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104K views 442 replies 45 participants last post by  LittleBlackDuck 
#1 ·
A Small Kids Seat inspired by S Maloof's work

After doing some experiments with Sam Maloof's signature joints, I decided to try a small project.

The reason being, doing a single joint in isolation is not really testing your skills, apart from providing the evidence you may have the capability to progress further, so lets see.

Making one off furniture in my mind is not something I would normally undertake, mainly because its attempting to compete with the finish, and cost of mass produced furniture.

So keeping that in mind why did I decide to undertake a task possibly doomed to failure for many reasons?

Simply beacause of the reason I wanted to see if I could actually do it, and also wanted to have a bit of fun in the process.

Post Addition: Here is an even better reason.

I found this comment whilst researching Sams work.

He never wavered from his contemporary design, even when wood furniture lost favor in the plastic-and-chrome 1960s, '70s and '80s.

He said the coldness of factory-made furniture could not compare in warmth and character to wood that a craftsman worked on from start to finish.


So here we go

Materials:

8 x lengths of Cherry Sticks ( or posibly European walnut) supplied from Lazy Larrys Woodworks

Confirmed by the expert…. its European walnut.

The process:

I jointed and thicknessed the material to suit the stock.

4 x for the seat which were glued together and 4 x individual pieces for the legs.

I cut a section off the end of the seat sections prior to the glue up to make the back rest.

This allowed me to hopefully match the grain from the seat base and allow it to continue onto the back rest.

I cut the edges of the backrest pieces at 5 deg and the ends at 5 deg reverse.
Then applied some titebond III and a shock cord to hold them together.

Wood Hardwood Composite material Wood stain Gas

The bases I aligned the grain as best as possible and butt jointed them with the same glue

Table Furniture Wood Outdoor furniture Outdoor table

Once the Back rest was set I bandsawed the edges to a rough curve then used and Osc sander to sand it to an acceptable pre finish
Rectangle Wood Floor Composite material Flooring


This is a couple of shots of the general layout, I will cut the rubbish off two legs destinied for the front of the stool
Wood Rectangle Wood stain Flooring Floor


Its my intention to do a double radius joint at the back and have the legs curve back and away from the seat.

Then a single radius for the front corner legs having them curve forward.

I do not think I have enough material thickness to splay the legs out side ways.



Thats all for today.

I shall do more and post an ongoing blog as work permits.
 

Attachments

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#2 ·
A Small Kids Seat inspired by S Maloof's work

After doing some experiments with Sam Maloof's signature joints, I decided to try a small project.

The reason being, doing a single joint in isolation is not really testing your skills, apart from providing the evidence you may have the capability to progress further, so lets see.

Making one off furniture in my mind is not something I would normally undertake, mainly because its attempting to compete with the finish, and cost of mass produced furniture.

So keeping that in mind why did I decide to undertake a task possibly doomed to failure for many reasons?

Simply beacause of the reason I wanted to see if I could actually do it, and also wanted to have a bit of fun in the process.

Post Addition: Here is an even better reason.

I found this comment whilst researching Sams work.

He never wavered from his contemporary design, even when wood furniture lost favor in the plastic-and-chrome 1960s, '70s and '80s.

He said the coldness of factory-made furniture could not compare in warmth and character to wood that a craftsman worked on from start to finish.


So here we go

Materials:

8 x lengths of Cherry Sticks ( or posibly European walnut) supplied from Lazy Larrys Woodworks

Confirmed by the expert…. its European walnut.

The process:

I jointed and thicknessed the material to suit the stock.

4 x for the seat which were glued together and 4 x individual pieces for the legs.

I cut a section off the end of the seat sections prior to the glue up to make the back rest.

This allowed me to hopefully match the grain from the seat base and allow it to continue onto the back rest.

I cut the edges of the backrest pieces at 5 deg and the ends at 5 deg reverse.
Then applied some titebond III and a shock cord to hold them together.

Wood Hardwood Composite material Wood stain Gas

The bases I aligned the grain as best as possible and butt jointed them with the same glue

Table Furniture Wood Outdoor furniture Outdoor table

Once the Back rest was set I bandsawed the edges to a rough curve then used and Osc sander to sand it to an acceptable pre finish
Rectangle Wood Floor Composite material Flooring


This is a couple of shots of the general layout, I will cut the rubbish off two legs destinied for the front of the stool
Wood Rectangle Wood stain Flooring Floor


Its my intention to do a double radius joint at the back and have the legs curve back and away from the seat.

