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Hope Chest for Daughter #2

39K views 151 replies 34 participants last post by  Mean_Dean 
#1 ·
Design approved and construction details planned out....

Furniture Drawer Rectangle Wood Chest of drawers


Daughter #2 has "approved" the design of her hope chest. Here's my rendered solid model….

I started from the same NYWS that I used for her sisters, but with the following skill builder changes:

1. outside edges will be joined with Lock Miter instead of tongue tenon and groove.
2. rails and styles will be profiled and joined with a cope cut instead of mortise and tenon .
3. panels will be raised and back cut instead of flat.
4. feet will be cut with a taper, instead of curve.
5. name will be CNC routed on top rail as b4
6. wood will be Mahogany (a stack of 44" cut offs left over from a 15 year old deck project and given to a buddy who later painted the house and in turn gave them to me). They are weathered gray from sitting under the deck all those years. but most are straight and all are sound.

The finnish is TBD, but I'd like to try spraying it. The wood has a nice "milk chocolate" color and I'd like to use a finish that highlights the grain and does not darken it.
 

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#2 ·
Design approved and construction details planned out....

Furniture Drawer Rectangle Wood Chest of drawers


Daughter #2 has "approved" the design of her hope chest. Here's my rendered solid model….

I started from the same NYWS that I used for her sisters, but with the following skill builder changes:

1. outside edges will be joined with Lock Miter instead of tongue tenon and groove.
2. rails and styles will be profiled and joined with a cope cut instead of mortise and tenon .
3. panels will be raised and back cut instead of flat.
4. feet will be cut with a taper, instead of curve.
5. name will be CNC routed on top rail as b4
6. wood will be Mahogany (a stack of 44" cut offs left over from a 15 year old deck project and given to a buddy who later painted the house and in turn gave them to me). They are weathered gray from sitting under the deck all those years. but most are straight and all are sound.

The finnish is TBD, but I'd like to try spraying it. The wood has a nice "milk chocolate" color and I'd like to use a finish that highlights the grain and does not darken it.
It's going to be a nice build, Matt. I like the plan.
 

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#3 ·
Design approved and construction details planned out....

Furniture Drawer Rectangle Wood Chest of drawers


Daughter #2 has "approved" the design of her hope chest. Here's my rendered solid model….

I started from the same NYWS that I used for her sisters, but with the following skill builder changes:

1. outside edges will be joined with Lock Miter instead of tongue tenon and groove.
2. rails and styles will be profiled and joined with a cope cut instead of mortise and tenon .
3. panels will be raised and back cut instead of flat.
4. feet will be cut with a taper, instead of curve.
5. name will be CNC routed on top rail as b4
6. wood will be Mahogany (a stack of 44" cut offs left over from a 15 year old deck project and given to a buddy who later painted the house and in turn gave them to me). They are weathered gray from sitting under the deck all those years. but most are straight and all are sound.

The finnish is TBD, but I'd like to try spraying it. The wood has a nice "milk chocolate" color and I'd like to use a finish that highlights the grain and does not darken it.
Matt, I have a chest out in the shop now that I started out of eastern cedar. It is a panel design like that. That looks pretty good, I may have to finish it some day…..
 

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#4 ·
Design approved and construction details planned out....

Furniture Drawer Rectangle Wood Chest of drawers


Daughter #2 has "approved" the design of her hope chest. Here's my rendered solid model….

I started from the same NYWS that I used for her sisters, but with the following skill builder changes:

1. outside edges will be joined with Lock Miter instead of tongue tenon and groove.
2. rails and styles will be profiled and joined with a cope cut instead of mortise and tenon .
3. panels will be raised and back cut instead of flat.
4. feet will be cut with a taper, instead of curve.
5. name will be CNC routed on top rail as b4
6. wood will be Mahogany (a stack of 44" cut offs left over from a 15 year old deck project and given to a buddy who later painted the house and in turn gave them to me). They are weathered gray from sitting under the deck all those years. but most are straight and all are sound.

The finnish is TBD, but I'd like to try spraying it. The wood has a nice "milk chocolate" color and I'd like to use a finish that highlights the grain and does not darken it.
For the sake of comparison, here's the rendered model of the first one I did, which is built and done…

Chest of drawers Rectangle Wood Dresser Drawer
 

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#5 ·
Design approved and construction details planned out....

Furniture Drawer Rectangle Wood Chest of drawers


Daughter #2 has "approved" the design of her hope chest. Here's my rendered solid model….

I started from the same NYWS that I used for her sisters, but with the following skill builder changes:

1. outside edges will be joined with Lock Miter instead of tongue tenon and groove.
2. rails and styles will be profiled and joined with a cope cut instead of mortise and tenon .
3. panels will be raised and back cut instead of flat.
4. feet will be cut with a taper, instead of curve.
5. name will be CNC routed on top rail as b4
6. wood will be Mahogany (a stack of 44" cut offs left over from a 15 year old deck project and given to a buddy who later painted the house and in turn gave them to me). They are weathered gray from sitting under the deck all those years. but most are straight and all are sound.

The finnish is TBD, but I'd like to try spraying it. The wood has a nice "milk chocolate" color and I'd like to use a finish that highlights the grain and does not darken it.
Well, when do we start? I'm ready to see the progress….. Maybe a video blog???
Good lookin design, Matt
 

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#6 ·
Design approved and construction details planned out....

Furniture Drawer Rectangle Wood Chest of drawers


Daughter #2 has "approved" the design of her hope chest. Here's my rendered solid model….

