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11K views 31 replies 9 participants last post by  TobiasZA 
#1 ·
Small Beginnings

As my "Honey-Do" and client projects wind down a little before it really gets cold here in Swellendam, I have at last made a start on my build. A few weeks of regular scrounging at my local tip has yielded some good lumber and adding this to my off cut stack, I think that I have enough lumber to do the job.

Buying the hardware kit and plans from ASFM at $500.00 means I would have been into about ZAR6,500.00 before I even made a start. So…..enter "Shipwright" who has been extremely helpful in my quest. Paul's drawings in Sketchup are very easy to follow and other than the steel bar, rod and hardware, I have worked so far in imperial measurements although we use only metric in South Africa.(Somewhat confusing at times!)

As my Chevy is built from "scrap", it has a real mixed bag of woods, Maple, Meranti, Pod Mahogany, Sapele Mahogany, ****************************************, Kiaat(Mukwa), Bubinga, African Cherry and Beech. I sourced the two fittings for sliding on the rod from a local auto parts store at $2.90 each, 10mm steel round bar at about $4.50, 16mm steel square bar at around $5.20 and I had all the bolts, washers and wing nuts were already in stock.

Last year I sold my table saw with Incra TS III and router wing as I was not really using it much and I felt that the space in my workshop could well be better utilised. I have not needed it at all during the build and am very happy with my big bandsaw for most of my work.

So far I have the main leg built and I am currently building the arm system. Today's work will include a few brass plates and the stepped shoulder mortice and tenon for the arm.

In my next post I shall include the first sets of pictures.

Do any of you know of anyone in South Africa who has built a Chevalet? I am interested in getting in touch with them.

Thank you Paul Miller (Shipwright) You are a true inspiration!
 
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#2 ·
Thank you Tobias. Anything I can do to help more people experience this amazing tool is my pleasure.
Don't hesitate to pm me if you have any questions or problems with my (entry level skills) Sketchup plans.
You may well be the "chevalet guy" in SA. If so it won't be long after people see yours that they will spread.

Good luck on the build and with your future marquetry endeavours.
 
#4 ·
Morning.
Paul, thanks so much for your enthusiasm and support. Thanks Dutchy for following my build. Below are a few pictures of the beginnings of the build. With me not using a table saw anymore, I have been cutting the joints, especially the bridle and M&T joints, by hand and I find immense enjoyment and satisfaction in doing them. Considering the time it used to take to set up the tenoning jig, cross checking the angle of the blade etc etc, I am finding that a good cup of coffee, no machine and dust extraction system noise and gently satisfying chiselling all go together well and only takes a few extra minutes to complete the joint.

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Wood Floor Wood stain Flooring Hardwood


Wood Art Hardwood Musical instrument Flooring


Wood Machine Flooring Retail Ceiling


Wood Floor Wood stain Flooring Hardwood


Wood Engineering Flooring Hardwood Table


Wood Building Hardwood Engineering Flooring


Wood Rectangle Flooring Floor Wood stain


Wood Floor Flooring Wood stain Hardwood


Property Furniture Wood Floor Flooring
 

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#5 ·
That is looking really good. Nice joinery!
You won't be needing any help from me. I can tell.

Thanks for posting this.
 
#8 ·
Hi Tobias!

Your chevalet looks great! Thank you for all of the information. Do you know where to get the fixtures that hold the blade? In the ASFM kit, they are listed as AFSN-1120….

Thank you for your help on this:)

Happy woodworking,
Carie Sexton
Carie.sexton@outlook.com
 
#9 ·
Hi Carie
Thanks for the thumbs up. I did not get my kit parts from Patrick Edwards and Patrice Lejeune, as I live in South Africa and postage is totally prohibitive from the US. I talked to Paul Miller AKA Shipwright on LJ and he was incredibly helpful. Based on his info, I fabricated my own parts and they are serving me very well. With a hacksaw, some files, a small set of taps & dies, patience and some sweat you should easily be able to make your own.
P.S. I am not sure whether ASFM sell individual parts on their price lists, but they are really nice guys and I am sure that if you contact them, they will help you.
Best regards and good luck with your Chevy
 
#10 ·
Hello Tobias,

Thank you so much for your response. I can only imagine what shipping to you would cost! I send items to my brother in Ireland and that's a fortune.

I've spoken to ASFM and they are very very nice as you say:). But, at the time, I didn't ask about the individual parts. They are not listed on the website separately, but I will still give them another call to ask.

Great job on fabricating your own parts! Thank you for all of the information and have a great day!

Sincerely,
Retro
 
#11 ·
Part #2

Morning.
Paul, thanks so much for your enthusiasm and support. Thanks Dutchy for following my build. Below are a few pictures of the beginnings of the build. With me not using a table saw anymore, I have been cutting the joints, especially the bridle and M&T joints, by hand and I find immense enjoyment and satisfaction in doing them. Considering the time it used to take to set up the tenoning jig, cross checking the angle of the blade etc etc, I am finding that a good cup of coffee, no machine and dust extraction system noise and gently satisfying chiselling all go together well and only takes a few extra minutes to complete the joint.

