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#1 ·
Slotted coin displays

One of my staples for sale at craft shows is slotted coin displays.
They are fairly simple to make and I try to make them in batches so I have inventory without setting up too often to make them.
All of them so far have been made from dunnage used to ship steel radio transmission towers from India to the US. Where we would use pine 2×4's to brace freight this particular company used an assortment of mid/far east woods. From what I can see and surmise it is the off-cuts from the Indian furniture and woodwork industry. (I'll blog the wood separately.)

This dunnage is roughly 2 by 2 1/2 inches and either 24 or 36 inches long.

This is the process.

I pick out the pieces I want to make the holders out of and joint one or two sides.
Table Wood Outdoor furniture Outdoor table Gas


Instead of planing the opposite sides I normally rip them to make the blanks smooth and parallel. I use at least a 40 tooth carbide blade which leaves a very smooth surface, usually better than the planer.
Table Furniture Desk Wood Gas


Next I rip the blanks into two pieces. Sometimes I try to make them the same thickness. Some I will intentionally rip into a thicker piece and a thinner piece. This allows me to have book-matched sets that are either the same height or slightly offset.
Wood Gas Hood Machine Space


Some of the wood is so figured that while I'm ripping the blanks in two I get a lot of curve in the wood. The saw doesn't have a riving knife so I have to keep an eye on the outfeed and watch for a closing up in the kerf. Sometime it will scorch a little. Those pieces are set aside and allowed to rest, then they are cut into shorter lengths or used for other projects. Figure the odds, the really pretty figured wood is the worst for curving in.
Wood Rectangle Building material Floor Table


If any pieces come out of the cutting process with too much tooth marks or schorching I sand them to 220 grit on the 6x48 belt sander.
Wood Rectangle Wood stain Flooring Floor


I end up with a lot of wood that is ripped in two.
Wood Table Workbench Hardwood Engineering


After cutting and rough smoothing I cut the grooves. I have found that my DeWalt biscuit jointer makes perfectly sized grooves. In addition, as opposed to cutting grooves on the tablesaw where they would run off the ends due to blade curvature, the biscuit jointer bit has a tight enough radius that I can start and stop the grooves about 1/2 inch from either end.
Wood Drill Tool Gas Machine


The jointer pins that are normally extended to prevent the jointer from moving when you plunge it I keep retracted so that I can slide it like a router along the blank.
Wood Tool Saw Machine tool Gas


Due to the weight of the jointer, my age, and the amount of grooves I cut (880 linear feet in the last batch), I rigged up a production area that lets me suspend the jointer from the ceiling of the shop on a bungee cord. The bungee holds the jointer throat just at the height of the blank surface so there is almost no effort on my part to grab it, put it in position, and cut the slot.
Wood Floor Engineering Flooring Gas


I hold the blanks in position with a piece of old flooring at the back, clamped to allow the edge of the blank to just stand proud of the RAS table where I cut the grooves.
Pneumatic tool Handheld power drill Saw Drill Hammer drill


I have two stop blocks that are clamped in place to prevent the jointer from running off either end.
The left stop block is stationary and is notched out lower than the blank wide enough to stop the jointer about 1/2 - 3/4 inch from the end.
Wood Floor Beige Flooring Gas


The right end block is cut identically to the left one and is re-positioned for each blank due to differences in length using a kreg vise grip clamp.
Wood Office supplies Gas Bumper Electronic instrument


The groove process is:
Set blank in position and clamp stop block in place.
Wood Table Flooring Floor Automotive exterior


Joint the first groove.
Wood Rectangle Table Wood stain Automotive exterior


Flip blank 180 degrees and joint second groove.
Wood Bumper Automotive exterior Gas Tints and shades


Repeat for next blank.
It's a fairly quick process once the work station is set up, about 30 seconds to route both grooves.
Here's about 880 feet of coin holders with slots cut.
Wood Floor Flooring Gas Machine


Once the slots are cut I route the edges. I normally use a Roman Ogee router bit, but will sometimes use a round-over or chamfer bit. (I really need a better router table.)
Table Wood Flooring Wood stain Hardwood


Next I finish sand.
Before sanding
Wood Table Wood stain Floor Plank


After sanding
Wood Wood stain Plank Hardwood Rectangle


Because the edge jointer and table saw cut very smoothly I can usually hit the blanks once with a 320 grit sanding mop. If I discover saw marks or some other blemish that requires more work I may go back to the belt sander, or switch to a 220 grit mop.
The 320 grit is aggressive enough to knock the edges down and smooth the surface without attacking or rounding the edges too much.

After sanding I wipe on a thin coat of 2# shellac as a sealer. As soon as I wipe it on I wipe it off, it's only to seal the grain. I've played with other finishes, teak oil, BLO, poly, lacquer, but the shellac just does what I need better and quicker (and cheaper) than the others.
Shellac VS teak oil
Wood Rectangle Floor Material property Flooring


After the shellac dries, and on cold days before it dries I start the polishing process.
I use the Beall Buff System to polish the wood.
It's a fairly straight forward process, red compound and wheel for rough polishing, white diamond compound and wheel for final polishing, carnauba wax and wheel for final finish.

It puts a mean shine on hard wood.
Rectangle Wood Ingredient Table Flooring


Appreciate any comments/critiques/suggestions.
 

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#2 ·
Slotted coin displays

One of my staples for sale at craft shows is slotted coin displays.
They are fairly simple to make and I try to make them in batches so I have inventory without setting up too often to make them.
All of them so far have been made from dunnage used to ship steel radio transmission towers from India to the US. Where we would use pine 2×4's to brace freight this particular company used an assortment of mid/far east woods. From what I can see and surmise it is the off-cuts from the Indian furniture and woodwork industry. (I'll blog the wood separately.)

This dunnage is roughly 2 by 2 1/2 inches and either 24 or 36 inches long.

This is the process.