I started from the same NYWS that I used for her sisters, but with the following skill builder changes:

1. outside edges will be joined with Lock Miter instead of tongue tenon and groove.
2. rails and styles will be profiled and joined with a cope cut instead of mortise and tenon .
3. panels will be raised and back cut instead of flat.
4. feet will be cut with a taper, instead of curve.
5. name will be CNC routed on top rail as b4
6. wood will be Mahogany (a stack of 44" cut offs left over from a 15 year old deck project and given to a buddy who later painted the house and in turn gave them to me). They are weathered gray from sitting under the deck all those years. but most are straight and all are sound.

The finnish is TBD, but I'd like to try spraying it. The wood has a nice "milk chocolate" color and I'd like to use a finish that highlights the grain and does not darken it.
I stuck with the NYWS plan, but I wanted my daughter to have a high sense of ownership, so we looked at a lot of images on line and this was the aesthetic style that she chose (and I must say she has good taste).

Furniture Drawer Rectangle Wood Chest of drawers


Again, encouraging her "ownership", I gave her some options for the raised panel profile….

Building Rectangle Wood Triangle Font


She chose the Ogee profile and by adapting that to the NYWS geometry (which she wanted to keep) we'll be making our own "style statement" :^)
 

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#7 ·
Design approved and construction details planned out....

Furniture Drawer Rectangle Wood Chest of drawers


Daughter #2 has "approved" the design of her hope chest. Here's my rendered solid model….

I started from the same NYWS that I used for her sisters, but with the following skill builder changes:

1. outside edges will be joined with Lock Miter instead of tongue tenon and groove.
2. rails and styles will be profiled and joined with a cope cut instead of mortise and tenon .
3. panels will be raised and back cut instead of flat.
4. feet will be cut with a taper, instead of curve.
5. name will be CNC routed on top rail as b4
6. wood will be Mahogany (a stack of 44" cut offs left over from a 15 year old deck project and given to a buddy who later painted the house and in turn gave them to me). They are weathered gray from sitting under the deck all those years. but most are straight and all are sound.

The finnish is TBD, but I'd like to try spraying it. The wood has a nice "milk chocolate" color and I'd like to use a finish that highlights the grain and does not darken it.
Great idea getting the Daughter involved. Looks like a great design.
 

Attachments

#8 ·
Design approved and construction details planned out....

Furniture Drawer Rectangle Wood Chest of drawers


Daughter #2 has "approved" the design of her hope chest. Here's my rendered solid model….

I started from the same NYWS that I used for her sisters, but with the following skill builder changes:

1. outside edges will be joined with Lock Miter instead of tongue tenon and groove.
2. rails and styles will be profiled and joined with a cope cut instead of mortise and tenon .
3. panels will be raised and back cut instead of flat.
4. feet will be cut with a taper, instead of curve.
5. name will be CNC routed on top rail as b4
6. wood will be Mahogany (a stack of 44" cut offs left over from a 15 year old deck project and given to a buddy who later painted the house and in turn gave them to me). They are weathered gray from sitting under the deck all those years. but most are straight and all are sound.

The finnish is TBD, but I'd like to try spraying it. The wood has a nice "milk chocolate" color and I'd like to use a finish that highlights the grain and does not darken it.
Looks like a great design Matt and really great to involve your daughters in the process…....it's all good.
 

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#9 ·
Design approved and construction details planned out....

Furniture Drawer Rectangle Wood Chest of drawers


Daughter #2 has "approved" the design of her hope chest. Here's my rendered solid model….

I started from the same NYWS that I used for her sisters, but with the following skill builder changes:

1. outside edges will be joined with Lock Miter instead of tongue tenon and groove.
2. rails and styles will be profiled and joined with a cope cut instead of mortise and tenon .
3. panels will be raised and back cut instead of flat.
4. feet will be cut with a taper, instead of curve.
5. name will be CNC routed on top rail as b4
6. wood will be Mahogany (a stack of 44" cut offs left over from a 15 year old deck project and given to a buddy who later painted the house and in turn gave them to me). They are weathered gray from sitting under the deck all those years. but most are straight and all are sound.

The finnish is TBD, but I'd like to try spraying it. The wood has a nice "milk chocolate" color and I'd like to use a finish that highlights the grain and does not darken it.
Sounds like a fun project, Matt. Will the daughter assist?
Have a project coming up using lock miters. My first. Let me know how you do.
 

Attachments

#10 ·
Design approved and construction details planned out....

Furniture Drawer Rectangle Wood Chest of drawers


Daughter #2 has "approved" the design of her hope chest. Here's my rendered solid model….

I started from the same NYWS that I used for her sisters, but with the following skill builder changes:

1. outside edges will be joined with Lock Miter instead of tongue tenon and groove.
2. rails and styles will be profiled and joined with a cope cut instead of mortise and tenon .
3. panels will be raised and back cut instead of flat.
4. feet will be cut with a taper, instead of curve.
5. name will be CNC routed on top rail as b4
6. wood will be Mahogany (a stack of 44" cut offs left over from a 15 year old deck project and given to a buddy who later painted the house and in turn gave them to me). They are weathered gray from sitting under the deck all those years. but most are straight and all are sound.

The finnish is TBD, but I'd like to try spraying it. The wood has a nice "milk chocolate" color and I'd like to use a finish that highlights the grain and does not darken it.
I agree with all above. Looks like a some good memories about to happen in the shop. Look forward to seeing it.
 

Attachments

#11 ·
Design approved and construction details planned out....

Furniture Drawer Rectangle Wood Chest of drawers


Daughter #2 has "approved" the design of her hope chest. Here's my rendered solid model….

