessed a piece of pine to 1/4" for the bottom. Dimensions were set by the #45 with short rods installed and the two Iron boxes I made several months ago. The result is exterior dimensions of: 12-3/4" (L) x 7-3/4" (W) x 7-1/4" (H).

Then some cutting and making finger joints. There were a couple of minor blowouts, most of which ended up inside

Wood Grey Rectangle Flooring Gas


Wood Wood stain Flooring Hardwood Plank


No, I did not hand cut the groove for the bottom using the #45. The dado blade was in so I spent 45 seconds and zipped the parts through. And then assembly. The joints turned out nice and tight.

Brown Wood Rectangle Flooring Wood stain


The top is a slab of 1/2" Oak. It was actually pieced together and as one piece of Oak was slightly short so a bit of Maple filled the gap

Rectangle Wood Flooring Floor Wood stain


The interior is nothing more than a several 5/16" battens that keep the #45 and boxes in place.

Wood Wood stain Hardwood Plank Plywood


Product Wood Rectangle Floor Varnish


Wood Table Flooring Rectangle Floor


Wood Hardwood Metal Machine Auto part


Wood Floor Flooring Wall Hardwood


The finish off is a swing latch from Woodcraft.

Door Household hardware Wood Nickel Bicycle part


It's finished with a single coat of satin poly and Johnson's Paste Wax. I still need to install a holder/retainer for the long rods - but those were boxed and in storage for a while. I'm pretty pleased with the result and my #45 is happy ;-)
 

Attachments

#52 ·
Stanley #45 Chest

Like many LJ'ers I've felt the tug of vintage hand tools. I discovered and acquired a Stanley #45 almost complete for a very reasonable price and got it mostly cleaned and sharpened and it's been laid out on a side bench. Finally found time to make a chest.

Table Wood Rectangle Hardwood Wood stain


I wanted to make a chest similar to the original ones with finger joints. So to get started I made a simple box joint jig.

Rectangle Wood Flooring Floor Wood stain


Then I thicknessed Red Oak stock to 1/2" for the sides/ends/top and I also thicknessed a piece of pine to 1/4" for the bottom. Dimensions were set by the #45 with short rods installed and the two Iron boxes I made several months ago. The result is exterior dimensions of: 12-3/4" (L) x 7-3/4" (W) x 7-1/4" (H).

Then some cutting and making finger joints. There were a couple of minor blowouts, most of which ended up inside

Wood Grey Rectangle Flooring Gas


Wood Wood stain Flooring Hardwood Plank


No, I did not hand cut the groove for the bottom using the #45. The dado blade was in so I spent 45 seconds and zipped the parts through. And then assembly. The joints turned out nice and tight.

Brown Wood Rectangle Flooring Wood stain


The top is a slab of 1/2" Oak. It was actually pieced together and as one piece of Oak was slightly short so a bit of Maple filled the gap

Rectangle Wood Flooring Floor Wood stain


The interior is nothing more than a several 5/16" battens that keep the #45 and boxes in place.

Wood Wood stain Hardwood Plank Plywood


Product Wood Rectangle Floor Varnish


Wood Table Flooring Rectangle Floor


Wood Hardwood Metal Machine Auto part


Wood Floor Flooring Wall Hardwood


The finish off is a swing latch from Woodcraft.

Door Household hardware Wood Nickel Bicycle part


It's finished with a single coat of satin poly and Johnson's Paste Wax. I still need to install a holder/retainer for the long rods - but those were boxed and in storage for a while. I'm pretty pleased with the result and my #45 is happy ;-)
I like projects like this. Well done.
 

Attachments

#57 ·
Jennings Style Auger Bit Box

The lure of vintage hand tools is like no other. Mostly be because they are small, storeable, transportable, are still useful and functional and as well as affordable. I've had a fist full of Irwin and Russell Jennings bits homeless stacked in a drawer. With the new Box Joint Jig and the fact that I was already setting up for the #45 chest I decided that I wanted a Russell Jennings style chest to secure them.

Rectangle Wood Wood stain Flooring Hardwood


Thanks to several of the LJ'ers on the Vintage Drills of Your Dreams thread I got the general dimensions. These translated into: 10-1/2" (L) x 4-1/2" (H) x 3-1/2" (D)

Wood Flooring Floor Hardwood Wood stain


Wood Rectangle Flooring Wood stain Hardwood


Once the box was assembled I separated int into the three sections I installed 1/4" bottoms. The rest was just hinges and latches.