Then a single radius for the front corner legs having them curve forward.

I do not think I have enough material thickness to splay the legs out side ways.

Table Wood Rectangle Flooring Floor


Thats all for today.

I shall do more and post an ongoing blog as work permits.
Nice work and what fun. I like your attitude.

I have been trying to get this joint to splay out at a slight angle. My brain is still chugging along with no good solution yet. I guess really thick stock all cut back is the easiest, but I don't want to do that. Oh well.

It will be neat to see this come together.
Steve
 

Attachments

#3 ·
A Small Kids Seat inspired by S Maloof's work

After doing some experiments with Sam Maloof's signature joints, I decided to try a small project.

The reason being, doing a single joint in isolation is not really testing your skills, apart from providing the evidence you may have the capability to progress further, so lets see.

Making one off furniture in my mind is not something I would normally undertake, mainly because its attempting to compete with the finish, and cost of mass produced furniture.

So keeping that in mind why did I decide to undertake a task possibly doomed to failure for many reasons?

Simply beacause of the reason I wanted to see if I could actually do it, and also wanted to have a bit of fun in the process.

Post Addition: Here is an even better reason.

I found this comment whilst researching Sams work.

He never wavered from his contemporary design, even when wood furniture lost favor in the plastic-and-chrome 1960s, '70s and '80s.

He said the coldness of factory-made furniture could not compare in warmth and character to wood that a craftsman worked on from start to finish.


So here we go

Materials:

8 x lengths of Cherry Sticks ( or posibly European walnut) supplied from Lazy Larrys Woodworks

Confirmed by the expert…. its European walnut.

The process:

I jointed and thicknessed the material to suit the stock.

4 x for the seat which were glued together and 4 x individual pieces for the legs.

I cut a section off the end of the seat sections prior to the glue up to make the back rest.

This allowed me to hopefully match the grain from the seat base and allow it to continue onto the back rest.

I cut the edges of the backrest pieces at 5 deg and the ends at 5 deg reverse.
Then applied some titebond III and a shock cord to hold them together.

Wood Hardwood Composite material Wood stain Gas

The bases I aligned the grain as best as possible and butt jointed them with the same glue

Table Furniture Wood Outdoor furniture Outdoor table

Once the Back rest was set I bandsawed the edges to a rough curve then used and Osc sander to sand it to an acceptable pre finish
Rectangle Wood Floor Composite material Flooring


This is a couple of shots of the general layout, I will cut the rubbish off two legs destinied for the front of the stool
Wood Rectangle Wood stain Flooring Floor


Its my intention to do a double radius joint at the back and have the legs curve back and away from the seat.

Then a single radius for the front corner legs having them curve forward.

I do not think I have enough material thickness to splay the legs out side ways.

Table Wood Rectangle Flooring Floor


Thats all for today.

I shall do more and post an ongoing blog as work permits.
Looking good Rob.

Bob.
 

Attachments

#4 ·
A Small Kids Seat inspired by S Maloof's work

After doing some experiments with Sam Maloof's signature joints, I decided to try a small project.

The reason being, doing a single joint in isolation is not really testing your skills, apart from providing the evidence you may have the capability to progress further, so lets see.

Making one off furniture in my mind is not something I would normally undertake, mainly because its attempting to compete with the finish, and cost of mass produced furniture.

So keeping that in mind why did I decide to undertake a task possibly doomed to failure for many reasons?

Simply beacause of the reason I wanted to see if I could actually do it, and also wanted to have a bit of fun in the process.

Post Addition: Here is an even better reason.

I found this comment whilst researching Sams work.

He never wavered from his contemporary design, even when wood furniture lost favor in the plastic-and-chrome 1960s, '70s and '80s.

He said the coldness of factory-made furniture could not compare in warmth and character to wood that a craftsman worked on from start to finish.


So here we go

Materials:

8 x lengths of Cherry Sticks ( or posibly European walnut) supplied from Lazy Larrys Woodworks

Confirmed by the expert…. its European walnut.

The process:

I jointed and thicknessed the material to suit the stock.

4 x for the seat which were glued together and 4 x individual pieces for the legs.

I cut a section off the end of the seat sections prior to the glue up to make the back rest.

This allowed me to hopefully match the grain from the seat base and allow it to continue onto the back rest.

I cut the edges of the backrest pieces at 5 deg and the ends at 5 deg reverse.
Then applied some titebond III and a shock cord to hold them together.