I started from the same NYWS that I used for her sisters, but with the following skill builder changes:

1. outside edges will be joined with Lock Miter instead of tongue tenon and groove.
2. rails and styles will be profiled and joined with a cope cut instead of mortise and tenon .
3. panels will be raised and back cut instead of flat.
4. feet will be cut with a taper, instead of curve.
5. name will be CNC routed on top rail as b4
6. wood will be Mahogany (a stack of 44" cut offs left over from a 15 year old deck project and given to a buddy who later painted the house and in turn gave them to me). They are weathered gray from sitting under the deck all those years. but most are straight and all are sound.

The finnish is TBD, but I'd like to try spraying it. The wood has a nice "milk chocolate" color and I'd like to use a finish that highlights the grain and does not darken it.
That will be a great chest….
Filled with hope & memories!!!

Looking forward to, seeing the build progress.
I will follow the travails!!!
 

Attachments

#12 ·
Design approved and construction details planned out....

Furniture Drawer Rectangle Wood Chest of drawers


Daughter #2 has "approved" the design of her hope chest. Here's my rendered solid model….

I started from the same NYWS that I used for her sisters, but with the following skill builder changes:

1. outside edges will be joined with Lock Miter instead of tongue tenon and groove.
2. rails and styles will be profiled and joined with a cope cut instead of mortise and tenon .
3. panels will be raised and back cut instead of flat.
4. feet will be cut with a taper, instead of curve.
5. name will be CNC routed on top rail as b4
6. wood will be Mahogany (a stack of 44" cut offs left over from a 15 year old deck project and given to a buddy who later painted the house and in turn gave them to me). They are weathered gray from sitting under the deck all those years. but most are straight and all are sound.

The finnish is TBD, but I'd like to try spraying it. The wood has a nice "milk chocolate" color and I'd like to use a finish that highlights the grain and does not darken it.
I cant wait for this one.
Keep us tuned in on the progress.
 

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#17 ·
Hauled in wood from the barn to acclimate

This pile of lumber was given to my good friend after painting a house. They apparently are the cutoffs from a deck build some years earlier and sat piled under the deck. He in turn gifted them to me.

38 boards of 4/4×3-1/2×50" S4S

My wood expert friends at work say it's Honduran Mahogany.

I've had it up in the barn loft for ~5 years since and today my A1 helper and I lugged it into the basement to get acclimated. We're hoping to get started on the chest while she's on Spring brake. Assuming spring ever comes.

Wood Plank Hardwood Wood stain Art


Brown Rectangle Table Wood Wood stain
 

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#18 ·
Hauled in wood from the barn to acclimate

This pile of lumber was given to my good friend after painting a house. They apparently are the cutoffs from a deck build some years earlier and sat piled under the deck. He in turn gifted them to me.

38 boards of 4/4×3-1/2×50" S4S

My wood expert friends at work say it's Honduran Mahogany.

I've had it up in the barn loft for ~5 years since and today my A1 helper and I lugged it into the basement to get acclimated. We're hoping to get started on the chest while she's on Spring brake. Assuming spring ever comes.

Wood Plank Hardwood Wood stain Art


Brown Rectangle Table Wood Wood stain
Very nice…...this will be a real beauty…..
 

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#27 ·
Stock prep day

Sorted boards to get the straightest ones, then hit them with a wire brush to get the dirt off of them.

Jointer-jointer-planer-table saw

Flat face - square and flat edge - parallel and flat opposite face - parallel square and flat opposite edge

When ripping I was only taking a skim cut to minimize loss of width. This can be really messy with most of the sawdust blowing back on me, so I set up the shop vac with a funnel to catch most of it….

Wood Flooring Rectangle Floor Hardwood


I stickered the boards under weight to let any residual internal stresses relax…

Wood Art Wood stain Hardwood Flooring


The dark is all from today…

Textile Automotive tire Camera lens Wood Comfort


It will be interesting to see if these get any curvy twisty mischief.

Finish dims are 7/8" thick by 3-7/16" wide.

If all goes well I may glue up the top on Monday.

Thanks for looking
 

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#28 ·
Stock prep day

Sorted boards to get the straightest ones, then hit them with a wire brush to get the dirt off of them.

Jointer-jointer-planer-table saw

Flat face - square and flat edge - parallel and flat opposite face - parallel square and flat opposite edge

When ripping I was only taking a skim cut to minimize loss of width. This can be really messy with most of the sawdust blowing back on me, so I set up the shop vac with a funnel to catch most of it….

Wood Flooring Rectangle Floor Hardwood


I stickered the boards under weight to let any residual internal stresses relax…

Wood Art Wood stain Hardwood Flooring


The dark is all from today…

Textile Automotive tire Camera lens Wood Comfort


It will be interesting to see if these get any curvy twisty mischief.

Finish dims are 7/8" thick by 3-7/16" wide.

If all goes well I may glue up the top on Monday.

Thanks for looking
Lookin good, that's some nice mahogany. I did a similar thing with so e poplar the other day and the first piece I planed twisted so I stopped to let it acclimate some more. Hoping later this week to face joint again and then plane to 3/4.

Gonna use mortise and tenon on this thing?
 

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#39 ·
Top is glued up

I am very happy with the quality of cut I am getting with the Fussion blade, and have no reservations about gluing up the panels right off of the TS. Smoother and straighter than my jointer produces (granted, it's a really old jointer).

My daughter came down and cut the biscuit joints and assisted with the glue up. I'm so glad she did, as we needed to move fast. We were much better organized and prepared than my first build, yet were still challenged to get it clamped up quickly.

After cutting all the biscuits in the first board she says to me "shouldn't I have safety glasses on"

Doh!!!! I'm glad somebody was on the ball…. as it sure wasn't me.