Wood Rectangle Hardwood Wood stain Plank


I looked for vintage/replica hinges and latches but none to be found. I had to kluge a couple kinds and offset to get them to work. So not as slick as the original. If I find new hinges I'll replace them.

Wood Table Rectangle Wooden block Wood stain


The top is a 1/2" slab pf Red Oak

Wood Rectangle Hardwood Wood stain Flooring


THe dividers are not yet installed - I have a lot of duplicate bits especially #5s and #7s. I still need 4,6, and 11 to complete the set. Once I have those I'll fit dividers.

Wood Rectangle Wood stain Hardwood Flooring


The two hole are just because it was a piece of scrap pine

Wood Tool Gas Wood stain Musical instrument


The latches are from Woodcraft

Musical instrument Wood Office equipment Metal Hardwood


Wood Musical instrument Jewellery Rim Auto part


Over alll this turned out pretty good - only changes I would make is to add 1/4" to the height and length, and 3/4" to the depth. It's a bit tight on the top tier for the dividers.

Wood Wood stain Plank Hardwood Flooring
 

Attachments

#58 ·
Jennings Style Auger Bit Box

The lure of vintage hand tools is like no other. Mostly be because they are small, storeable, transportable, are still useful and functional and as well as affordable. I've had a fist full of Irwin and Russell Jennings bits homeless stacked in a drawer. With the new Box Joint Jig and the fact that I was already setting up for the #45 chest I decided that I wanted a Russell Jennings style chest to secure them.

Rectangle Wood Wood stain Flooring Hardwood


Thanks to several of the LJ'ers on the Vintage Drills of Your Dreams thread I got the general dimensions. These translated into: 10-1/2" (L) x 4-1/2" (H) x 3-1/2" (D)

Wood Flooring Floor Hardwood Wood stain


Wood Rectangle Flooring Wood stain Hardwood


Once the box was assembled I separated int into the three sections I installed 1/4" bottoms. The rest was just hinges and latches.

Wood Rectangle Hardwood Wood stain Plank


I looked for vintage/replica hinges and latches but none to be found. I had to kluge a couple kinds and offset to get them to work. So not as slick as the original. If I find new hinges I'll replace them.

Wood Table Rectangle Wooden block Wood stain


The top is a 1/2" slab pf Red Oak

Wood Rectangle Hardwood Wood stain Flooring


THe dividers are not yet installed - I have a lot of duplicate bits especially #5s and #7s. I still need 4,6, and 11 to complete the set. Once I have those I'll fit dividers.

Wood Rectangle Wood stain Hardwood Flooring


The two hole are just because it was a piece of scrap pine

Wood Tool Gas Wood stain Musical instrument


The latches are from Woodcraft

Musical instrument Wood Office equipment Metal Hardwood


Wood Musical instrument Jewellery Rim Auto part


Over alll this turned out pretty good - only changes I would make is to add 1/4" to the height and length, and 3/4" to the depth. It's a bit tight on the top tier for the dividers.

Wood Wood stain Plank Hardwood Flooring
Nice, Bill.

I have a lot of duplicate bits especially #5s and #7s. I still need 4,6, and 11 to complete the set. Once I have those I'll fit dividers.
I'll check through my bits in the morning. I may have a spare or two that'll help you fill things in. We'll see.
 

Attachments

#61 ·
Drill Press Table

I've been needing a Drill Press Table for quite a while and finally got one built. This is not one of those huge "do everything" tables. It's 14" deep by 22" wide - mostly made from scrap - which is the reason for the size. I selected/included features that support my methods of work and 90% of the project types I do.

Wood Flooring Hardwood Gas Wood stain


Nothing fancy here, just a couple (2) layers of 3/4" plywood screwed together. I had to clip the tips of the 1-1/2" screws so they wouldn't poke through.

Wood Shelving Computer monitor Hardwood Engineering


The table is held to the cast iron table with 5/16" carriage bolts countersunk in to the bottom piece with wing nuts to hold it down.

Wood Gas Machine Engineering Ceiling


The table itself has two Rockler T-Tracks dropped into dados made on my table saw using Freud Super Dado set. That Dado Set is really GREAT!! The fit was precise and installation easy.

Wood Camera accessory Cameras & optics Gas Tripod


The edge is trimmed with a few strips of poplar leftover from a library project and have bee sitting around for a long time. The edge does cover the T-Track but the back is open so the T-Bolts can be removed.