Wood Hardwood Composite material Wood stain Gas

The bases I aligned the grain as best as possible and butt jointed them with the same glue

Table Furniture Wood Outdoor furniture Outdoor table

Once the Back rest was set I bandsawed the edges to a rough curve then used and Osc sander to sand it to an acceptable pre finish
Rectangle Wood Floor Composite material Flooring


This is a couple of shots of the general layout, I will cut the rubbish off two legs destinied for the front of the stool
Wood Rectangle Wood stain Flooring Floor


Its my intention to do a double radius joint at the back and have the legs curve back and away from the seat.

Then a single radius for the front corner legs having them curve forward.

I do not think I have enough material thickness to splay the legs out side ways.

Table Wood Rectangle Flooring Floor


Thats all for today.

I shall do more and post an ongoing blog as work permits.
now that was cool.
 

Attachments

#5 ·
A Small Kids Seat inspired by S Maloof's work

After doing some experiments with Sam Maloof's signature joints, I decided to try a small project.

The reason being, doing a single joint in isolation is not really testing your skills, apart from providing the evidence you may have the capability to progress further, so lets see.

Making one off furniture in my mind is not something I would normally undertake, mainly because its attempting to compete with the finish, and cost of mass produced furniture.

So keeping that in mind why did I decide to undertake a task possibly doomed to failure for many reasons?

Simply beacause of the reason I wanted to see if I could actually do it, and also wanted to have a bit of fun in the process.

Post Addition: Here is an even better reason.

I found this comment whilst researching Sams work.

He never wavered from his contemporary design, even when wood furniture lost favor in the plastic-and-chrome 1960s, '70s and '80s.

He said the coldness of factory-made furniture could not compare in warmth and character to wood that a craftsman worked on from start to finish.


So here we go

Materials:

8 x lengths of Cherry Sticks ( or posibly European walnut) supplied from Lazy Larrys Woodworks

Confirmed by the expert…. its European walnut.

The process:

I jointed and thicknessed the material to suit the stock.

4 x for the seat which were glued together and 4 x individual pieces for the legs.

I cut a section off the end of the seat sections prior to the glue up to make the back rest.

This allowed me to hopefully match the grain from the seat base and allow it to continue onto the back rest.

I cut the edges of the backrest pieces at 5 deg and the ends at 5 deg reverse.
Then applied some titebond III and a shock cord to hold them together.

Wood Hardwood Composite material Wood stain Gas

The bases I aligned the grain as best as possible and butt jointed them with the same glue

Table Furniture Wood Outdoor furniture Outdoor table

Once the Back rest was set I bandsawed the edges to a rough curve then used and Osc sander to sand it to an acceptable pre finish
Rectangle Wood Floor Composite material Flooring


This is a couple of shots of the general layout, I will cut the rubbish off two legs destinied for the front of the stool
Wood Rectangle Wood stain Flooring Floor


Its my intention to do a double radius joint at the back and have the legs curve back and away from the seat.

Then a single radius for the front corner legs having them curve forward.

I do not think I have enough material thickness to splay the legs out side ways.

Table Wood Rectangle Flooring Floor


Thats all for today.

I shall do more and post an ongoing blog as work permits.
Looked up making chairs and came across this. Awesome jig you have there to lay your clamps while standin them up. Outstanding. Hopefully looking to maybe/possibly make chairs for the dinning room table i haven't started yet. LOL priorities i know.
 

Attachments

#6 ·
Maloof Stool rear legs rough out

I kinda chickened out making the "good" stool just yet, and knocked up some Camphor Laurel to do a prototype, read as a nervous departure from the final product!

Here is the current result having made the base/seat and rough out of the two back legs.

This is a side view of the legs just dry fitted at this stage
Road surface Wood Asphalt Tints and shades Composite material


I am not overly worried about the overlap as it will be profiled down at a later stage
Wood Natural material Chair Road surface Outdoor furniture


However I need to pay more attebtion to cutting detail as here there is too much gap, and it may not clamp out at glue up
Road surface Asphalt Wood Tints and shades Automotive tire


The process, apart from the preparation of the materials I drew up the leg profiles and cut out the seat base area
I then cut one edge profile off each leg, with the bandsaw, then and did some more research on just how I could do the joint.

With a little more knowledge and confidence off I went again.

I cut the legs on a table saw and the base was initally table sawed then routed.

Once I had the first leg fitted and accurate I effectively duplicated the second leg mirror image fashion.

I then clamped the two legs together and bandsawed the rough final profile.

Fitted them up and examined my work. (attached photos)

A bit rough in places but progressing reasonably well.