Here she is scraping the squeezed out glue off when we were all done.

Wood Table Clock Flooring Engineering
 

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#40 ·
Top is glued up

I am very happy with the quality of cut I am getting with the Fussion blade, and have no reservations about gluing up the panels right off of the TS. Smoother and straighter than my jointer produces (granted, it's a really old jointer).

My daughter came down and cut the biscuit joints and assisted with the glue up. I'm so glad she did, as we needed to move fast. We were much better organized and prepared than my first build, yet were still challenged to get it clamped up quickly.

After cutting all the biscuits in the first board she says to me "shouldn't I have safety glasses on"

Doh!!!! I'm glad somebody was on the ball…. as it sure wasn't me.

Here she is scraping the squeezed out glue off when we were all done.

Wood Table Clock Flooring Engineering
Good to see the that the family that glues together….
STICKS together!!!

A really good thing….
Your daughter has a brain on her shoulders.
You on the other hand should be protecting what brain cells you have left!!! ;^)
 

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#53 ·
Cleaned up the top and sanded.... almost blew it.

So this is the one tool in my shop that has time and time again brought me to the brink of catastrophe….

Wood Audio equipment Gas Automotive tire Hardwood


Within the first 60 seconds of sanding with 100 grit, I had put several depressions in the top. And of course, I started on the better of the two sides. :^(

I had no problems using the belt sander on my first daughters hope chest in Red Oak, but lesson learned today…. Mahogany is not nearly as hard of a hard wood and Oak.

Here's what we used for the save….

Hand tool Wood Tool Metalworking hand tool Hardwood


We went over the entire panel with the scraper, and were able to get the depressions out. Then on the other side, we abandoned the belt sander and used the large 2" timber framing chisel for paring the glue lines off and then scraped the glue lines. Here's my girl using the scraper…. I told her not to think about it, but rather to feel it, and adjust the angle and bow until she could tell she was getting a good scrape.

Wood Sleeve Sunglasses Eyewear Flooring


Smile Vision care Wood Table Machine


Then we hit it with the random orbital sander, starting with 150 and finishing with 220. And this is what we wound up with when we were done.

Brown Wood Rectangle Table Flooring


Next job is bread boards.

Adios
 

Attachments

#54 ·
Cleaned up the top and sanded.... almost blew it.

So this is the one tool in my shop that has time and time again brought me to the brink of catastrophe….

Wood Audio equipment Gas Automotive tire Hardwood


Within the first 60 seconds of sanding with 100 grit, I had put several depressions in the top. And of course, I started on the better of the two sides. :^(

I had no problems using the belt sander on my first daughters hope chest in Red Oak, but lesson learned today…. Mahogany is not nearly as hard of a hard wood and Oak.

Here's what we used for the save….

Hand tool Wood Tool Metalworking hand tool Hardwood


We went over the entire panel with the scraper, and were able to get the depressions out. Then on the other side, we abandoned the belt sander and used the large 2" timber framing chisel for paring the glue lines off and then scraped the glue lines. Here's my girl using the scraper…. I told her not to think about it, but rather to feel it, and adjust the angle and bow until she could tell she was getting a good scrape.

Wood Sleeve Sunglasses Eyewear Flooring


Smile Vision care Wood Table Machine


Then we hit it with the random orbital sander, starting with 150 and finishing with 220. And this is what we wound up with when we were done.

Brown Wood Rectangle Table Flooring


Next job is bread boards.

Adios
Great pictures, Matt. Father - daughter days make for sweet memories.
 

Attachments

#62 ·
Cleaned up the top and sanded.... almost blew it.

So this is the one tool in my shop that has time and time again brought me to the brink of catastrophe….

Wood Audio equipment Gas Automotive tire Hardwood


Within the first 60 seconds of sanding with 100 grit, I had put several depressions in the top. And of course, I started on the better of the two sides. :^(

I had no problems using the belt sander on my first daughters hope chest in Red Oak, but lesson learned today…. Mahogany is not nearly as hard of a hard wood and Oak.

Here's what we used for the save….

Hand tool Wood Tool Metalworking hand tool Hardwood


We went over the entire panel with the scraper, and were able to get the depressions out. Then on the other side, we abandoned the belt sander and used the large 2" timber framing chisel for paring the glue lines off and then scraped the glue lines. Here's my girl using the scraper…. I told her not to think about it, but rather to feel it, and adjust the angle and bow until she could tell she was getting a good scrape.

Wood Sleeve Sunglasses Eyewear Flooring


Smile Vision care Wood Table Machine


Then we hit it with the random orbital sander, starting with 150 and finishing with 220. And this is what we wound up with when we were done.

Brown Wood Rectangle Table Flooring


Next job is bread boards.

Adios
Hi Dan, Yes, please let me know your wood source. I've never worked with Cherry, but I've hot one more daughter to build a chest for after this one, so that might be a good option.

Did ya ever take a crackpot at re-sawing that maple?

Yes Andy, I think I might be ready to hang up the belt sander for a while.
 

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#66 ·
Aftèr a long delay, we have bread boards

It's been a 2 year delay, so I guess I better get going on this project again…

The bread boards were previously planed at the same time as the top boards.

I cut the dados with a slot cutting router bit on the router table. Then I cut the top to length on the TS with a panel sled. I cut the tennons on the ends with a hand router and a rabbiting bit with a guide bearing.

Table Wood Rectangle Flooring Plank


I cut the slots short on the front side of the bread boards to hide the joint…

Brown Rectangle Wood Wood stain Hardwood


One of these ruptured when mounted, so I had to chisel out the blow out square and plug it.