Wood Wood stain Hardwood Workbench Composite material


The fence is again scrap plywood and poplar. The T-Bolts are actually 1/4-20 hex bolt from the junk drawer and I started with wingnuts but swapped over to 1" knobs I picked up in Atlanta at Peachtree woodworking for $1 each. One if the bolts is capture in a 5/16" hole and the other is in a 5/16" x 2-1/2" slot.

Table Wood Desk Flooring Machine


A lot of the DP Table fences I've seen have a cut out for the chuck. I decided to just allow the fence to be flipped around to accommodate close-in short, small work.

Wood Table Workbench Flooring Gas


I wanted a place to set my coffee so on the left side I extended the bottom piece of plywood to create a cup holder/shelf.

Tableware Drinkware Cup Wood Serveware


Because the table is not really big enough to accommodate a couple of those super cool drawers that some have I decided to put in a swing out box for taps, drills, and miscellaneous stuff.

Wood Automotive design Bumper Automotive exterior Gas


The box is 5" x 6" x 2-1/2" deep with a small tray a about 1/2" deep

Wood Tool Paint Drawer Art


The table size and position allow clearance for both the column release handle

Bicycle frame Bicycle tire Automotive tire Bicycle fork Tire


and table elevation crank.

Wood Machine tool Workbench Hardwood Wood stain


Oh it does have a 3" Square replaceable center and before I set it in place I waxed the cast iron.

Overall I'm really happy with t utility of the table and the features and how it supports my methods of work.

Line Wood Gas Space Electric blue


Happy Woodworking in 2020!
 

Attachments

#62 ·
Drill Press Table

I've been needing a Drill Press Table for quite a while and finally got one built. This is not one of those huge "do everything" tables. It's 14" deep by 22" wide - mostly made from scrap - which is the reason for the size. I selected/included features that support my methods of work and 90% of the project types I do.

Wood Flooring Hardwood Gas Wood stain


Nothing fancy here, just a couple (2) layers of 3/4" plywood screwed together. I had to clip the tips of the 1-1/2" screws so they wouldn't poke through.

Wood Shelving Computer monitor Hardwood Engineering


The table is held to the cast iron table with 5/16" carriage bolts countersunk in to the bottom piece with wing nuts to hold it down.

Wood Gas Machine Engineering Ceiling


The table itself has two Rockler T-Tracks dropped into dados made on my table saw using Freud Super Dado set. That Dado Set is really GREAT!! The fit was precise and installation easy.

Wood Camera accessory Cameras & optics Gas Tripod


The edge is trimmed with a few strips of poplar leftover from a library project and have bee sitting around for a long time. The edge does cover the T-Track but the back is open so the T-Bolts can be removed.

Wood Wood stain Hardwood Workbench Composite material


The fence is again scrap plywood and poplar. The T-Bolts are actually 1/4-20 hex bolt from the junk drawer and I started with wingnuts but swapped over to 1" knobs I picked up in Atlanta at Peachtree woodworking for $1 each. One if the bolts is capture in a 5/16" hole and the other is in a 5/16" x 2-1/2" slot.

Table Wood Desk Flooring Machine


A lot of the DP Table fences I've seen have a cut out for the chuck. I decided to just allow the fence to be flipped around to accommodate close-in short, small work.

Wood Table Workbench Flooring Gas


I wanted a place to set my coffee so on the left side I extended the bottom piece of plywood to create a cup holder/shelf.

Tableware Drinkware Cup Wood Serveware


Because the table is not really big enough to accommodate a couple of those super cool drawers that some have I decided to put in a swing out box for taps, drills, and miscellaneous stuff.

Wood Automotive design Bumper Automotive exterior Gas


The box is 5" x 6" x 2-1/2" deep with a small tray a about 1/2" deep

Wood Tool Paint Drawer Art


The table size and position allow clearance for both the column release handle

Bicycle frame Bicycle tire Automotive tire Bicycle fork Tire


and table elevation crank.

Wood Machine tool Workbench Hardwood Wood stain


Oh it does have a 3" Square replaceable center and before I set it in place I waxed the cast iron.

Overall I'm really happy with t utility of the table and the features and how it supports my methods of work.

Line Wood Gas Space Electric blue


Happy Woodworking in 2020!
Nice job there. A drill press table is the first project on my to do list after I finish restoring my hand planes. It's been long over due.
 

Attachments

#68 ·
Gents Saw Upgrade

After seeing the Youtube video on this I really wanted to try it out myself. So I started with a Two Cherries Gents Saw that's been laying around collecting dust.