I noticed there was an abnormally large amount of material in the waste bin, so its a bit of a hungry wood method to produce a chair this way.
 

Attachments

#7 ·
Maloof Stool rear legs rough out

I kinda chickened out making the "good" stool just yet, and knocked up some Camphor Laurel to do a prototype, read as a nervous departure from the final product!

Here is the current result having made the base/seat and rough out of the two back legs.

This is a side view of the legs just dry fitted at this stage
Road surface Wood Asphalt Tints and shades Composite material


I am not overly worried about the overlap as it will be profiled down at a later stage
Wood Natural material Chair Road surface Outdoor furniture


However I need to pay more attebtion to cutting detail as here there is too much gap, and it may not clamp out at glue up
Road surface Asphalt Wood Tints and shades Automotive tire


The process, apart from the preparation of the materials I drew up the leg profiles and cut out the seat base area
I then cut one edge profile off each leg, with the bandsaw, then and did some more research on just how I could do the joint.

With a little more knowledge and confidence off I went again.

I cut the legs on a table saw and the base was initally table sawed then routed.

Once I had the first leg fitted and accurate I effectively duplicated the second leg mirror image fashion.

I then clamped the two legs together and bandsawed the rough final profile.

Fitted them up and examined my work. (attached photos)

A bit rough in places but progressing reasonably well.

I noticed there was an abnormally large amount of material in the waste bin, so its a bit of a hungry wood method to produce a chair this way.
nice work.
 

Attachments

#10 ·
Maloof Stool Front legs and seat rough out

An absolutley brilliant winters Day here in Brisbane, and although I dont usually disturb the peace of a Sunday I decided to do some more work on the prototype stool..
First up I forgot to post a picture of the rough stock I made the stool from.
So here is a reconstiited section fro the original 4 m piece

Rectangle Wood Flooring Hardwood Wood stain


From it I resawed everything to make the stool.

Now onward to the front legs

I marked out a rough concept and cut them out with the bandsaw.

Both legs are clamped together to do the cutout.
Automotive tire Wood Floor Stairs Bumper


Wood Rectangle Composite material Flooring Tints and shades


To allow the tenons to be cut accurately I left the original stock on the end so I could use it as a datum point

I then did a fitup up to see what they looked like

Wood Tints and shades Rectangle Hardwood Road surface


I had some minor chip out but nothing worth worrying about it will get profiled out.

I did have a serious lapse of concentration and cut a deep groove in one leg. rats I will have to shim it out
otherwise all went reasonably well again.
The perils of using timber so soft chip outs are very easy to do, even with a backing block fracturing was still occuring.
Wood Plant Grass Tints and shades Concrete


Next I profiled the seat area and did a dry fit up.

Here is where I am up to today.

The back of the stool is just clamped on for effect at this stage.

Wood Rectangle Automotive exterior Outdoor furniture Grass


Lots of work ahead sanding the profiles and making everything smooth.
Furniture Outdoor bench Wood Outdoor furniture Street furniture


Outdoor bench Street furniture Outdoor furniture Rectangle Wood


Furniture Wood Rectangle Grass Hardwood


Overall a resonably pleasing few hours, I guess now the real work starts in the final assembly and finishing it to an acceptable standard.
 

Attachments

#11 ·
Maloof Stool Front legs and seat rough out

An absolutley brilliant winters Day here in Brisbane, and although I dont usually disturb the peace of a Sunday I decided to do some more work on the prototype stool..
First up I forgot to post a picture of the rough stock I made the stool from.
So here is a reconstiited section fro the original 4 m piece

Rectangle Wood Flooring Hardwood Wood stain


From it I resawed everything to make the stool.

Now onward to the front legs

I marked out a rough concept and cut them out with the bandsaw.

Both legs are clamped together to do the cutout.
Automotive tire Wood Floor Stairs Bumper


Wood Rectangle Composite material Flooring Tints and shades


To allow the tenons to be cut accurately I left the original stock on the end so I could use it as a datum point

I then did a fitup up to see what they looked like

Wood Tints and shades Rectangle Hardwood Road surface


I had some minor chip out but nothing worth worrying about it will get profiled out.

I did have a serious lapse of concentration and cut a deep groove in one leg. rats I will have to shim it out
otherwise all went reasonably well again.
The perils of using timber so soft chip outs are very easy to do, even with a backing block fracturing was still occuring.
Wood Plant Grass Tints and shades Concrete


Next I profiled the seat area and did a dry fit up.

Here is where I am up to today.