Brown Rectangle Wood Wood stain Flooring


I ripped both sides to get the final width and the ripped the ends in the panel sled to get the final length.

Sanded 80-150-220 and have a silly smooth surface.

Wood Yellow Rectangle Flooring Hardwood
 

Attachments

#67 ·
Aftèr a long delay, we have bread boards

It's been a 2 year delay, so I guess I better get going on this project again…

The bread boards were previously planed at the same time as the top boards.

I cut the dados with a slot cutting router bit on the router table. Then I cut the top to length on the TS with a panel sled. I cut the tennons on the ends with a hand router and a rabbiting bit with a guide bearing.

Table Wood Rectangle Flooring Plank


I cut the slots short on the front side of the bread boards to hide the joint…

Brown Rectangle Wood Wood stain Hardwood


One of these ruptured when mounted, so I had to chisel out the blow out square and plug it.

Brown Rectangle Wood Wood stain Flooring


I ripped both sides to get the final width and the ripped the ends in the panel sled to get the final length.

Sanded 80-150-220 and have a silly smooth surface.

Wood Yellow Rectangle Flooring Hardwood
Beautiful job Matt, really fetching. Great work. Fine craftsmanship.
 

Attachments

#71 ·
Back at it...

I've finally wrapped up my last interfering project and have cleared the decks for action to get back into this project…

My intention is to work it until completion…

Broke out the raised panel set and reviewed my plans…
Font Material property Carmine Audio equipment Pattern


Then I sorted my stock, selected boards for the long rails, cut off the checked ends, cut them to 3/4" over sized, and set up the style bit on my router table….
Wood Wood stain Hardwood Plank Flooring


I used 13,000 rpm on the router (Porter Cable 3HP VS) and it cut effortlessly, leaving a very nice finish…

Unfortunately, I discovered a hidden defect in one of the boards, but this one was already designated for the back side and I'm going to see if I can get away with filling the little blow outs.

Next up, short rails, then styles, then glue up panels.

I'm tight on stock, so I have to plan this out carefully.
 

Attachments

#72 ·
Back at it...

I've finally wrapped up my last interfering project and have cleared the decks for action to get back into this project…

My intention is to work it until completion…

Broke out the raised panel set and reviewed my plans…
Font Material property Carmine Audio equipment Pattern


Then I sorted my stock, selected boards for the long rails, cut off the checked ends, cut them to 3/4" over sized, and set up the style bit on my router table….
Wood Wood stain Hardwood Plank Flooring


I used 13,000 rpm on the router (Porter Cable 3HP VS) and it cut effortlessly, leaving a very nice finish…

Unfortunately, I discovered a hidden defect in one of the boards, but this one was already designated for the back side and I'm going to see if I can get away with filling the little blow outs.

Next up, short rails, then styles, then glue up panels.

I'm tight on stock, so I have to plan this out carefully.
Good to see you back at this.

BTW: The contest is for a chair build…. ya better hurry!!!
 

Attachments

#80 ·
gluing up panels with the new clamping cauls

Got a couple hours in the shop tonight. Sorting boards to match grain, color and shade, and then put together the first of several panel glue ups.

It's been >1 year since I joined and planed these, so I gave each board a quick rip on the TS to straighten the edges. The Fusion blade gave me a very clean cut that was ready for glue.

First time using the new cauls (posted as a project some time ago if anyone wants to see more info) and they worked very well. I can hardly feel a seem between the boards.

Wood Engineering Rolling Machine Hardwood


Of course, I'm a glutton for punishment, so I put in #20 biscuits anyways…. primarily so I can say to myself "I didn't waste money on the biscuit jointer after all"

Fun, fun, fun :^)
 

Attachments

#81 ·
Panels Cleaned Up

I finished the 5 panel glue ups and put the clamping cauls and clamps away, and cleared the bench for the next step, cleaning up the panels.

I wiped off as much of the glue that squeezed out off right away with wet paper towels, so the tops were in pretty good shape.

Table Wood Rectangle Flooring Floor


The bottoms were a different story.
Table Wood Rectangle Flooring Floor

Brown Wood Flooring Wood stain Hardwood


I like to take the big boogers off by paring with a large 2" timber framing chisel, using it like a slick.
Table Tableware Wood Wood stain Hardwood


Then I hit the joints with a card scraper.
Wood Rectangle Flooring Wood stain Hardwood


And I'm ready to sand.
Brown Wood Table Flooring Door


I use a down draft table that doubles as my TS outfeed table, with a shop vac connected to the sanders, and a Jet AFS air filter mounted above, and I ware a dust mask.
Automotive design Wood Engineering Flooring Machine


I started with the belt sander, 80 grit, then 100 grit.
Artisan Bottle Wood Art Engineering


I should have started with 60 grit, as I got impatient with the 80 and applied too much force, which generated too much heat and made the seam fail (twice).
Musical instrument Musical instrument accessory Guitar accessory Audio equipment Wood


Then 150 grit on the RO sander.
Wood Saw Pneumatic tool Artisan Tool


Here's one all done. Something funny is going on with the light here… the color is actually uniform across the surface.
Wood Flooring Floor Audio equipment Rectangle


And here's all 5 finished up.
Table Wood Engineering Flooring Roof


Looks like the filter is doing its job.
Lighting Wood Window Gas Flooring


And that's all she wrote. Time to put a dry shirt on and sit down to enjoy a cold one.

Thanks for stopping by to take a look.
 

Attachments

#82 ·
Panels Cleaned Up

I finished the 5 panel glue ups and put the clamping cauls and clamps away, and cleared the bench for the next step, cleaning up the panels.