Rectangle Font Fashion accessory Metal Titanium


I pulled the handle - and reused it as a file handle. Then cut/trim the plate.

Pneumatic tool Handheld power drill Drill Wood Hammer drill


I used a Blackburn Tools handle pattern and pasted it on a 4/4 slab of Marblewood and cut the basic shape on the bandsaw. Lots of work with rasps, files, and sandpaper brought the hand to shape the came the critical cut. The slice for the saw plate - it made me really nervous.

Wood Automotive exterior Bumper Luggage and bags Motor vehicle


Then of course came fitting of the back into the handle. I have to admit that I really did a rough job getting the slot widened. It work but it's not pretty. I have a lot to learn yet.

Cutting mat Wood Electric blue Art Fashion accessory


Finally more Scraping and sanding then a coat of Watco Danish oil which went bad (had to bake the handle for about and hour at 180F to get it to kind of dry). Then a lot of rubbing and wiping to clean of the sticky finish. Fortunately between the baking, wiping and wax it turned out ok.

Musical instrument Wood String instrument String instrument Hardwood


Overall the project turned out well. The saw cuts nicely and feels good in my hand. Blackburn Tools grip guide really worked.

Table Furniture Wood Hardwood Wood stain
 

Attachments

#69 ·
Gents Saw Upgrade

After seeing the Youtube video on this I really wanted to try it out myself. So I started with a Two Cherries Gents Saw that's been laying around collecting dust.

Rectangle Font Fashion accessory Metal Titanium


I pulled the handle - and reused it as a file handle. Then cut/trim the plate.

Pneumatic tool Handheld power drill Drill Wood Hammer drill


I used a Blackburn Tools handle pattern and pasted it on a 4/4 slab of Marblewood and cut the basic shape on the bandsaw. Lots of work with rasps, files, and sandpaper brought the hand to shape the came the critical cut. The slice for the saw plate - it made me really nervous.

Wood Automotive exterior Bumper Luggage and bags Motor vehicle


Then of course came fitting of the back into the handle. I have to admit that I really did a rough job getting the slot widened. It work but it's not pretty. I have a lot to learn yet.

Cutting mat Wood Electric blue Art Fashion accessory


Finally more Scraping and sanding then a coat of Watco Danish oil which went bad (had to bake the handle for about and hour at 180F to get it to kind of dry). Then a lot of rubbing and wiping to clean of the sticky finish. Fortunately between the baking, wiping and wax it turned out ok.

Musical instrument Wood String instrument String instrument Hardwood


Overall the project turned out well. The saw cuts nicely and feels good in my hand. Blackburn Tools grip guide really worked.

Table Furniture Wood Hardwood Wood stain
Looks like it'll cut, Bill. And you learned a bunch along the way. Nice work!
 

Attachments

#72 ·
Squares, Squares and more Squares...

OK, I'm not a galoot. I use hand tools to augment my power tools. While the quite whisper of a sharp plane on pine like the silent fall of heavy snow is wondrous, the screaming song of an 6 inch jointer and instant piles of wood shavings fits me better. That said I do like a well made tool. Earlier I rehandled a Two Cherries backsaw and honestly I like it better than my Veritas Dovetail saw - more on that later. It got me to thinking about other tools I could make.

And then… the 2020 Surprise Swap started. If you've never done an LJ Swap you owe it to yourself to give it a try. WOW - these guys are good and boy will it challenge you.

I ended up making a host of squares each better and more accurate than the last.

Wood Rectangle Material property Art Tints and shades


Some looked stunning but boy were they out of square… and not by only a couple thou. Those really nice looking Bloodwood and Osage Orange things (Not Squares) were the worst.

Wood Wood stain Hardwood Font Plank


Talk about "factory seconds" I had to split out the handle of the five.

Eventually I managed a set that was equal to my Starrett. Those went out as Swap items

Wood Wood stain Material property Hardwood Font


The two wooden squares are interpretations of 16th century Melencolia (Honduran Rosewood & Spruce) and Wierix (Honduran Mahogany & Oak) squares. The name come from the artists who included these tools in their paintings. The black handled square is Gaboon Ebony and brass with Aluminum pins.

Wood Wooden block Rectangle Art Wood stain


I still need to rebuild the rest so more stripping fitting riveting and finishing

Automotive tire Jig grinder Drilling Asphalt Wood


Wood Rectangle Flooring Hardwood Wood stain


Interesting note though. The Melencolia and Wierix Style squares have kind of be come my "go to" tools. The are light, easy to use, don't ding the wood when I'm a bit clumsy and are never cold.