I pick out the pieces I want to make the holders out of and joint one or two sides.
Table Wood Outdoor furniture Outdoor table Gas


Instead of planing the opposite sides I normally rip them to make the blanks smooth and parallel. I use at least a 40 tooth carbide blade which leaves a very smooth surface, usually better than the planer.
Table Furniture Desk Wood Gas


Next I rip the blanks into two pieces. Sometimes I try to make them the same thickness. Some I will intentionally rip into a thicker piece and a thinner piece. This allows me to have book-matched sets that are either the same height or slightly offset.
Wood Gas Hood Machine Space


Some of the wood is so figured that while I'm ripping the blanks in two I get a lot of curve in the wood. The saw doesn't have a riving knife so I have to keep an eye on the outfeed and watch for a closing up in the kerf. Sometime it will scorch a little. Those pieces are set aside and allowed to rest, then they are cut into shorter lengths or used for other projects. Figure the odds, the really pretty figured wood is the worst for curving in.
Wood Rectangle Building material Floor Table


If any pieces come out of the cutting process with too much tooth marks or schorching I sand them to 220 grit on the 6x48 belt sander.
Wood Rectangle Wood stain Flooring Floor


I end up with a lot of wood that is ripped in two.
Wood Table Workbench Hardwood Engineering


After cutting and rough smoothing I cut the grooves. I have found that my DeWalt biscuit jointer makes perfectly sized grooves. In addition, as opposed to cutting grooves on the tablesaw where they would run off the ends due to blade curvature, the biscuit jointer bit has a tight enough radius that I can start and stop the grooves about 1/2 inch from either end.
Wood Drill Tool Gas Machine


The jointer pins that are normally extended to prevent the jointer from moving when you plunge it I keep retracted so that I can slide it like a router along the blank.
Wood Tool Saw Machine tool Gas


Due to the weight of the jointer, my age, and the amount of grooves I cut (880 linear feet in the last batch), I rigged up a production area that lets me suspend the jointer from the ceiling of the shop on a bungee cord. The bungee holds the jointer throat just at the height of the blank surface so there is almost no effort on my part to grab it, put it in position, and cut the slot.
Wood Floor Engineering Flooring Gas


I hold the blanks in position with a piece of old flooring at the back, clamped to allow the edge of the blank to just stand proud of the RAS table where I cut the grooves.
Pneumatic tool Handheld power drill Saw Drill Hammer drill


I have two stop blocks that are clamped in place to prevent the jointer from running off either end.
The left stop block is stationary and is notched out lower than the blank wide enough to stop the jointer about 1/2 - 3/4 inch from the end.
Wood Floor Beige Flooring Gas


The right end block is cut identically to the left one and is re-positioned for each blank due to differences in length using a kreg vise grip clamp.
Wood Office supplies Gas Bumper Electronic instrument


The groove process is:
Set blank in position and clamp stop block in place.
Wood Table Flooring Floor Automotive exterior


Joint the first groove.
Wood Rectangle Table Wood stain Automotive exterior


Flip blank 180 degrees and joint second groove.
Wood Bumper Automotive exterior Gas Tints and shades


Repeat for next blank.
It's a fairly quick process once the work station is set up, about 30 seconds to route both grooves.
Here's about 880 feet of coin holders with slots cut.
Wood Floor Flooring Gas Machine


Once the slots are cut I route the edges. I normally use a Roman Ogee router bit, but will sometimes use a round-over or chamfer bit. (I really need a better router table.)
Table Wood Flooring Wood stain Hardwood


Next I finish sand.
Before sanding
Wood Table Wood stain Floor Plank


After sanding
Wood Wood stain Plank Hardwood Rectangle


Because the edge jointer and table saw cut very smoothly I can usually hit the blanks once with a 320 grit sanding mop. If I discover saw marks or some other blemish that requires more work I may go back to the belt sander, or switch to a 220 grit mop.
The 320 grit is aggressive enough to knock the edges down and smooth the surface without attacking or rounding the edges too much.

After sanding I wipe on a thin coat of 2# shellac as a sealer. As soon as I wipe it on I wipe it off, it's only to seal the grain. I've played with other finishes, teak oil, BLO, poly, lacquer, but the shellac just does what I need better and quicker (and cheaper) than the others.
Shellac VS teak oil
Wood Rectangle Floor Material property Flooring


After the shellac dries, and on cold days before it dries I start the polishing process.
I use the Beall Buff System to polish the wood.
It's a fairly straight forward process, red compound and wheel for rough polishing, white diamond compound and wheel for final polishing, carnauba wax and wheel for final finish.

It puts a mean shine on hard wood.
Rectangle Wood Ingredient Table Flooring


Appreciate any comments/critiques/suggestions.
Very good procedure…

FYI: I have a Slot Cutter router bit that I think could also cut those slots… I would have to try it… sounds easier & safer to me.

Thank you for sharing.
 

Attachments

#3 ·
Slotted coin displays

One of my staples for sale at craft shows is slotted coin displays.
They are fairly simple to make and I try to make them in batches so I have inventory without setting up too often to make them.
All of them so far have been made from dunnage used to ship steel radio transmission towers from India to the US. Where we would use pine 2×4's to brace freight this particular company used an assortment of mid/far east woods. From what I can see and surmise it is the off-cuts from the Indian furniture and woodwork industry. (I'll blog the wood separately.)

This dunnage is roughly 2 by 2 1/2 inches and either 24 or 36 inches long.

This is the process.

I pick out the pieces I want to make the holders out of and joint one or two sides.
Table Wood Outdoor furniture Outdoor table Gas


Instead of planing the opposite sides I normally rip them to make the blanks smooth and parallel. I use at least a 40 tooth carbide blade which leaves a very smooth surface, usually better than the planer.
Table Furniture Desk Wood Gas


Next I rip the blanks into two pieces. Sometimes I try to make them the same thickness. Some I will intentionally rip into a thicker piece and a thinner piece. This allows me to have book-matched sets that are either the same height or slightly offset.
Wood Gas Hood Machine Space


Some of the wood is so figured that while I'm ripping the blanks in two I get a lot of curve in the wood. The saw doesn't have a riving knife so I have to keep an eye on the outfeed and watch for a closing up in the kerf. Sometime it will scorch a little. Those pieces are set aside and allowed to rest, then they are cut into shorter lengths or used for other projects. Figure the odds, the really pretty figured wood is the worst for curving in.
Wood Rectangle Building material Floor Table