The back of the stool is just clamped on for effect at this stage.

Wood Rectangle Automotive exterior Outdoor furniture Grass


Lots of work ahead sanding the profiles and making everything smooth.
Furniture Outdoor bench Wood Outdoor furniture Street furniture


Outdoor bench Street furniture Outdoor furniture Rectangle Wood


Furniture Wood Rectangle Grass Hardwood


Overall a resonably pleasing few hours, I guess now the real work starts in the final assembly and finishing it to an acceptable standard.
This is looking really good Robert. An interesting project for sure. It will be fun to see how the shaping goes.
 

Attachments

#17 ·
Maloof Stool Final construction and initial sanding complete

I have completed the prototype stool,

I just finished 4 hours sanding attaching the back and tidying up

Here is the raw product, currently sanded to 320 Grit, it still has a few dings to remove but overall construction is finished

Wood Gas Composite material Chair Rectangle


Chair Outdoor furniture Table Wood Desk


Now I need to answer a couple of questions from the last blog

SPalm:

The sculpturing of the seat was done using a Arbortech Turbo planer

Automotive tire Wood Wheel Rim Gas


How I did it was:

I marked out a general shape and then removed a strip from each side straight down the centers.
Then profiled/dished it back to the edge and into the center section.

Took me all of five minutes, I didnt take and pickies at the time but will do so on my final chair.

Roger:

Its only a little kids chair/stool here are some pictorial dimensions.

Tape measure Office ruler Measuring instrument Tool Rectangle


Tire Automotive tire Tread Bicycle tire Wood


Office ruler Tape measure Gas Tints and shades Composite material


Now the joints which what its all about, did they work out? well almost

Here are some close ups to cast a critical eye over.

First up the almost good ones

Table Wood Fender Automotive exterior Bumper


Wood Tints and shades Human leg Auto part Composite material


Wood Tints and shades Rim Trunk Composite material


And the not so good ones
This one was a direct result of me screwing up on the table saw, hence the shim added in.

Fender Human leg Wood Automotive exterior Automotive design


This one would have been OK had I checked to see if it had seated correctly, the dark band is actually glue.

Bicycle part Automotive design Automotive tire Vehicle Wood


I will continue on and do the final finishing then post it as a project so thats all from me for now.

Conclusion:

I have one more real chair to make and I will direct my attention to "other" projects away from furniture, it was fun and i enjoyed learning about Sam's career in furniture making. Just out of interest I saw one of his Rockers had just sold recently some where,
Correction:
Highlighting the April sale was a striking group of design from the 1970s and 1980s. Among the items on offer was a walnut and ebony rocking chair, dated 1986, by renowned studio craftsman, Sam Maloof. The iconic piece was estimated to bring $30,000-50,000 and sold for $80,500, a new world auction record for a Maloof rocking chair.

Looking at his work you can understand why!....I wonder who got the loot?
 

Attachments

#18 ·
Maloof Stool Final construction and initial sanding complete

I have completed the prototype stool,

I just finished 4 hours sanding attaching the back and tidying up

Here is the raw product, currently sanded to 320 Grit, it still has a few dings to remove but overall construction is finished

Wood Gas Composite material Chair Rectangle


Chair Outdoor furniture Table Wood Desk


Now I need to answer a couple of questions from the last blog

SPalm:

The sculpturing of the seat was done using a Arbortech Turbo planer

Automotive tire Wood Wheel Rim Gas


How I did it was:

I marked out a general shape and then removed a strip from each side straight down the centers.
Then profiled/dished it back to the edge and into the center section.

Took me all of five minutes, I didnt take and pickies at the time but will do so on my final chair.

Roger:

Its only a little kids chair/stool here are some pictorial dimensions.

Tape measure Office ruler Measuring instrument Tool Rectangle


Tire Automotive tire Tread Bicycle tire Wood


Office ruler Tape measure Gas Tints and shades Composite material


Now the joints which what its all about, did they work out? well almost

Here are some close ups to cast a critical eye over.

First up the almost good ones

Table Wood Fender Automotive exterior Bumper


Wood Tints and shades Human leg Auto part Composite material


Wood Tints and shades Rim Trunk Composite material


And the not so good ones
This one was a direct result of me screwing up on the table saw, hence the shim added in.

Fender Human leg Wood Automotive exterior Automotive design


This one would have been OK had I checked to see if it had seated correctly, the dark band is actually glue.

Bicycle part Automotive design Automotive tire Vehicle Wood


I will continue on and do the final finishing then post it as a project so thats all from me for now.