Hmmmmm - I have to say that I learned a lot. I think maybe I'll make a few more.
 

Attachments

#73 ·
Squares, Squares and more Squares...

OK, I'm not a galoot. I use hand tools to augment my power tools. While the quite whisper of a sharp plane on pine like the silent fall of heavy snow is wondrous, the screaming song of an 6 inch jointer and instant piles of wood shavings fits me better. That said I do like a well made tool. Earlier I rehandled a Two Cherries backsaw and honestly I like it better than my Veritas Dovetail saw - more on that later. It got me to thinking about other tools I could make.

And then… the 2020 Surprise Swap started. If you've never done an LJ Swap you owe it to yourself to give it a try. WOW - these guys are good and boy will it challenge you.

I ended up making a host of squares each better and more accurate than the last.

Wood Rectangle Material property Art Tints and shades


Some looked stunning but boy were they out of square… and not by only a couple thou. Those really nice looking Bloodwood and Osage Orange things (Not Squares) were the worst.

Wood Wood stain Hardwood Font Plank


Talk about "factory seconds" I had to split out the handle of the five.

Eventually I managed a set that was equal to my Starrett. Those went out as Swap items

Wood Wood stain Material property Hardwood Font


The two wooden squares are interpretations of 16th century Melencolia (Honduran Rosewood & Spruce) and Wierix (Honduran Mahogany & Oak) squares. The name come from the artists who included these tools in their paintings. The black handled square is Gaboon Ebony and brass with Aluminum pins.

Wood Wooden block Rectangle Art Wood stain


I still need to rebuild the rest so more stripping fitting riveting and finishing

Automotive tire Jig grinder Drilling Asphalt Wood


Wood Rectangle Flooring Hardwood Wood stain


Interesting note though. The Melencolia and Wierix Style squares have kind of be come my "go to" tools. The are light, easy to use, don't ding the wood when I'm a bit clumsy and are never cold.

Hmmmmm - I have to say that I learned a lot. I think maybe I'll make a few more.
It's fun having your own shop-made tools, isn't it?
 

Attachments

#76 ·
Sucking Sawdust

I use my RAS… a lot. For the longest time I've had a wheelbarrow behind it where most of the sawdust lands and it is a lot of sawdust. Almost as much as my table saw. I've seen several LJ'ers and Youtubers with various RAS dust collection methods and decided that I like the fence port style best.

Wood Table Wood stain Floor Flooring


I start out by collecting scraps then turning the inside of a 2.5" Sched 40 pipe to fit the vac hose.

Gas Wood Machine Engineering Auto part


Then using scrap I built a box about 9" Deep by 12" Wide Skinned top and bottom with 1/4" plywood and then glued in the pipe

Furniture Table Wood Rectangle Bumper


It's not fancy and only for 90 degree cross cuts

Cup Drinkware Wood Serveware Gas


The difference it makes in dust is AWSOME! Now I need to make a new fence just a bit higher so the top slots are above a std 2Ă—4. That will pick up those final pieces. All in all for "free from scrap" it's a keeper.

Wood Flooring Gas Machine Hardwood


Btw - the dust gets sucked into Big Blue

Engineering Gas Machine Auto part Cylinder
 

Attachments

#77 ·
Sucking Sawdust

I use my RAS… a lot. For the longest time I've had a wheelbarrow behind it where most of the sawdust lands and it is a lot of sawdust. Almost as much as my table saw. I've seen several LJ'ers and Youtubers with various RAS dust collection methods and decided that I like the fence port style best.



I start out by collecting scraps then turning the inside of a 2.5" Sched 40 pipe to fit the vac hose.



Then using scrap I built a box about 9" Deep by 12" Wide Skinned top and bottom with 1/4" plywood and then glued in the pipe



It's not fancy and only for 90 degree cross cuts



The difference it makes in dust is AWSOME! Now I need to make a new fence just a bit higher so the top slots are above a std 2Ă—4. That will pick up those final pieces. All in all for "free from scrap" it's a keeper.



Btw - the dust gets sucked into Big Blue

You sawdust sucker! (if you could hear the voice in my head it would sound funny)

My portable DC is aggravating me of late. Takes too much floor space. I can't live without my shop vac so I've been debating the possibility of getting rid of the DC and forcing the shop vac to double duty. Your rig there may just give me the push I need :)
 

Attachments

#81 ·
Moving Forward on the Tool Cabinet

COVID has done weird things everywhere. But I have managed to get out in the shop make progress on my Tool Cabinet.