Wood Floor Flooring Wood stain Hardwood


Wood Floor Wood stain Flooring Hardwood


Wood Art Hardwood Musical instrument Flooring


Wood Machine Flooring Retail Ceiling


Wood Floor Wood stain Flooring Hardwood


Wood Engineering Flooring Hardwood Table


Wood Building Hardwood Engineering Flooring


Wood Rectangle Flooring Floor Wood stain


Wood Floor Flooring Wood stain Hardwood


Property Furniture Wood Floor Flooring
 

Attachments

#12 ·
Part #2

Morning.
Paul, thanks so much for your enthusiasm and support. Thanks Dutchy for following my build. Below are a few pictures of the beginnings of the build. With me not using a table saw anymore, I have been cutting the joints, especially the bridle and M&T joints, by hand and I find immense enjoyment and satisfaction in doing them. Considering the time it used to take to set up the tenoning jig, cross checking the angle of the blade etc etc, I am finding that a good cup of coffee, no machine and dust extraction system noise and gently satisfying chiselling all go together well and only takes a few extra minutes to complete the joint.

Wood Floor Flooring Wood stain Hardwood


Wood Floor Wood stain Flooring Hardwood


Wood Art Hardwood Musical instrument Flooring


Wood Machine Flooring Retail Ceiling


Wood Floor Wood stain Flooring Hardwood


Wood Engineering Flooring Hardwood Table


Wood Building Hardwood Engineering Flooring


Wood Rectangle Flooring Floor Wood stain


Wood Floor Flooring Wood stain Hardwood


Property Furniture Wood Floor Flooring
Thought I commented on this but I guess it showed up on the first segment.
Anyway, looking really good.
 

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#16 ·
Some Progress and Pictures

Morning all. I have made a reasonable amount of progress on the various parts. Today's job
is the seat frame. This is made of locally grown air dried ****************************************. Heavy wood! Below are a few more pics to bring the project up to date.

I started wandering around Inkscape last night…."Daunting" is a phrase that comes to mind. Anyway, I have a few projects for clients that I have held off until the Chevy is ready to work, these were originally planned to do with a bird's mouth and a fretsaw, so hopefully they will be ideal to cut my teeth on the new toy!

Wood Floor Flooring Wood stain Hardwood

Wood Interior design Floor Flooring Wood stain

Wood Interior design Floor Flooring Wood stain


Yesterday, I also moved my bandsaw to the upper level in my machine room, this has given me a better workflow and more room on the lower level for more lumber! Yippee!!
 

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#17 ·
Some Progress and Pictures

Morning all. I have made a reasonable amount of progress on the various parts. Today's job
is the seat frame. This is made of locally grown air dried ****************************************. Heavy wood! Below are a few more pics to bring the project up to date.

I started wandering around Inkscape last night…."Daunting" is a phrase that comes to mind. Anyway, I have a few projects for clients that I have held off until the Chevy is ready to work, these were originally planned to do with a bird's mouth and a fretsaw, so hopefully they will be ideal to cut my teeth on the new toy!

Wood Floor Flooring Wood stain Hardwood

Wood Interior design Floor Flooring Wood stain

Wood Interior design Floor Flooring Wood stain


Yesterday, I also moved my bandsaw to the upper level in my machine room, this has given me a better workflow and more room on the lower level for more lumber! Yippee!!
You obviously have some great material and your skills aren't too shaby either.
This is going to be one fine chevalet.
What size are you making it?
 

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#19 ·
And the hip bone's connected to.......

A great day in the shop today. Did my habitual Saturday morning chisel check, sharpen and hone and then settled down to finish the construction of the seat section. This I made entirely out of the air dried **************************************** and I am getting more and more enamoured with this particular species, it joints crisply, sands reasonable fast and planes beautifully, although there will always be some interlocking grain to mess with one's kharma! (main reason is I get it really cheaply)

I did the tenon for the for the spring clamp system base part which fits into the seat with wedges as well…it ain't coming out!

All in all, a lovely day in the shop, the rest of the weekend I shall turn the wheels for the clamps, cut and fit the connector blocks for the two assemblies and and work on the metal carrier bar.

Thanks again Paul, your Sketchup drawing makes the whole project extremely easy to follow and I could not have got this far without it.

Some more pics:

Wood Hardwood Shelving Art Lumber


Wood Hardwood Wood stain Art Machine


Wood Hardwood Wood stain Shelving Machine


Thanks for looking in.
 

Attachments

#20 ·
And the hip bone's connected to.......

A great day in the shop today. Did my habitual Saturday morning chisel check, sharpen and hone and then settled down to finish the construction of the seat section. This I made entirely out of the air dried **************************************** and I am getting more and more enamoured with this particular species, it joints crisply, sands reasonable fast and planes beautifully, although there will always be some interlocking grain to mess with one's kharma! (main reason is I get it really cheaply)

I did the tenon for the for the spring clamp system base part which fits into the seat with wedges as well…it ain't coming out!

