I made some progress on the actual caddy portion, including it’s base box, on 4/9/2011 (and on Sunday, 4/10/2011 I rested lol – my back and feet are needing some aspirin!).
This portion wasn’t terribly difficult. For the actuall caddy portion I used a bit more of the 7” wide pine I had. I cut a couple of lenghts to the 15” width I needed. I used spray adhesive to stick them together, being mindful of orienting the cupping the same way.
I have NOT milled much of this material prior to use – and some of the joints show it. This is a conscious decision – this prototype MAY have some useful parts but I’m not counting on it other than to get the experience out of it and to try some design ideas.
I traced the circle using a lid from one of my wife’s pans (I need to get some trammel points…). I cut it on the band saw, staying about 1/16” or so outside the line on the waste side. Then I used my Ridgid sander for the final shaping.
I’m glad and thankful I have those tools – I don’t have to try to figure out how to do that sort of thing. It’s such a change from when I made my Adirondack chair where I had to figure out how to do everything because I didn’t have the tools I wanted to use.
I had decided to rip the slats from 3x pine – it was cheaper to buy the larger pine than to buy the pieces ripped to size. I got to try out my new Freud LU88R010 blade (yeah, I know it’s not specifically for this purpose) and was really happy with the results.
I made a quick little stop / jig for my drill press to drill the clearance holes in the end of each slat. I happened to have exactly 20 appropriate wood screws on hand and attached the slats by starting with the bottom slats on each side. I held the slats in place, started the screw pilot hole with my hand held cordless drill, then pulled the slat away and finished drilling the pilot holes.
I attached each slat and then put a couple of spacers on the installed slat to set the position of the subsequent slats until I was done.
For the box under the caddy, the sides extend past the frame on one side for the handle. On the other end I used a box joint but for the cross piece by the handle I used another French dovetail joint. I had to use my Grizzly miter in my Bosch table to cut these but once I figured out how to do it they were pretty easy. I like the looks of these joints too – they’re hidden from the top.
I still need to pick up the hinge to complete this portion. I know I have an unresolved issue at this point – how to use a hinge and have the necessary clearance for the slat on the hinge side. I may also need / want to add some sort of latch on the non-hinge side to keep the caddy from twisting or opening during transit. But, here it is so far:
I did do a test fit using my wife’s saddles and it fits great. Both a western and english saddle (I think that’s what they’re called).
-- Randy Morter, Phoenix, AZ