Cabinetry Drawer Chest of drawers Wood Shelving


Throughout 2020 I managed to get all the lower cabinet drawers made and set.

Wood Rectangle Shelf Flooring Floor


Created a mid-deck gallery and knocked together the main section of the upper cabinet. And installed and finished the top.

Wood Shelf Floor Cabinetry Shelving


Over Christmas of 2021 I added some trim to the Mid-deck Gallery

And in February-March completed Walnut trimmed drawer faces and installed handles and bolted the Mid-deck gallery to the lower cabinet

Property Cabinetry Wood Shelf Shelving
 

Attachments

#82 ·
Moving Forward on the Tool Cabinet

COVID has done weird things everywhere. But I have managed to get out in the shop make progress on my Tool Cabinet.

Cabinetry Drawer Chest of drawers Wood Shelving


Throughout 2020 I managed to get all the lower cabinet drawers made and set.

Wood Rectangle Shelf Flooring Floor


Created a mid-deck gallery and knocked together the main section of the upper cabinet. And installed and finished the top.

Wood Shelf Floor Cabinetry Shelving


Over Christmas of 2021 I added some trim to the Mid-deck Gallery

And in February-March completed Walnut trimmed drawer faces and installed handles and bolted the Mid-deck gallery to the lower cabinet

Property Cabinetry Wood Shelf Shelving
sweet looking storage cabinet. The drawer fronts look like figured maple and the walnut trim sets them off nicely. High end shop storage for sure.
 

Attachments

#91 ·
Initial Trim and Inlay

A bit more progress on the Tool Chest. Btw - don't think I'm doing all of this now. It's 16F out and while I can heat the garage to a comfortable 55F it takes a butt load of propane. Probably this weekend but I need to get cracking on the Turning Swap.

November I trimmed the edge of the upper cabinet in Walnut and inlaid 8mm Mother of Pearl dots along the edge using a Fibonacci sequence. Turned out pretty good. The dots are VERY precise and a bit expensive ($25 usd / 100pcs). I used a freshly sharpened card scraper to level everything out.

Wood Flooring Floor Rectangle Composite material


Wood Gas Electrical wiring Audio equipment Metalworking hand tool


Wood Floor Flooring Wood stain Hardwood


In December I completed the Mid-deck Gallery drawers. They are solid poplar - still considering what the drawer faces should be and what style of pulls

Wood Flooring Hardwood Boats and boating--Equipment and supplies Wood stain


I picked up 16 antique solid brass Index Drawer Pulls but not not totally sold on those either. I think I'll DS Tape the rest in place and see what it looks like. I have a ton of other handles in brass, stainless, nickel. And antique Hepplewhite, Chippendale, Midcentury salvage.

Rectangle Wood Floor Shelving Wood stain
 

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#92 ·
Initial Trim and Inlay

A bit more progress on the Tool Chest. Btw - don't think I'm doing all of this now. It's 16F out and while I can heat the garage to a comfortable 55F it takes a butt load of propane. Probably this weekend but I need to get cracking on the Turning Swap.

November I trimmed the edge of the upper cabinet in Walnut and inlaid 8mm Mother of Pearl dots along the edge using a Fibonacci sequence. Turned out pretty good. The dots are VERY precise and a bit expensive ($25 usd / 100pcs). I used a freshly sharpened card scraper to level everything out.

Wood Flooring Floor Rectangle Composite material


Wood Gas Electrical wiring Audio equipment Metalworking hand tool


Wood Floor Flooring Wood stain Hardwood


In December I completed the Mid-deck Gallery drawers. They are solid poplar - still considering what the drawer faces should be and what style of pulls

Wood Flooring Hardwood Boats and boating--Equipment and supplies Wood stain


I picked up 16 antique solid brass Index Drawer Pulls but not not totally sold on those either. I think I'll DS Tape the rest in place and see what it looks like. I have a ton of other handles in brass, stainless, nickel. And antique Hepplewhite, Chippendale, Midcentury salvage.