I wiped off as much of the glue that squeezed out off right away with wet paper towels, so the tops were in pretty good shape.

Table Wood Rectangle Flooring Floor


The bottoms were a different story.
Table Wood Rectangle Flooring Floor

Brown Wood Flooring Wood stain Hardwood


I like to take the big boogers off by paring with a large 2" timber framing chisel, using it like a slick.
Table Tableware Wood Wood stain Hardwood


Then I hit the joints with a card scraper.
Wood Rectangle Flooring Wood stain Hardwood


And I'm ready to sand.
Brown Wood Table Flooring Door


I use a down draft table that doubles as my TS outfeed table, with a shop vac connected to the sanders, and a Jet AFS air filter mounted above, and I ware a dust mask.
Automotive design Wood Engineering Flooring Machine


I started with the belt sander, 80 grit, then 100 grit.
Artisan Bottle Wood Art Engineering


I should have started with 60 grit, as I got impatient with the 80 and applied too much force, which generated too much heat and made the seam fail (twice).
Musical instrument Musical instrument accessory Guitar accessory Audio equipment Wood


Then 150 grit on the RO sander.
Wood Saw Pneumatic tool Artisan Tool


Here's one all done. Something funny is going on with the light here… the color is actually uniform across the surface.
Wood Flooring Floor Audio equipment Rectangle


And here's all 5 finished up.
Table Wood Engineering Flooring Roof


Looks like the filter is doing its job.
Lighting Wood Window Gas Flooring


And that's all she wrote. Time to put a dry shirt on and sit down to enjoy a cold one.

Thanks for stopping by to take a look.
Good progress Matt.
 

Attachments

#84 ·
How I prep card scrapers.

I make no claim to be a "real" galoot with the card scraper, but this process to renew the burr has worked for me.

After a lot of use, the burr will get mangled and need to be created afresh. I start by setting up the scraper in a make shift jig using the bench vise and a couple scrap blocks of identical thickness. I set the scraper just above the blocks using a feeler gauge to get uniform height exposed.
Table Wood Wood stain Material property Plank


Then I file the old burr off with a mill file, using the jig to keep the file square.
Wood Flooring Wood stain Hardwood Tire


Then I go to the granite surface plate and stone out the rough filed surface, using the side face to keep the stone square (note: I keep the granite plate set up for scary sharp sharpening).
Hand Wood Tints and shades Thumb Everyday carry


Next, I remove any small burrs residual from the filing.
Wood Gesture Floor Finger Hood


And inspect the edge to see if it's smoothe and square.
Liquid Fluid Gas Rim Recipe


I made a burnishing tool by putting the shank of a broken solid carbide router bit into an old screw driver handle.
Office supplies Writing implement Handwriting Wood Tints and shades


Burnishing the new burr is just swiping the tool across the edge at ~ 20 deg. angle

When your all done, you want the scraper to make shavings and not saw dust.
Wood Rectangle Flooring Wood stain Hardwood

Brown Wood Insect Pest Hardwood


After some use, I use the burnisher to renew the burr. This can be done several times, until you have to start all over.

Not a first class setup, but it gets the job done pretty well.
 

Attachments

#85 ·
How I prep card scrapers.

I make no claim to be a "real" galoot with the card scraper, but this process to renew the burr has worked for me.

After a lot of use, the burr will get mangled and need to be created afresh. I start by setting up the scraper in a make shift jig using the bench vise and a couple scrap blocks of identical thickness. I set the scraper just above the blocks using a feeler gauge to get uniform height exposed.
Table Wood Wood stain Material property Plank


Then I file the old burr off with a mill file, using the jig to keep the file square.
Wood Flooring Wood stain Hardwood Tire


Then I go to the granite surface plate and stone out the rough filed surface, using the side face to keep the stone square (note: I keep the granite plate set up for scary sharp sharpening).
Hand Wood Tints and shades Thumb Everyday carry


Next, I remove any small burrs residual from the filing.
Wood Gesture Floor Finger Hood


And inspect the edge to see if it's smoothe and square.
Liquid Fluid Gas Rim Recipe


I made a burnishing tool by putting the shank of a broken solid carbide router bit into an old screw driver handle.
Office supplies Writing implement Handwriting Wood Tints and shades


Burnishing the new burr is just swiping the tool across the edge at ~ 20 deg. angle

When your all done, you want the scraper to make shavings and not saw dust.
Wood Rectangle Flooring Wood stain Hardwood

Brown Wood Insect Pest Hardwood


After some use, I use the burnisher to renew the burr. This can be done several times, until you have to start all over.

Not a first class setup, but it gets the job done pretty well.
Interesting post, I am not sure what your inteperation of "galoot" is, but what is your opinion as to the finish produced by a scraper is when compared to the grit system?

Its obviously in the 1000 Grit or higher?
 