If any pieces come out of the cutting process with too much tooth marks or schorching I sand them to 220 grit on the 6x48 belt sander.
Wood Rectangle Wood stain Flooring Floor


I end up with a lot of wood that is ripped in two.
Wood Table Workbench Hardwood Engineering


After cutting and rough smoothing I cut the grooves. I have found that my DeWalt biscuit jointer makes perfectly sized grooves. In addition, as opposed to cutting grooves on the tablesaw where they would run off the ends due to blade curvature, the biscuit jointer bit has a tight enough radius that I can start and stop the grooves about 1/2 inch from either end.
Wood Drill Tool Gas Machine


The jointer pins that are normally extended to prevent the jointer from moving when you plunge it I keep retracted so that I can slide it like a router along the blank.
Wood Tool Saw Machine tool Gas


Due to the weight of the jointer, my age, and the amount of grooves I cut (880 linear feet in the last batch), I rigged up a production area that lets me suspend the jointer from the ceiling of the shop on a bungee cord. The bungee holds the jointer throat just at the height of the blank surface so there is almost no effort on my part to grab it, put it in position, and cut the slot.
Wood Floor Engineering Flooring Gas


I hold the blanks in position with a piece of old flooring at the back, clamped to allow the edge of the blank to just stand proud of the RAS table where I cut the grooves.
Pneumatic tool Handheld power drill Saw Drill Hammer drill


I have two stop blocks that are clamped in place to prevent the jointer from running off either end.
The left stop block is stationary and is notched out lower than the blank wide enough to stop the jointer about 1/2 - 3/4 inch from the end.
Wood Floor Beige Flooring Gas


The right end block is cut identically to the left one and is re-positioned for each blank due to differences in length using a kreg vise grip clamp.
Wood Office supplies Gas Bumper Electronic instrument


The groove process is:
Set blank in position and clamp stop block in place.
Wood Table Flooring Floor Automotive exterior


Joint the first groove.
Wood Rectangle Table Wood stain Automotive exterior


Flip blank 180 degrees and joint second groove.
Wood Bumper Automotive exterior Gas Tints and shades


Repeat for next blank.
It's a fairly quick process once the work station is set up, about 30 seconds to route both grooves.
Here's about 880 feet of coin holders with slots cut.
Wood Floor Flooring Gas Machine


Once the slots are cut I route the edges. I normally use a Roman Ogee router bit, but will sometimes use a round-over or chamfer bit. (I really need a better router table.)
Table Wood Flooring Wood stain Hardwood


Next I finish sand.
Before sanding
Wood Table Wood stain Floor Plank


After sanding
Wood Wood stain Plank Hardwood Rectangle


Because the edge jointer and table saw cut very smoothly I can usually hit the blanks once with a 320 grit sanding mop. If I discover saw marks or some other blemish that requires more work I may go back to the belt sander, or switch to a 220 grit mop.
The 320 grit is aggressive enough to knock the edges down and smooth the surface without attacking or rounding the edges too much.

After sanding I wipe on a thin coat of 2# shellac as a sealer. As soon as I wipe it on I wipe it off, it's only to seal the grain. I've played with other finishes, teak oil, BLO, poly, lacquer, but the shellac just does what I need better and quicker (and cheaper) than the others.
Shellac VS teak oil
Wood Rectangle Floor Material property Flooring


After the shellac dries, and on cold days before it dries I start the polishing process.
I use the Beall Buff System to polish the wood.
It's a fairly straight forward process, red compound and wheel for rough polishing, white diamond compound and wheel for final polishing, carnauba wax and wheel for final finish.

It puts a mean shine on hard wood.
Rectangle Wood Ingredient Table Flooring


Appreciate any comments/critiques/suggestions.
Very creative and resourceful process Pete. Amazing wood too, and it looks wonderful after finishing. I'ver never seen any pallet wood like that here, but I will keep my eyes open for it in the future.
 

Attachments

#4 ·
Slotted coin displays

One of my staples for sale at craft shows is slotted coin displays.
They are fairly simple to make and I try to make them in batches so I have inventory without setting up too often to make them.
All of them so far have been made from dunnage used to ship steel radio transmission towers from India to the US. Where we would use pine 2×4's to brace freight this particular company used an assortment of mid/far east woods. From what I can see and surmise it is the off-cuts from the Indian furniture and woodwork industry. (I'll blog the wood separately.)

This dunnage is roughly 2 by 2 1/2 inches and either 24 or 36 inches long.

This is the process.

I pick out the pieces I want to make the holders out of and joint one or two sides.
Table Wood Outdoor furniture Outdoor table Gas


Instead of planing the opposite sides I normally rip them to make the blanks smooth and parallel. I use at least a 40 tooth carbide blade which leaves a very smooth surface, usually better than the planer.
Table Furniture Desk Wood Gas


Next I rip the blanks into two pieces. Sometimes I try to make them the same thickness. Some I will intentionally rip into a thicker piece and a thinner piece. This allows me to have book-matched sets that are either the same height or slightly offset.
Wood Gas Hood Machine Space


Some of the wood is so figured that while I'm ripping the blanks in two I get a lot of curve in the wood. The saw doesn't have a riving knife so I have to keep an eye on the outfeed and watch for a closing up in the kerf. Sometime it will scorch a little. Those pieces are set aside and allowed to rest, then they are cut into shorter lengths or used for other projects. Figure the odds, the really pretty figured wood is the worst for curving in.
Wood Rectangle Building material Floor Table


If any pieces come out of the cutting process with too much tooth marks or schorching I sand them to 220 grit on the 6x48 belt sander.
Wood Rectangle Wood stain Flooring Floor


I end up with a lot of wood that is ripped in two.
Wood Table Workbench Hardwood Engineering


After cutting and rough smoothing I cut the grooves. I have found that my DeWalt biscuit jointer makes perfectly sized grooves. In addition, as opposed to cutting grooves on the tablesaw where they would run off the ends due to blade curvature, the biscuit jointer bit has a tight enough radius that I can start and stop the grooves about 1/2 inch from either end.
Wood Drill Tool Gas Machine


The jointer pins that are normally extended to prevent the jointer from moving when you plunge it I keep retracted so that I can slide it like a router along the blank.
Wood Tool Saw Machine tool Gas