Conclusion:

I have one more real chair to make and I will direct my attention to "other" projects away from furniture, it was fun and i enjoyed learning about Sam's career in furniture making. Just out of interest I saw one of his Rockers had just sold recently some where,
Correction:
Highlighting the April sale was a striking group of design from the 1970s and 1980s. Among the items on offer was a walnut and ebony rocking chair, dated 1986, by renowned studio craftsman, Sam Maloof. The iconic piece was estimated to bring $30,000-50,000 and sold for $80,500, a new world auction record for a Maloof rocking chair.

Looking at his work you can understand why!....I wonder who got the loot?
great job.
 

Attachments

#22 ·
Maloof Stool (the real one) makes Progress

Today I decided to progress the "real" Maloof stool I began in June.

I started off doing the rear legs however I must have had some sort of lapse of the brain as I cut the legs out on the bandsaw first, why I did it who knows I had already made a prototype as well!

Automotive tire Hood Bumper Tread Automotive design


So after I realised the monumental error of having no datum surfaces to work with I had to Double Side Tape them and the off cuts back together again temporarly.
Tire Textile Automotive design Automotive tire Motor vehicle


A vist to the sander returned a level working surface again Phew Saved!!

Wood Rectangle Wood stain Flooring Road surface


So I then set to work cutting the resesses and grooves for the seat attachment

This went reasonably well and needless to say the seat or base was progressed concurrently,
This provided exact mating surfces to they could be constantly checked for fit as I progressed.

Wood Gas Hardwood Flooring Wood stain


The rear legs rebate (under way)

Wood Wood stain Table Floor Flooring


Here is the seat and rear legs as they are dry fitted

The rear view

Wood Composite material Gas Automotive exterior Metal


The left view

Wood Wood stain Hardwood Tints and shades Flooring


The right view

Wood Stairs Automotive exterior Flooring Bumper


Then it was on to the front legs


This time I did all the joint work first and then bandsawed the profiles !!

Wood Road surface Grey Asphalt Flooring


I regretted having different length wings on the sides as it made duplication difficult and quite nerve wracking to ensure I didnt miss cut any thing.

I was almost finished and I screwed up again!

This time I had just enough material to allow me to cut off the incorrect rebated joint and start over…. plucked it again !!

I used Double Sided Tape and replicated all the original cuts from the good leg. Take a look at the top and there is an odd radius, its the remains of my re work, I only just had enough material to pull this move off and it will get profiled out at the finishing stage.

Wood Road surface Grey Asphalt Flooring


Then bandsawed the rough profile

Wood Rectangle Automotive exterior Flooring Automotive design


Again I used the seat to precisely match the corresponding joints as I went.

With that done it was time to profile the seat edge features and fit it all together for a dry fit up test

The stool in its raw form

Wood Hardwood Flooring Wood stain Outdoor furniture


The back will be the next stage and profiling the seat area.

Furniture Chair Wood Rectangle Comfort


It took me all day toget to this stage so I called it quits for the afternoon.
 

Attachments

#23 ·
Maloof Stool (the real one) makes Progress

Today I decided to progress the "real" Maloof stool I began in June.

I started off doing the rear legs however I must have had some sort of lapse of the brain as I cut the legs out on the bandsaw first, why I did it who knows I had already made a prototype as well!

Automotive tire Hood Bumper Tread Automotive design


So after I realised the monumental error of having no datum surfaces to work with I had to Double Side Tape them and the off cuts back together again temporarly.
Tire Textile Automotive design Automotive tire Motor vehicle


A vist to the sander returned a level working surface again Phew Saved!!

Wood Rectangle Wood stain Flooring Road surface


So I then set to work cutting the resesses and grooves for the seat attachment

This went reasonably well and needless to say the seat or base was progressed concurrently,
This provided exact mating surfces to they could be constantly checked for fit as I progressed.

Wood Gas Hardwood Flooring Wood stain


The rear legs rebate (under way)

Wood Wood stain Table Floor Flooring


Here is the seat and rear legs as they are dry fitted

The rear view

Wood Composite material Gas Automotive exterior Metal


The left view

Wood Wood stain Hardwood Tints and shades Flooring


The right view

Wood Stairs Automotive exterior Flooring Bumper


Then it was on to the front legs


This time I did all the joint work first and then bandsawed the profiles !!

Wood Road surface Grey Asphalt Flooring


I regretted having different length wings on the sides as it made duplication difficult and quite nerve wracking to ensure I didnt miss cut any thing.