Rectangle Wood Floor Shelving Wood stain
I like the blue pulls Bill
 

Attachments

#100 ·
Bowling League 2022 Turned Epoxy & Wood Beer "Glass"

Tin Wood Table Drinkware Hat


I had such great ideas for this swap. BTW if you have not joined a swap, you should - it will push your limits and you will learn a lot. First idea was a low rim open segment bowl with the openings filled with epoxy. Seemed like a good idea at the time. I didn't do something right and it literally blew up. Good thing I had a jacket and face shield on. (I should show a picture, but it was too embarrassing, and I didn't take one) After that disaster I made a small Movingui Salt bowl just to be sure I'd have something to ship if my next invention failed. Shown here in the hand of my recipient JD77 because I didn't get a picture of it myself.

Hat Finger Wood Drink Serveware


I had a couple of 3.5" x 3.5" Osage Orange chunks too small for much of anything but I figure if I spaced them and filled the gap with a metallic epoxy I'd have something interesting. Sealed the two pieces, mixed the epoxy and poured, waited a couple days and finally got it out of the "mold." I glued a piece to the bottom to fit my chuck and started turning. Dang, chips and chunks of epoxy were flying off and hitting my face shield like rain. I did learn to lighten my cut and finally got it round (mostly).

After all the chips and chunks (I thought) I got the diameter down in what I intended to be a graceful curve. Hmmm… more chips and catches. Eventually I ended up with and kind of Bombay curve mostly because I was afraid of shattering the whole thing.

Finally finished the outside and tried to turn the inside. After a couple attempts I decided to just drill it our with a Forstner bit. Boy was that slow going. Cutting the end grain was tough. The bit would heat and gum up and the wood would toast. I spent almost as much time cooling and cleaning the bit as I did drilling. Here, I'm using a tool from another swap to gauge depth.

Wood Art Wood stain Hardwood Engineering


Finally made it to depth and wanted to thin the lip. Another bad idea - the whole sequence went MUCH better in my head, but caught an edge, flipped it off the lathe and onto the floor which chipped it.

Gas Thigh Knee Human leg Cylinder


Result? I had to trim off 3/8". I finally knocked off the sacrificial piece on the bottom that allowed me to chuck the part.

Wood Burin Tableware Scratch awl Paint brush


With saw, file, and sandpaper I managed to get the lip where I wanted. Then I mixed a very thin epoxy to coat the inside and lip. That went VERY well and I did a second coat. The result is an OK (I think) Beer"Glass" that holds 8oz exactly and only by shear chance.

Wood Table Drinkware Wood stain Kitchen utensil


I think overall I learned a ton but I need to capitalize on techniques in the coming months.
 

Attachments

#101 ·
Bowling League 2022 Turned Epoxy & Wood Beer "Glass"

Tin Wood Table Drinkware Hat


I had such great ideas for this swap. BTW if you have not joined a swap, you should - it will push your limits and you will learn a lot. First idea was a low rim open segment bowl with the openings filled with epoxy. Seemed like a good idea at the time. I didn't do something right and it literally blew up. Good thing I had a jacket and face shield on. (I should show a picture, but it was too embarrassing, and I didn't take one) After that disaster I made a small Movingui Salt bowl just to be sure I'd have something to ship if my next invention failed. Shown here in the hand of my recipient JD77 because I didn't get a picture of it myself.

Hat Finger Wood Drink Serveware


I had a couple of 3.5" x 3.5" Osage Orange chunks too small for much of anything but I figure if I spaced them and filled the gap with a metallic epoxy I'd have something interesting. Sealed the two pieces, mixed the epoxy and poured, waited a couple days and finally got it out of the "mold." I glued a piece to the bottom to fit my chuck and started turning. Dang, chips and chunks of epoxy were flying off and hitting my face shield like rain. I did learn to lighten my cut and finally got it round (mostly).

After all the chips and chunks (I thought) I got the diameter down in what I intended to be a graceful curve. Hmmm… more chips and catches. Eventually I ended up with and kind of Bombay curve mostly because I was afraid of shattering the whole thing.

Finally finished the outside and tried to turn the inside. After a couple attempts I decided to just drill it our with a Forstner bit. Boy was that slow going. Cutting the end grain was tough. The bit would heat and gum up and the wood would toast. I spent almost as much time cooling and cleaning the bit as I did drilling. Here, I'm using a tool from another swap to gauge depth.

Wood Art Wood stain Hardwood Engineering


Finally made it to depth and wanted to thin the lip. Another bad idea - the whole sequence went MUCH better in my head, but caught an edge, flipped it off the lathe and onto the floor which chipped it.

Gas Thigh Knee Human leg Cylinder


Result? I had to trim off 3/8". I finally knocked off the sacrificial piece on the bottom that allowed me to chuck the part.