Due to the weight of the jointer, my age, and the amount of grooves I cut (880 linear feet in the last batch), I rigged up a production area that lets me suspend the jointer from the ceiling of the shop on a bungee cord. The bungee holds the jointer throat just at the height of the blank surface so there is almost no effort on my part to grab it, put it in position, and cut the slot.
Wood Floor Engineering Flooring Gas


I hold the blanks in position with a piece of old flooring at the back, clamped to allow the edge of the blank to just stand proud of the RAS table where I cut the grooves.
Pneumatic tool Handheld power drill Saw Drill Hammer drill


I have two stop blocks that are clamped in place to prevent the jointer from running off either end.
The left stop block is stationary and is notched out lower than the blank wide enough to stop the jointer about 1/2 - 3/4 inch from the end.
Wood Floor Beige Flooring Gas


The right end block is cut identically to the left one and is re-positioned for each blank due to differences in length using a kreg vise grip clamp.
Wood Office supplies Gas Bumper Electronic instrument


The groove process is:
Set blank in position and clamp stop block in place.
Wood Table Flooring Floor Automotive exterior


Joint the first groove.
Wood Rectangle Table Wood stain Automotive exterior


Flip blank 180 degrees and joint second groove.
Wood Bumper Automotive exterior Gas Tints and shades


Repeat for next blank.
It's a fairly quick process once the work station is set up, about 30 seconds to route both grooves.
Here's about 880 feet of coin holders with slots cut.
Wood Floor Flooring Gas Machine


Once the slots are cut I route the edges. I normally use a Roman Ogee router bit, but will sometimes use a round-over or chamfer bit. (I really need a better router table.)
Table Wood Flooring Wood stain Hardwood


Next I finish sand.
Before sanding
Wood Table Wood stain Floor Plank


After sanding
Wood Wood stain Plank Hardwood Rectangle


Because the edge jointer and table saw cut very smoothly I can usually hit the blanks once with a 320 grit sanding mop. If I discover saw marks or some other blemish that requires more work I may go back to the belt sander, or switch to a 220 grit mop.
The 320 grit is aggressive enough to knock the edges down and smooth the surface without attacking or rounding the edges too much.

After sanding I wipe on a thin coat of 2# shellac as a sealer. As soon as I wipe it on I wipe it off, it's only to seal the grain. I've played with other finishes, teak oil, BLO, poly, lacquer, but the shellac just does what I need better and quicker (and cheaper) than the others.
Shellac VS teak oil
Wood Rectangle Floor Material property Flooring


After the shellac dries, and on cold days before it dries I start the polishing process.
I use the Beall Buff System to polish the wood.
It's a fairly straight forward process, red compound and wheel for rough polishing, white diamond compound and wheel for final polishing, carnauba wax and wheel for final finish.

It puts a mean shine on hard wood.
Rectangle Wood Ingredient Table Flooring


Appreciate any comments/critiques/suggestions.
Hey Joe,
I got a slot cutter bit for that very purpose, but I've found the biscuit jointer really works better.
The two fences of the biscuit jointer lock the blank into position better.
And I found that picking up the router table to slide it along the blanks was very tiring, what with the tool chest the whole thing is bolted to…..
lol
I gotta make a video of the slot cutting process.
 

Attachments

#5 ·
Slotted coin displays

One of my staples for sale at craft shows is slotted coin displays.
They are fairly simple to make and I try to make them in batches so I have inventory without setting up too often to make them.
All of them so far have been made from dunnage used to ship steel radio transmission towers from India to the US. Where we would use pine 2×4's to brace freight this particular company used an assortment of mid/far east woods. From what I can see and surmise it is the off-cuts from the Indian furniture and woodwork industry. (I'll blog the wood separately.)

This dunnage is roughly 2 by 2 1/2 inches and either 24 or 36 inches long.

This is the process.

I pick out the pieces I want to make the holders out of and joint one or two sides.
Table Wood Outdoor furniture Outdoor table Gas


Instead of planing the opposite sides I normally rip them to make the blanks smooth and parallel. I use at least a 40 tooth carbide blade which leaves a very smooth surface, usually better than the planer.
Table Furniture Desk Wood Gas


Next I rip the blanks into two pieces. Sometimes I try to make them the same thickness. Some I will intentionally rip into a thicker piece and a thinner piece. This allows me to have book-matched sets that are either the same height or slightly offset.
Wood Gas Hood Machine Space


Some of the wood is so figured that while I'm ripping the blanks in two I get a lot of curve in the wood. The saw doesn't have a riving knife so I have to keep an eye on the outfeed and watch for a closing up in the kerf. Sometime it will scorch a little. Those pieces are set aside and allowed to rest, then they are cut into shorter lengths or used for other projects. Figure the odds, the really pretty figured wood is the worst for curving in.
Wood Rectangle Building material Floor Table


If any pieces come out of the cutting process with too much tooth marks or schorching I sand them to 220 grit on the 6x48 belt sander.
Wood Rectangle Wood stain Flooring Floor


I end up with a lot of wood that is ripped in two.
Wood Table Workbench Hardwood Engineering


After cutting and rough smoothing I cut the grooves. I have found that my DeWalt biscuit jointer makes perfectly sized grooves. In addition, as opposed to cutting grooves on the tablesaw where they would run off the ends due to blade curvature, the biscuit jointer bit has a tight enough radius that I can start and stop the grooves about 1/2 inch from either end.
Wood Drill Tool Gas Machine


The jointer pins that are normally extended to prevent the jointer from moving when you plunge it I keep retracted so that I can slide it like a router along the blank.
Wood Tool Saw Machine tool Gas


Due to the weight of the jointer, my age, and the amount of grooves I cut (880 linear feet in the last batch), I rigged up a production area that lets me suspend the jointer from the ceiling of the shop on a bungee cord. The bungee holds the jointer throat just at the height of the blank surface so there is almost no effort on my part to grab it, put it in position, and cut the slot.
Wood Floor Engineering Flooring Gas


I hold the blanks in position with a piece of old flooring at the back, clamped to allow the edge of the blank to just stand proud of the RAS table where I cut the grooves.
Pneumatic tool Handheld power drill Saw Drill Hammer drill