All in all, a lovely day in the shop, the rest of the weekend I shall turn the wheels for the clamps, cut and fit the connector blocks for the two assemblies and and work on the metal carrier bar.

Thanks again Paul, your Sketchup drawing makes the whole project extremely easy to follow and I could not have got this far without it.

Some more pics:

Wood Hardwood Shelving Art Lumber


Wood Hardwood Wood stain Art Machine


Wood Hardwood Wood stain Shelving Machine


Thanks for looking in.
It's coming along nicely.
Jim
 

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#25 ·
Wife: What on earth is that Thing?

When I told her that it is going to be a "Chevalet de Marqueterie", she told me not to swear at her!

I have managed a bit more progress yesterday and today, and to me it feels that it looks a little more like the thingy that I set out to build.

Quite a bit still to go though….. metalwork for the saw frame, the saw frame itself, the foot pedal system, cleaning up here and there, and then the tuning…..I am feeling somewhat daunted by the tuning part, but am sure that with the help of Paul and others I will manage it.
Here are a few pics from today:

Wood Flooring Floor Hardwood Room


Wood Flooring Floor Hardwood Wood stain


Wood Gas Hardwood Wood stain Plywood


Wood Hardwood Composite material Tool Wood stain


Hood Automotive tire Wood Tire Wheel


Wood Wheel Tire Car Automotive tire


Thanks for looking in.
 

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#26 ·
Wife: What on earth is that Thing?

When I told her that it is going to be a "Chevalet de Marqueterie", she told me not to swear at her!

I have managed a bit more progress yesterday and today, and to me it feels that it looks a little more like the thingy that I set out to build.

Quite a bit still to go though….. metalwork for the saw frame, the saw frame itself, the foot pedal system, cleaning up here and there, and then the tuning…..I am feeling somewhat daunted by the tuning part, but am sure that with the help of Paul and others I will manage it.
Here are a few pics from today:

Wood Flooring Floor Hardwood Room


Wood Flooring Floor Hardwood Wood stain


Wood Gas Hardwood Wood stain Plywood


Wood Hardwood Composite material Tool Wood stain


Hood Automotive tire Wood Tire Wheel


Wood Wheel Tire Car Automotive tire


Thanks for looking in.
That thing looks strangely familiar.
I'm going to be a proud uncle again!
If you've kept everything nice and square the tuning will be really easy. I'll be happy to talk you through it.
I PM'd you my email.
 

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#30 ·
Almost Complete...

On Friday I finished all of the wood componentry for my Chevalet. Out here in Swellendam, it is a little difficult to find certain things such as light thin chain for the foot pedal clamp. I know I have brass chain somewhere in the shop, but just cannot find it. My alternative will be to order some from Cape Town if it does not turn up.

I approached the wonderful plane maker, Jan Nezar (LJ-Toolchap) of Mossel Bay about 1.5 hours away to make up the metal components for the saw frame and he has very kindly agreed to help me. Jan is a real tool making legend.

My blades are on their way from Germany via Niqua's local agent, Cape Watch & Co. in Cape Town and Rodger Brown of Cape Watch has agreed to keep the blades in stock for me. Kind, genuine wonderful helpful people all round.

So now I wait for bits and bobs. I should really have started the blade and saw frame fittings procurement process earlier so that I had them before I finished the build, planning has never been my strongest talent!

I did try to follow Paul's drawing to make up the saw frame bits, but my metalworking skill are so very similar to my skiing skills, and I cannot ski! So I turned to the talents of the expert.

Once I have the fittings in hand, I shall post a photos of the completed Chevy.
 
#31 ·
It has to be tough waiting for parts when you are otherwise finished. Maybe you can do some relief carving on the column or something.
If you are having the clamp parts made you can make better than my originals. They were a compromise based on the materials I could get at the hardware store and the tools I had on hand. They worked but I have since had better ones made for me.
 
#32 ·
Metal parts for the build

A few days ago, a very dear friend and I went off to Dana Bay to visit another lumberjock. This enigmatic and remarkable fellow calls himself Toolchap. His workshop reminds me of my dad's shop when I was young…. and the perennial question came to mind once again, how the hell does he get his mind boggling array of tools into that small space, the best part is that he knows exactly where everything is, I bow humbly before him!!

What a wonderful trip it turned out to be. We had gone to fetch two metal parts that he had kindly made for my Chevalet project. They were beautifully made, even down to period style custom wing nuts!

Toolchap is a repository. One of knowledge, enthusiasm, cynicism, romance, and most wonderful of all, love for his passion. I learned a lot that day, not only about Stewart Spiers and Norris, Marples and Stanley, not only about spiral staircases, not only about the feeling of woodwork and its tools, but about shared values, dreams and creativity in its most honest forms.

Thank you Jan, for your hospitality and your fervent passion, for your home baked bread and permanent supply of hot tea, and thank you mostly for your infectious way of sharing.

PS..Thank you doubly for the vintage Wadkin Miter Trimmer it is already most comfortable and warm in my workshop.
 
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