Attachments

#90 ·
panels cut to size and styles prepped

My first big mistake happened earlier this week when I set up the TS sled to cut my panels to size.
One of these things is not like the other… 3/4" short to be precise… and of course it was the panel with the nicest wood figure.
Rectangle Wood Floor Flooring Hardwood


So after sulking for a few days, I went back into my design and made it 1.5" shorter, and cut the other side panels to match. I should have set up with a stop block like this the first time around…
Wood Floor Flooring Hardwood Automotive design


Then I moved on to prepping the stock for the corner post/styles, doing my best to cut around the splits and checks…
Wood Shelving Gas Hardwood Machine


Here they are all ready to rout. Just one piece that still has a split. I'll have to try to stabilize that one with CA glue…
Table Musical instrument Wood Keyboard Digital piano


Decided to pre-sand before routing…
Wheel Automotive tire Motor vehicle Tire Wood


So far I'm pretty happy with the Amana AGE line raised panel set as I'm getting a clean, effortless cut…
Gas Wood Font Machine Screw


A couple sticks had hidden defects that appeared after routing, but nothing a little Timber Mate filler can't take care of…
Furniture Table Cabinetry Wood Rectangle


I thought I'd give a shout out for the DC on the Rockler router table tops, as it is catching 99% of the waste…
Automotive tire Bumper Wood Automotive exterior Tread


Here's the stack so far. This is my first time attempting raised panels and things go pretty fast once you have the router table set up…
Cabinetry Furniture Drawer Wood Shelving


The Inspector General stopped in to check up on my progress. Though she's not so interested in helping out, she is still very interested in receiving the finished product…
Smile Wood Publication Shelving Office supplies


That's all for now. Thanks for stopping in.
 

Attachments

#91 ·
panels cut to size and styles prepped

My first big mistake happened earlier this week when I set up the TS sled to cut my panels to size.
One of these things is not like the other… 3/4" short to be precise… and of course it was the panel with the nicest wood figure.
Rectangle Wood Floor Flooring Hardwood


So after sulking for a few days, I went back into my design and made it 1.5" shorter, and cut the other side panels to match. I should have set up with a stop block like this the first time around…
Wood Floor Flooring Hardwood Automotive design


Then I moved on to prepping the stock for the corner post/styles, doing my best to cut around the splits and checks…
Wood Shelving Gas Hardwood Machine


Here they are all ready to rout. Just one piece that still has a split. I'll have to try to stabilize that one with CA glue…
Table Musical instrument Wood Keyboard Digital piano


Decided to pre-sand before routing…
Wheel Automotive tire Motor vehicle Tire Wood


So far I'm pretty happy with the Amana AGE line raised panel set as I'm getting a clean, effortless cut…
Gas Wood Font Machine Screw


A couple sticks had hidden defects that appeared after routing, but nothing a little Timber Mate filler can't take care of…
Furniture Table Cabinetry Wood Rectangle


I thought I'd give a shout out for the DC on the Rockler router table tops, as it is catching 99% of the waste…
Automotive tire Bumper Wood Automotive exterior Tread


Here's the stack so far. This is my first time attempting raised panels and things go pretty fast once you have the router table set up…
Cabinetry Furniture Drawer Wood Shelving


The Inspector General stopped in to check up on my progress. Though she's not so interested in helping out, she is still very interested in receiving the finished product…
Smile Wood Publication Shelving Office supplies


That's all for now. Thanks for stopping in.
Great progress. Looks like a great inspector too. She looks happy with your work.
 

Attachments

#94 ·
one step back

When I glued up my panels one of the end panels had some week spots that looked as if they might crack, but the grain was very interesting on these sticks and I wanted to use them if I could.

Everything looked good after the initial glue up, but after a couple weeks sitting dormant while I was distracted, the panel cracked almost right down the middle.

Rectangle Wood Floor Flooring Tints and shades


Fortunately, the crack was very close to parallel with the edge of the panel, so I decided to cut a kerf and see if I could rip it out. Panel was a little short (and slightly bowed) so I broke out the sled to keep things stable and safe.

Rectangle Wood Floor Flooring Hardwood


This worked very well, and I only had to make one add'l pass. This one was done as a normal rip cut, trimming off ~1/16", which took out the rest of the crack and because this was a less wide piece, it laid more flat on the table and changed the angle of the cut just slightly, which took out most of the bow.

Glued up and will trim the other end panel to match the total width of this one when done.

Wood Flooring Hardwood Outdoor furniture Bench


So I'm "almost" back to where I started from :^o
 

Attachments

#95 ·
one step back

When I glued up my panels one of the end panels had some week spots that looked as if they might crack, but the grain was very interesting on these sticks and I wanted to use them if I could.

Everything looked good after the initial glue up, but after a couple weeks sitting dormant while I was distracted, the panel cracked almost right down the middle.

Rectangle Wood Floor Flooring Tints and shades


Fortunately, the crack was very close to parallel with the edge of the panel, so I decided to cut a kerf and see if I could rip it out. Panel was a little short (and slightly bowed) so I broke out the sled to keep things stable and safe.

Rectangle Wood Floor Flooring Hardwood


This worked very well, and I only had to make one add'l pass. This one was done as a normal rip cut, trimming off ~1/16", which took out the rest of the crack and because this was a less wide piece, it laid more flat on the table and changed the angle of the cut just slightly, which took out most of the bow.

Glued up and will trim the other end panel to match the total width of this one when done.

Wood Flooring Hardwood Outdoor furniture Bench


So I'm "almost" back to where I started from :^o
So sorry Matt, wood, what're ya gonna do, can't live with it, can't shoot it.
 

Attachments

#98 ·
A little metal working

This entry illustrates metal working in support of woodworking. I snapped the pics and added it to the blog thinking that some of you might find this work interesting.

The panel raising bit from my new set is too big for the hole in my router table plate…

Gas Circle Wood Tints and shades Electric blue


So I broke down the table to have at modifying the aluminum plate. On a side note, you can see here that this beastly 3 HP PC VS router has been modified to put an incremental depth dial on the plunge mechanism, which is handy for use on the router table.