I have two stop blocks that are clamped in place to prevent the jointer from running off either end.
The left stop block is stationary and is notched out lower than the blank wide enough to stop the jointer about 1/2 - 3/4 inch from the end.
Wood Floor Beige Flooring Gas


The right end block is cut identically to the left one and is re-positioned for each blank due to differences in length using a kreg vise grip clamp.
Wood Office supplies Gas Bumper Electronic instrument


The groove process is:
Set blank in position and clamp stop block in place.
Wood Table Flooring Floor Automotive exterior


Joint the first groove.
Wood Rectangle Table Wood stain Automotive exterior


Flip blank 180 degrees and joint second groove.
Wood Bumper Automotive exterior Gas Tints and shades


Repeat for next blank.
It's a fairly quick process once the work station is set up, about 30 seconds to route both grooves.
Here's about 880 feet of coin holders with slots cut.
Wood Floor Flooring Gas Machine


Once the slots are cut I route the edges. I normally use a Roman Ogee router bit, but will sometimes use a round-over or chamfer bit. (I really need a better router table.)
Table Wood Flooring Wood stain Hardwood


Next I finish sand.
Before sanding
Wood Table Wood stain Floor Plank


After sanding
Wood Wood stain Plank Hardwood Rectangle


Because the edge jointer and table saw cut very smoothly I can usually hit the blanks once with a 320 grit sanding mop. If I discover saw marks or some other blemish that requires more work I may go back to the belt sander, or switch to a 220 grit mop.
The 320 grit is aggressive enough to knock the edges down and smooth the surface without attacking or rounding the edges too much.

After sanding I wipe on a thin coat of 2# shellac as a sealer. As soon as I wipe it on I wipe it off, it's only to seal the grain. I've played with other finishes, teak oil, BLO, poly, lacquer, but the shellac just does what I need better and quicker (and cheaper) than the others.
Shellac VS teak oil
Wood Rectangle Floor Material property Flooring


After the shellac dries, and on cold days before it dries I start the polishing process.
I use the Beall Buff System to polish the wood.
It's a fairly straight forward process, red compound and wheel for rough polishing, white diamond compound and wheel for final polishing, carnauba wax and wheel for final finish.

It puts a mean shine on hard wood.
Rectangle Wood Ingredient Table Flooring


Appreciate any comments/critiques/suggestions.
A different way to make a long slot, but, hey, it works and looks gr8. Ha!, I can picture you holding your router table upside down and routing that little slot on that short board… That's purdee funny.
 

Attachments

#6 ·
Open form in oak, day 1

Seth (my daughter's boyfriend) does yard work for spending money and got some oak logs for me (about 4,000 pounds worth).
I decided to try an open form with a (small) piece of it.
Since it was green it was heavier than I wanted to try lifting onto the lathe. Besides that's why I have a chain hoist and trolley.

Seth was doing the hoisting…lots of pulling to bring it up…but he's young.
Automotive tire Wood Bermuda shorts Gas Flooring


Initial mount to the headstock is a 4" faceplate, the biggest I've got.
Idiophone Wood Hat Engineering Automotive wheel system


There was minimal sag with just the faceplate, but I didn't want to even try starting it up without the live center supporting it. I didn't feel like setting up the chainsaw so I just used the large cone on the live center to start the turning.
Motor vehicle Automotive tire Wood Automotive design Gas


Mounted, safety cage in place, ready to rumble.
Wood Cabinetry Gas Machine Engineering


5:57 p.m. Starting the debarking process.
I could have just knocked it off, but wanted the practice so I used my 1" roughing gouge.
Wood Office ruler Ruler Wood stain Gas


6:26 p.m. After half an hour the bottom is starting to come into shape, at least the angle is coming off.
Wood Automotive tire Gas Engineering Adhesive


6:35 p.m. Taking the sides to round. Too bad the picture is out of focus, there's a puddle of water in the gouge.
Wood Animal feed Safety glove Fish Soil


And there was water dripping off my face shield. As a side note I wear either a hard hat with full face shield or a full face respirator when I'm turning. I like my face the way it is and I personally think wrinkles are preferable to scars. And the pocket on the t-shirt is full of shavings.
Neck Jaw Sleeve Ear Beard


6:41 p.m. All the rough edges off. Water dripping everywhere.
Wood Gas Engineering Machine tool Factory


6:41 to 7:15 p.m. took a break for supper or something.
The plan was to leave the 4" faceplate on as the center support for the top of the form and to put the Nova Titan chuck on a tenon on the bottom.
So I started to form the outer contour of the form and to cut in for the tenon. I switched to the Sorby Sovereign. I pulled the middle joint out so the round cutter was attached directly to the bar, like a straight gouge.
Motor vehicle Gas Engineering Machine Auto part


It really started pulling off the wet wood. Seth said I was throwing shavings all the way across the garage.
I got a couple of them off the floor, about 1/4" wide and 5 feet long. Things were going well and fast.
Wood Engineering Gas Machine Wire


8:36 p.m. The outer shape was rough turned and the tenon was cut.
Engineering Gas Wood Machine Auto part


8:39 p.m. I turned down the end off the tenon as far as I felt comfortable. The piece was round, but not balanced. It was easy to tell because the tailstock extension was wobbling around (flexing) when I was turning.
Automotive tire Tool Tire Gas Machine


8:42 p.m. We sawed the nub off the tenon so the chuck could snug up against the bottom of the form.
Wood Engineering Gas Machine tool Machine


8:44 p.m. Titan chuck on the tenon. Ready to swap ends.
Machine tool Gas Engineering Machine Cylinder


8:49 p.m. Back to the hoist. Took the strain off the headstock and unscrewed the form.
Wood Gas Engineering Machine Auto part


8:54 p.m. Turned the form around, screwed the Titan chuck on the headstock, screwed the faceplate on the tailstock…ready to hollow.
Wood Gas Engineering Machine Machine tool


Closeup of the 4" faceplate screwed onto the live center threaded adapter.
Wood Wheel Automotive tire Gas Machine


9:06 p.m. A couple of inches in.
Saw Gas Engineering Machine tool Wood


Breaking the blog entry at this point, continuing day 1, and adding day 2 in the next entry.
 

