I am not sure how much time I’ll have for this project, so I’m taking every moment I can and do baby steps to hopefully drive this thing through.
Last night I went and picked up what boards seem to be most fitting for this project that will yield the best materials for the parts. The toolbox is 10” deep, but I did not find anything that wide. the widest I have is 8” so I’ll have to make some glue ups for full width boards. I did get a good selection of mahogany for the exterior, and some poplar for the drawers (and walnut for the pulls):
Today during my lunch break I was able to roughly surface 1 face of each board (since these are 8” wide, I hand planed them as they would not fit on my jointer, plus since there are not many boards, it’s easier to plane it by hand) getting it ready to be planned flat and parallel with the planer, then flipped it and using the planer surfaced the 1st face again to finish it off. I then jointed 1 edge by hand to have S3S boards that I could resaw from each flat face to get 2 boards ~7/8” in thickness each having 1 flat surface, and a jointed edge that I could then easily thickness to it’s final dimension of 3/4”. At this point I’m going to let the boards acclimate a bit to their new size and release any tension they might have had before thicknessing them to final dimension to avoid having them cup on me later on when it’s too late.
So this is what it looks like now:
You can also see the parts print out from the SketchUp model that I keep on the workbench as a reference to sizing.
Next, some glue ups to get the boards to their full width of 10” (+some extra), and planing them down to final dimension before cutting them to size.
I also took the opportunity to swap blades on my planer as I got some nicks from hidden nails which gave the blades some hard beating (hardened nails). This is the first time I change blades on this planer, quite simple, although there are a lot of bolts to take off, and put back on. I ended up flipping the blades to their 2nd edge (double edged blades) and did not have to actually replace them as of yet. so far so good. I would leave the blades on if they were not nicked which leaves 2 stripes on the wood unplaned which can lead to trouble feeding the boards through. bottom line -the blades on the DW735 seem to hold well in general.
I also think I’m allergic to Mahogany which is not really good. it makes my skin itchy. until today I thought it was bug bites, but after todays experience planing those boards by hand and coming in direct contact with the lumber, I think the Mahogany was the source to my irritated skin all along.
-- ㊍ When in doubt - There is no doubt - Go the safer route.