Gas Electrical wiring Machine Auto part Tool


Fortunately, one of my other hobbies is metal working, so I figured I could mount the plate in the four jaw chuck and bore out the hole…. No joy! The plate is too big for the lathes ~10" swing

Cameras & optics Gadget Electronic engineering Gas Camera lens


So that left using the boring bar on the mill…

Hand tool Wood Table Tool Set tool


But the plate is too big for my 5" machinist vise…

Gas Composite material Electronic device Auto part Aluminium


Fortunately, you can flip the jaws outboard on these vises…

Bumper Wood Automotive exterior Gas Rectangle


Now it fits…

Wood Gas Flooring Audio equipment Composite material


Next step is to indicate in the existing hole, so it's on center with the mill's spindle axis…

Composite material Gas Electric blue Machine Wood


Then mount the boring head and go to town. The boring bar has a dovetailed mechanism that allows you to precisely move the cutter position with a lead screw and a dial graduated to .001" increments. You have to remember that your diameter changes by double the dialed amount however. I was cutting ~0.030" with each pass. Note: I had to add a spacer in the vise so the boring head was clear of the movable vise block.

Product Milling Drilling Machine tool Drill presses


The actual machining didn't take very long, and the aluminum cut so easily that I over shot and bored the hole a little too big. Fortunately, I avoided fouling the threaded holes for the plate insert.

Now the raised panel bit fits…

Hood Automotive design Automotive exterior Motor vehicle Automotive lighting


I'm quite the novice when it comes to metal working. I understand the processes, but lack experience and it takes me a long time to muddle through. This little modification took most of the afternoon, and the clean up took another hour after dinner. But it's done now, and I did it myself. :^)
 

Attachments

#99 ·
A little metal working

This entry illustrates metal working in support of woodworking. I snapped the pics and added it to the blog thinking that some of you might find this work interesting.

The panel raising bit from my new set is too big for the hole in my router table plate…

Gas Circle Wood Tints and shades Electric blue


So I broke down the table to have at modifying the aluminum plate. On a side note, you can see here that this beastly 3 HP PC VS router has been modified to put an incremental depth dial on the plunge mechanism, which is handy for use on the router table.

Gas Electrical wiring Machine Auto part Tool


Fortunately, one of my other hobbies is metal working, so I figured I could mount the plate in the four jaw chuck and bore out the hole…. No joy! The plate is too big for the lathes ~10" swing

Cameras & optics Gadget Electronic engineering Gas Camera lens


So that left using the boring bar on the mill…

Hand tool Wood Table Tool Set tool


But the plate is too big for my 5" machinist vise…

Gas Composite material Electronic device Auto part Aluminium


Fortunately, you can flip the jaws outboard on these vises…

Bumper Wood Automotive exterior Gas Rectangle


Now it fits…

Wood Gas Flooring Audio equipment Composite material


Next step is to indicate in the existing hole, so it's on center with the mill's spindle axis…

Composite material Gas Electric blue Machine Wood


Then mount the boring head and go to town. The boring bar has a dovetailed mechanism that allows you to precisely move the cutter position with a lead screw and a dial graduated to .001" increments. You have to remember that your diameter changes by double the dialed amount however. I was cutting ~0.030" with each pass. Note: I had to add a spacer in the vise so the boring head was clear of the movable vise block.

Product Milling Drilling Machine tool Drill presses


The actual machining didn't take very long, and the aluminum cut so easily that I over shot and bored the hole a little too big. Fortunately, I avoided fouling the threaded holes for the plate insert.

Now the raised panel bit fits…

Hood Automotive design Automotive exterior Motor vehicle Automotive lighting


I'm quite the novice when it comes to metal working. I understand the processes, but lack experience and it takes me a long time to muddle through. This little modification took most of the afternoon, and the clean up took another hour after dinner. But it's done now, and I did it myself. :^)
Good on ya, Matt. I just knew you'd get it done somehow, some way.
 

Attachments

#103 ·
First raised panels (ever)

Well this was a little nerve racking, but it seems to have turned out OK. After cutting a couple test pieces and adjusting the set up, I produced my first ever raised panel. I cut these in one pass and got just a little burn on one of the long edges…

Brown Wood Rectangle Wood stain Hardwood


Here's the router table set up…

Table Wood Machine tool Tool Gas


I used 1/4" scrap Masonite for a zero clearance sacrificial fence…

Human body Neck Automotive design Art Paint


The panel had already been sanded and the thickness was no longer perfectly uniform, and I think that's why I got this wiggle…

Table Rectangle Wood Beige Wood stain


And of course, I had another crack open up on the end grain. This one's going to get stabilized with CA glue…

Brown Wood Flooring Rectangle Plank


All went well accept for the shop vac dust collection on the router table….

Automotive tire Motor vehicle Bumper Hood Wood


One down, five more to go. Thanks for looking in.
 

Attachments

#104 ·
First raised panels (ever)

Well this was a little nerve racking, but it seems to have turned out OK. After cutting a couple test pieces and adjusting the set up, I produced my first ever raised panel. I cut these in one pass and got just a little burn on one of the long edges…

Brown Wood Rectangle Wood stain Hardwood


Here's the router table set up…

Table Wood Machine tool Tool Gas


I used 1/4" scrap Masonite for a zero clearance sacrificial fence…

Human body Neck Automotive design Art Paint


The panel had already been sanded and the thickness was no longer perfectly uniform, and I think that's why I got this wiggle…

Table Rectangle Wood Beige Wood stain


And of course, I had another crack open up on the end grain. This one's going to get stabilized with CA glue…

Brown Wood Flooring Rectangle Plank


All went well accept for the shop vac dust collection on the router table….

Automotive tire Motor vehicle Bumper Hood Wood


One down, five more to go. Thanks for looking in.
Looks great. Love the way it is coming out.
 

Attachments

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