Attachments

#7 ·
Open form in oak, day 1

Seth (my daughter's boyfriend) does yard work for spending money and got some oak logs for me (about 4,000 pounds worth).
I decided to try an open form with a (small) piece of it.
Since it was green it was heavier than I wanted to try lifting onto the lathe. Besides that's why I have a chain hoist and trolley.

Seth was doing the hoisting…lots of pulling to bring it up…but he's young.
Automotive tire Wood Bermuda shorts Gas Flooring


Initial mount to the headstock is a 4" faceplate, the biggest I've got.
Idiophone Wood Hat Engineering Automotive wheel system


There was minimal sag with just the faceplate, but I didn't want to even try starting it up without the live center supporting it. I didn't feel like setting up the chainsaw so I just used the large cone on the live center to start the turning.
Motor vehicle Automotive tire Wood Automotive design Gas


Mounted, safety cage in place, ready to rumble.
Wood Cabinetry Gas Machine Engineering


5:57 p.m. Starting the debarking process.
I could have just knocked it off, but wanted the practice so I used my 1" roughing gouge.
Wood Office ruler Ruler Wood stain Gas


6:26 p.m. After half an hour the bottom is starting to come into shape, at least the angle is coming off.
Wood Automotive tire Gas Engineering Adhesive


6:35 p.m. Taking the sides to round. Too bad the picture is out of focus, there's a puddle of water in the gouge.
Wood Animal feed Safety glove Fish Soil


And there was water dripping off my face shield. As a side note I wear either a hard hat with full face shield or a full face respirator when I'm turning. I like my face the way it is and I personally think wrinkles are preferable to scars. And the pocket on the t-shirt is full of shavings.
Neck Jaw Sleeve Ear Beard


6:41 p.m. All the rough edges off. Water dripping everywhere.
Wood Gas Engineering Machine tool Factory


6:41 to 7:15 p.m. took a break for supper or something.
The plan was to leave the 4" faceplate on as the center support for the top of the form and to put the Nova Titan chuck on a tenon on the bottom.
So I started to form the outer contour of the form and to cut in for the tenon. I switched to the Sorby Sovereign. I pulled the middle joint out so the round cutter was attached directly to the bar, like a straight gouge.
Motor vehicle Gas Engineering Machine Auto part


It really started pulling off the wet wood. Seth said I was throwing shavings all the way across the garage.
I got a couple of them off the floor, about 1/4" wide and 5 feet long. Things were going well and fast.
Wood Engineering Gas Machine Wire


8:36 p.m. The outer shape was rough turned and the tenon was cut.
Engineering Gas Wood Machine Auto part


8:39 p.m. I turned down the end off the tenon as far as I felt comfortable. The piece was round, but not balanced. It was easy to tell because the tailstock extension was wobbling around (flexing) when I was turning.
Automotive tire Tool Tire Gas Machine


8:42 p.m. We sawed the nub off the tenon so the chuck could snug up against the bottom of the form.
Wood Engineering Gas Machine tool Machine


8:44 p.m. Titan chuck on the tenon. Ready to swap ends.
Machine tool Gas Engineering Machine Cylinder


8:49 p.m. Back to the hoist. Took the strain off the headstock and unscrewed the form.
Wood Gas Engineering Machine Auto part


8:54 p.m. Turned the form around, screwed the Titan chuck on the headstock, screwed the faceplate on the tailstock…ready to hollow.
Wood Gas Engineering Machine Machine tool


Closeup of the 4" faceplate screwed onto the live center threaded adapter.
Wood Wheel Automotive tire Gas Machine


9:06 p.m. A couple of inches in.
Saw Gas Engineering Machine tool Wood


Breaking the blog entry at this point, continuing day 1, and adding day 2 in the next entry.
That is some seriously hardcore turning.
 

Attachments

#14 ·
Open form in oak, day 2, oops day 1 (part deaux) and day 2

I didn't want the first entry to be too long, it was War and Peace just for day 1.

So, here's the rest of day 1 followed by day 2.
It's really just hollowing mostly…hollowing, hollowing, and more hollowing.
I stopped the first entry at 9:06 p.m. at about 2 inches depth.
9:14 p.m. It's not brain surgery…a long handled, a study tool rest, wood hitting the cutter head, me hanging on the back of the handle.
Motor vehicle Wood Gas Automotive tire Fender


Down to 4 inches in 8 minutes. The Sovereign can really chew some wood.
Ruler Wood Office ruler Gas Tints and shades


And fyi the blank is 13 inches deep.
Wood Gas Engineering Machine Metal

9:24 p.m. another 10 minutes, deeper in but now the Sorby isn't able to track along the inner wall. The tool is working fine but I don't have the articulated link in, so the edge of the cutter can't get to the wood.
Wood Saw Office ruler Automotive tire Machine tool

Wood Cabinetry Gas Machine Tool


So I put the articulating link back in and put a slight left angle into the tool.
Automotive tire Fender Wood Gas Auto part


9:44 p.m. Working the angle on the tool between straight and left I got a lot more chewed out.
Wood Machine Machine tool Saw Wood stain


Down to 6 1/2 inches.
Wood Gas Machine Metal Nickel


9:55 p.m. Finishing up day 1, a lot of wood on the shop floor, and cabinets, and shelves, and me. A good portion of the blank to a reasonable thickness ~1 inch for drying.
Wood Gas Machine tool Engineering Cylinder


General outside form. Will turn the top more narrow as warpage allows.
Motor vehicle Automotive tire Gas Engineering Machine


9:57 p.m. The scene of the crime. I hung a sheet on behind me to keep shavings from the outer turning from drenching the workbench and stuff on it. Shavings about 3-6 inches thick on the floor. A nice light smell of oak sap in the shop.
Automotive tire Motor vehicle Wood Automotive design Engineering


10:01 p.m. Trash bag wrapped around blank to stop uneven drying overnight. Turning the lights off.
Automotive tire Motor vehicle Automotive design Tire Bin bag


DAY 2

I don't seem to get into the shop before the afternoon most days. Reading email and forum posts. Surfing up ideas, tips, and tricks, playing a couple of games, then lunch.