Wood Burin Tableware Scratch awl Paint brush


With saw, file, and sandpaper I managed to get the lip where I wanted. Then I mixed a very thin epoxy to coat the inside and lip. That went VERY well and I did a second coat. The result is an OK (I think) Beer"Glass" that holds 8oz exactly and only by shear chance.

Wood Table Drinkware Wood stain Kitchen utensil


I think overall I learned a ton but I need to capitalize on techniques in the coming months.
For me, the projects that give me the most trouble are always the ones where I learn a bunch of things that make the next attempt go a lot smoother. Sounds like you had a good learning experience on this one, Bill!
 

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#107 ·
Cargo Style Pencil Box

Musical instrument Rectangle Wood Table Bench


I needed a couple of quick gifts and a pencil box seemed like a good idea. This Cargo Crate Style Pencil Box features simple butt joints and a tilting lid. And uses the material scraps to create a cargo crate esthetic. The finish is a wipe on Boiled Linseed Oil (BLO) which is perfect for this project.

I started with 1/4" Red Oak stock from the big box store 3-1/2" wide x 48" long. Enough material for two 9" x 4" x 2-1/4" boxes (outside dimensions)

I cut the top, bottom and sides all to 9" in length leaving the top and bottom at stock width of 3-1/2" and ripped the sides to 2-1/4" wide. The ends I cut to 3-1/2" long x 2-1/4" wide. You can see where this is going, right? I sanded everything at this stage.

I PVA glued and butted the sides to the edges of the bottom, and glued and butted the sides and bottom to the edges of the ends and clamped it up.

Wood Wood stain Flooring Hardwood Plank


Once dry, I pulled the clamps and fitted the lid. I cut it to length, 1/32" shorter than the inside dimension (theoretically 8-31/32"). Then I used a block plane to trim the edge to allow about 1/32" clearance.

Hand Wood Wood stain Hardwood Engineering


Once the lid was fitted I used the scrap to make the cargo straps - four 1/2" wide x 2-1/4" long strips for the sides and two 1/2" wide x 4-1/2 long top pieces. These I glued in place 2" in from each end using CA Glue.

Table Wood Tableware Flooring Wood stain


After everything was dry I rubbed on a coat of Boiled Linseed Oil. I love the way it brings out the grain.
and…ta-da, DONE!

Rectangle Wood Wood stain Hardwood Wooden block


This was really a quick project. And these have a lot of uses. I have up sized then for wine and whisky too.

Wood Rectangle Table Flooring Floor


Over all a really satisfying project that was well received.
 

Attachments

#108 ·
Cargo Style Pencil Box

Musical instrument Rectangle Wood Table Bench


I needed a couple of quick gifts and a pencil box seemed like a good idea. This Cargo Crate Style Pencil Box features simple butt joints and a tilting lid. And uses the material scraps to create a cargo crate esthetic. The finish is a wipe on Boiled Linseed Oil (BLO) which is perfect for this project.

I started with 1/4" Red Oak stock from the big box store 3-1/2" wide x 48" long. Enough material for two 9" x 4" x 2-1/4" boxes (outside dimensions)

I cut the top, bottom and sides all to 9" in length leaving the top and bottom at stock width of 3-1/2" and ripped the sides to 2-1/4" wide. The ends I cut to 3-1/2" long x 2-1/4" wide. You can see where this is going, right? I sanded everything at this stage.

I PVA glued and butted the sides to the edges of the bottom, and glued and butted the sides and bottom to the edges of the ends and clamped it up.

Wood Wood stain Flooring Hardwood Plank


Once dry, I pulled the clamps and fitted the lid. I cut it to length, 1/32" shorter than the inside dimension (theoretically 8-31/32"). Then I used a block plane to trim the edge to allow about 1/32" clearance.

Hand Wood Wood stain Hardwood Engineering


Once the lid was fitted I used the scrap to make the cargo straps - four 1/2" wide x 2-1/4" long strips for the sides and two 1/2" wide x 4-1/2 long top pieces. These I glued in place 2" in from each end using CA Glue.

Table Wood Tableware Flooring Wood stain


After everything was dry I rubbed on a coat of Boiled Linseed Oil. I love the way it brings out the grain.
and…ta-da, DONE!

Rectangle Wood Wood stain Hardwood Wooden block


This was really a quick project. And these have a lot of uses. I have up sized then for wine and whisky too.

Wood Rectangle Table Flooring Floor


Over all a really satisfying project that was well received.
Thanks for the background details. Nice project!
 

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