I was almost finished and I screwed up again!

This time I had just enough material to allow me to cut off the incorrect rebated joint and start over…. plucked it again !!

I used Double Sided Tape and replicated all the original cuts from the good leg. Take a look at the top and there is an odd radius, its the remains of my re work, I only just had enough material to pull this move off and it will get profiled out at the finishing stage.

Wood Road surface Grey Asphalt Flooring


Then bandsawed the rough profile

Wood Rectangle Automotive exterior Flooring Automotive design


Again I used the seat to precisely match the corresponding joints as I went.

With that done it was time to profile the seat edge features and fit it all together for a dry fit up test

The stool in its raw form

Wood Hardwood Flooring Wood stain Outdoor furniture


The back will be the next stage and profiling the seat area.

Furniture Chair Wood Rectangle Comfort


It took me all day toget to this stage so I called it quits for the afternoon.
nice work there.
 

Attachments

#29 ·
Oh no how may mistakes can a person make

My Sam Maloof inspired stool has yet another error.

I am very disapointed that after making a prototype stool of which I had on the ground with me I find yet another really dumb error.

I have cut the front profile in reverse!

Brown Wood Wood stain Hardwood Rectangle


I was going to go inside for a beer to celebrate my days work when after a reply I realised the front profile was reversed!

How could one do this and after already making a prototype and having it with me at the time.

I think I must be going senile or something my memory and ability to recognise errors is starting to let me down

I even passed on the beer when I saw how stupid I was !

Instead I got the gear back out and started to fix the problem

Handwriting Wood Rectangle Font Gas


I was going OK but the dark beat me

Handwriting Wood Rectangle Font Gas


On the positive side at least I know what I am going to do tomorrow!!..... life is good !!
 

Attachments

#30 ·
Oh no how may mistakes can a person make

My Sam Maloof inspired stool has yet another error.

I am very disapointed that after making a prototype stool of which I had on the ground with me I find yet another really dumb error.

I have cut the front profile in reverse!

Brown Wood Wood stain Hardwood Rectangle


I was going to go inside for a beer to celebrate my days work when after a reply I realised the front profile was reversed!

How could one do this and after already making a prototype and having it with me at the time.

I think I must be going senile or something my memory and ability to recognise errors is starting to let me down

I even passed on the beer when I saw how stupid I was !

Instead I got the gear back out and started to fix the problem

Handwriting Wood Rectangle Font Gas


I was going OK but the dark beat me

Handwriting Wood Rectangle Font Gas


On the positive side at least I know what I am going to do tomorrow!!..... life is good !!
OOPs …
 

Attachments

#39 ·
Maloof stool Rough Profile and glue up

The day started well.
I read all the blog comments and replied accordingly. Thats about all that needs to be said about posting screwups.

Stools seat work:


After fixing the front profile and annotaing the template accordingly I set up for the seat area shaping.
I fixed the base onto a saw horse and marked out the areas I was going to work on, the chalk lines were as accurate as I needed

Wood Bumper Automotive exterior Fender Tints and shades


The tool I used was an angle grinder fitted with an Arbortech Turboplane.

Camera lens Camera accessory Cameras & optics Digital camera Film camera


The first rough out completed.

Musical instrument Wood Tints and shades Bumper Artifact


I then used a 115mm random orbital sander to tidy it up

Wood Tints and shades Artifact Plywood Table


That was about as neat as I needed and took about 15 minutes.

Wood Gesture Tints and shades Hardwood Musical instrument


Individual part finishing:

Then it was onto rough sanding profiling the legs seat and back rest.

Wood Automotive exterior Bumper Table Gas


I have individual process pictures but dont want to bore you with them all.

To do the rough sanding I used a disk sander and Osc Sander
Then I used the same round over bit for the rough rounding of all components

Assembly and glue up:

Here is the stool rough rounded and ready to assemble

Wood Automotive exterior Gas Hardwood Bumper


With that done it was time to glue everything together
Interestingly enough I only had to use three clamps on the legs
Two diagonally on the back legs and one at 90 deg on the front legs.

Hopefully this time it will pull all the joints tight.

Wood Natural material Composite material Chair Hardwood


Another general arrangment shot

Triangle Tints and shades Gas Automotive wheel system Monoplane


The back rest:

How I did this was using a cove bit cut two profiles into the back of the seat

I then rounded over the tops of the rear legs with a file to get the best profile fit possible
Its a bit raggedy but it worked for me.

Chair Gas Outdoor furniture Wood Armrest


Then left it all to dry.
 