So about 2 p.m. I was back in the shop. Side note. I use my Samsung Note II phone for most of my photographs right now. It's always in a pouch on my left hip. And it takes pretty good pictures. And I try to take a picture at the start of a project, and when I stop/finish/switch to another so I have an idea how much time I spend on each phase and each project.
Wouldn't you know it, I was so eager to get started that I forgot to get a start time picture.
2:44 p.m. Hollowing continues. I'm at 8 or 9 inches by now and the Sorby is really starting to bounce. The tool rest is right next to the top of the form, but the cutter is WAY past that. I've got the end of the tool handle under my armpit. At least it's not really catching, just the changes in wood texture and density make it seem that way. I'm getting bruised under the arm I think.
Drill Wood Automotive tire Drilling Saw


Finally deep enough to put the bowl rest in. MUCH less vibration, very smooth cutting again, and much faster.
2:48 p.m. Tremendous progress with the bowl rest in.
Wood Gas Engineering Machine Metal


Hollow hollow hollow, stop, blow out shavings, repeat.
5:45 p.m. took a break somewhere in there for supper. Hollowed out as far as I wanted before drying.
Entire form is about 1 inch thick.
Wood Machine Engineering Cylinder Metal


A nice thick cushion of shavings on the shop floor.
Motor vehicle Automotive tire Wood Gas Machine


6:34 p.m. Dismounted, found a box to pack it in.
Stuck it in the back of the shop. Will weigh it later and then start tracking weight loss until it stabilizes. Then will see what warping and cracking have occurred and will see what I can do to finish it up.
Comfort Automotive design Beige Car seat Auto part
 

Attachments

#15 ·
Open form in oak, day 2, oops day 1 (part deaux) and day 2

I didn't want the first entry to be too long, it was War and Peace just for day 1.

So, here's the rest of day 1 followed by day 2.
It's really just hollowing mostly…hollowing, hollowing, and more hollowing.
I stopped the first entry at 9:06 p.m. at about 2 inches depth.
9:14 p.m. It's not brain surgery…a long handled, a study tool rest, wood hitting the cutter head, me hanging on the back of the handle.
Motor vehicle Wood Gas Automotive tire Fender


Down to 4 inches in 8 minutes. The Sovereign can really chew some wood.
Ruler Wood Office ruler Gas Tints and shades


And fyi the blank is 13 inches deep.
Wood Gas Engineering Machine Metal

9:24 p.m. another 10 minutes, deeper in but now the Sorby isn't able to track along the inner wall. The tool is working fine but I don't have the articulated link in, so the edge of the cutter can't get to the wood.
Wood Saw Office ruler Automotive tire Machine tool

Wood Cabinetry Gas Machine Tool


So I put the articulating link back in and put a slight left angle into the tool.
Automotive tire Fender Wood Gas Auto part


9:44 p.m. Working the angle on the tool between straight and left I got a lot more chewed out.
Wood Machine Machine tool Saw Wood stain


Down to 6 1/2 inches.
Wood Gas Machine Metal Nickel


9:55 p.m. Finishing up day 1, a lot of wood on the shop floor, and cabinets, and shelves, and me. A good portion of the blank to a reasonable thickness ~1 inch for drying.
Wood Gas Machine tool Engineering Cylinder


General outside form. Will turn the top more narrow as warpage allows.
Motor vehicle Automotive tire Gas Engineering Machine


9:57 p.m. The scene of the crime. I hung a sheet on behind me to keep shavings from the outer turning from drenching the workbench and stuff on it. Shavings about 3-6 inches thick on the floor. A nice light smell of oak sap in the shop.
Automotive tire Motor vehicle Wood Automotive design Engineering


10:01 p.m. Trash bag wrapped around blank to stop uneven drying overnight. Turning the lights off.
Automotive tire Motor vehicle Automotive design Tire Bin bag


DAY 2

I don't seem to get into the shop before the afternoon most days. Reading email and forum posts. Surfing up ideas, tips, and tricks, playing a couple of games, then lunch.

So about 2 p.m. I was back in the shop. Side note. I use my Samsung Note II phone for most of my photographs right now. It's always in a pouch on my left hip. And it takes pretty good pictures. And I try to take a picture at the start of a project, and when I stop/finish/switch to another so I have an idea how much time I spend on each phase and each project.
Wouldn't you know it, I was so eager to get started that I forgot to get a start time picture.
2:44 p.m. Hollowing continues. I'm at 8 or 9 inches by now and the Sorby is really starting to bounce. The tool rest is right next to the top of the form, but the cutter is WAY past that. I've got the end of the tool handle under my armpit. At least it's not really catching, just the changes in wood texture and density make it seem that way. I'm getting bruised under the arm I think.
Drill Wood Automotive tire Drilling Saw


Finally deep enough to put the bowl rest in. MUCH less vibration, very smooth cutting again, and much faster.
2:48 p.m. Tremendous progress with the bowl rest in.
Wood Gas Engineering Machine Metal


Hollow hollow hollow, stop, blow out shavings, repeat.
5:45 p.m. took a break somewhere in there for supper. Hollowed out as far as I wanted before drying.
Entire form is about 1 inch thick.
Wood Machine Engineering Cylinder Metal


A nice thick cushion of shavings on the shop floor.
Motor vehicle Automotive tire Wood Gas Machine


6:34 p.m. Dismounted, found a box to pack it in.
Stuck it in the back of the shop. Will weigh it later and then start tracking weight loss until it stabilizes. Then will see what warping and cracking have occurred and will see what I can do to finish it up.
Comfort Automotive design Beige Car seat Auto part
COOL!

Very interesting!

That is going to be one good-sized bowl!

Thank you for your Sharing!
 

Attachments

#21 ·
Cane in mystery red wood

I use a lot of dunnage for my projects.
It's from freight shipped out of India and is usually some type of exhotic hardwood.
Some pieces are a reddish hardwood.
It has a very fine grain, is VERY hard, and every piece has cracks running down it.
I have decided to only make mallets and other hard type things out of it.
But I'd already cut a cane blank and decided to go on and make the cane. Besides I wanted to see how it turned out.

I'd turned the blank to round a few weeks ago so this picks up from there.

When I turn canes I use a spindle steady and a bowl steady. I use the bowl steady because I have it and in conjunction with the spindle steady it works well.

When mounting either one I try to make sure they are at 90 degrees to the piece.
Wood Metal Hardwood Engineering Plywood


Whether rounding down or turning to final shape I always work from the tip of the cane to the handle.
Wood Motor vehicle Engineering Gas Machine


Turning the tip end to size.
Because customers come in different sizes I make the bottom 6-8 inches the same diameter. That way I can cut them to size at the point of sale. In this case the tip end is 3/4 inches in diameter. Future tip ends will be 7/8 inches because it's easier to get tips that size.
Loom Wood Gas Bumper Machine


Finishing as I go.
SOP for canes is turned, sanded to 320 grit, wiped on/wiped off shellac, polished on the Beall Buff system.
Turning and sanding are worked tip to handle. But shellac is done when everything is turned and sanded.
All sanded.
Motor vehicle Wood Gas Machine tool Engineering


Straight and even.
Wood Engineering Gas Auto part Machine


Shellaced. It's 2# shellac, applied with an old acid brush I keep in the jar, then wiped off at slow speed while still wet. Then I kick the speed up and buff it with the rag to get any residue off the surface. The idea is to seal the grain in preparation for polishing.
Motor vehicle Wood Machine Engineering Automotive exterior


CRACKS
As I mentioned, cracks seem to be a characteristic of this wood.
Wood Wood stain Gas Tints and shades Hardwood


Wood Wood stain Stairs Hardwood Tints and shades


Wood Natural material Wood stain Hardwood Tool


For this can I decided to fill the cracks. Partly as an appearance issue but mostly because the wood is so hard and dense that after sanding and shellacking the edges of the cracks were like knife blades. Seriously, sharp enough to cut skin (I know….I did.) I thought about using coffee grounds (probably should have) but decided to just use sawdust from the belt sander.
The process was simple, rub sawdust into the crack, put in some superglue, spray on accelerator, repeat until filled/satisfied with amount filled, sand smooth.
Crack.
Wood Wood stain Stairs Hardwood Tints and shades


Filled and sanded.
Wood Gesture Elbow Blazer Wrist


2nd coat of shellac applied due to sanding of the cracks.
Wood Spinning Linens Bedding Metal


Filled, sanded, shellacked.
Wood Wood stain Hardwood Tints and shades Gas


Polished on the Beall Buff. I think the superglue hadn't completely cured as the heat from the polish bubbled it some. On a plus note I brought a highlight to the cracks. Hey, If someone likes it enough they'll buy it.
Wood Wood stain Natural material Hardwood Wrist


Polished.
Wood Motor vehicle Bicycle part Bicycle fork Gas


Will post the finished and assembled cane later.
If anyone has any idea what this wood might be I'd love to know.
 

Attachments

#22 ·
Cane in mystery red wood

I use a lot of dunnage for my projects.
It's from freight shipped out of India and is usually some type of exhotic hardwood.
Some pieces are a reddish hardwood.
It has a very fine grain, is VERY hard, and every piece has cracks running down it.
I have decided to only make mallets and other hard type things out of it.
But I'd already cut a cane blank and decided to go on and make the cane. Besides I wanted to see how it turned out.

I'd turned the blank to round a few weeks ago so this picks up from there.

When I turn canes I use a spindle steady and a bowl steady. I use the bowl steady because I have it and in conjunction with the spindle steady it works well.

When mounting either one I try to make sure they are at 90 degrees to the piece.
Wood Metal Hardwood Engineering Plywood


Whether rounding down or turning to final shape I always work from the tip of the cane to the handle.
Wood Motor vehicle Engineering Gas Machine


Turning the tip end to size.
Because customers come in different sizes I make the bottom 6-8 inches the same diameter. That way I can cut them to size at the point of sale. In this case the tip end is 3/4 inches in diameter. Future tip ends will be 7/8 inches because it's easier to get tips that size.
Loom Wood Gas Bumper Machine


Finishing as I go.
SOP for canes is turned, sanded to 320 grit, wiped on/wiped off shellac, polished on the Beall Buff system.
Turning and sanding are worked tip to handle. But shellac is done when everything is turned and sanded.
All sanded.
Motor vehicle Wood Gas Machine tool Engineering


Straight and even.
Wood Engineering Gas Auto part Machine


Shellaced. It's 2# shellac, applied with an old acid brush I keep in the jar, then wiped off at slow speed while still wet. Then I kick the speed up and buff it with the rag to get any residue off the surface. The idea is to seal the grain in preparation for polishing.
Motor vehicle Wood Machine Engineering Automotive exterior


CRACKS
As I mentioned, cracks seem to be a characteristic of this wood.
Wood Wood stain Gas Tints and shades Hardwood


Wood Wood stain Stairs Hardwood Tints and shades


Wood Natural material Wood stain Hardwood Tool


For this can I decided to fill the cracks. Partly as an appearance issue but mostly because the wood is so hard and dense that after sanding and shellacking the edges of the cracks were like knife blades. Seriously, sharp enough to cut skin (I know….I did.) I thought about using coffee grounds (probably should have) but decided to just use sawdust from the belt sander.
The process was simple, rub sawdust into the crack, put in some superglue, spray on accelerator, repeat until filled/satisfied with amount filled, sand smooth.
Crack.
Wood Wood stain Stairs Hardwood Tints and shades


Filled and sanded.
Wood Gesture Elbow Blazer Wrist


2nd coat of shellac applied due to sanding of the cracks.
Wood Spinning Linens Bedding Metal


Filled, sanded, shellacked.
Wood Wood stain Hardwood Tints and shades Gas


Polished on the Beall Buff. I think the superglue hadn't completely cured as the heat from the polish bubbled it some. On a plus note I brought a highlight to the cracks. Hey, If someone likes it enough they'll buy it.
Wood Wood stain Natural material Hardwood Wrist


Polished.
Wood Motor vehicle Bicycle part Bicycle fork Gas


Will post the finished and assembled cane later.
If anyone has any idea what this wood might be I'd love to know.
That is a REAL COOL Cane!

The way you handled those cracks was GREAT… worked like a charm… You Antiqued them!

Thank you!

Good job!
 

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