Attachments

#40 ·
Maloof stool Rough Profile and glue up

The day started well.
I read all the blog comments and replied accordingly. Thats about all that needs to be said about posting screwups.

Stools seat work:


After fixing the front profile and annotaing the template accordingly I set up for the seat area shaping.
I fixed the base onto a saw horse and marked out the areas I was going to work on, the chalk lines were as accurate as I needed

Wood Bumper Automotive exterior Fender Tints and shades


The tool I used was an angle grinder fitted with an Arbortech Turboplane.

Camera lens Camera accessory Cameras & optics Digital camera Film camera


The first rough out completed.

Musical instrument Wood Tints and shades Bumper Artifact


I then used a 115mm random orbital sander to tidy it up

Wood Tints and shades Artifact Plywood Table


That was about as neat as I needed and took about 15 minutes.

Wood Gesture Tints and shades Hardwood Musical instrument


Individual part finishing:

Then it was onto rough sanding profiling the legs seat and back rest.

Wood Automotive exterior Bumper Table Gas


I have individual process pictures but dont want to bore you with them all.

To do the rough sanding I used a disk sander and Osc Sander
Then I used the same round over bit for the rough rounding of all components

Assembly and glue up:

Here is the stool rough rounded and ready to assemble

Wood Automotive exterior Gas Hardwood Bumper


With that done it was time to glue everything together
Interestingly enough I only had to use three clamps on the legs
Two diagonally on the back legs and one at 90 deg on the front legs.

Hopefully this time it will pull all the joints tight.

Wood Natural material Composite material Chair Hardwood


Another general arrangment shot

Triangle Tints and shades Gas Automotive wheel system Monoplane


The back rest:

How I did this was using a cove bit cut two profiles into the back of the seat

I then rounded over the tops of the rear legs with a file to get the best profile fit possible
Its a bit raggedy but it worked for me.

Chair Gas Outdoor furniture Wood Armrest


Then left it all to dry.
Getting there… Looks like a COOL STOOL! :)
 

Attachments

#43 ·
Maloof Stool Raw finished

Here is the finished (as a blog) stool

Once it came out of the clamps all the joints looked OK so it underwent 3 hours of sculpting and preliminary 80 Grit sanding.

Followed by a good blast down with compressed air and an through examination of the joints was conducted.

There are some gaps in the joints, knots and areas of the back rest needing filling so that will happen along with final series of finish sanding, a protective coat applied, and then posted as a project, so that ends the blog series on the Maloof Stool.

The raw pictures:

Front

Chair Outdoor furniture Wood Natural material Plant


Rear

Furniture Plant Wood Chair Natural material


Left

Furniture Plant Wood Outdoor furniture Comfort


Right

Plant Wood Outdoor furniture Chair Natural material


Underneath

Wood Grass Outdoor furniture Plant Chair


Now for some close ups of the joints as that is what the design is all about

Front Left

Musical instrument Wood Flooring Wood stain Hardwood


Front Right

Plant Table Cloud Wood Outdoor furniture


Rear Left

Leg Plant Human body Wood Branch


Rear Right

Wood Trunk Fawn Floor Tree


So are they real Sam Maloof Joints ?

No they are not!

The real mcCoys are three dimensional meaning there are three exposures of timber on the real joints
The front, the rear, and the side.

But I worked with the timber I had available.

Was it fun to make ? yes it was, a do again? possibly if my arm was twisted.

Enjoy
 

Attachments

#44 ·
Maloof Stool Raw finished

Here is the finished (as a blog) stool

Once it came out of the clamps all the joints looked OK so it underwent 3 hours of sculpting and preliminary 80 Grit sanding.

Followed by a good blast down with compressed air and an through examination of the joints was conducted.

There are some gaps in the joints, knots and areas of the back rest needing filling so that will happen along with final series of finish sanding, a protective coat applied, and then posted as a project, so that ends the blog series on the Maloof Stool.

The raw pictures:

Front

Chair Outdoor furniture Wood Natural material Plant


Rear

Furniture Plant Wood Chair Natural material


Left

Furniture Plant Wood Outdoor furniture Comfort


Right

Plant Wood Outdoor furniture Chair Natural material


Underneath

Wood Grass Outdoor furniture Plant Chair


Now for some close ups of the joints as that is what the design is all about

Front Left

Musical instrument Wood Flooring Wood stain Hardwood


Front Right

Plant Table Cloud Wood Outdoor furniture


Rear Left

Leg Plant Human body Wood Branch


Rear Right

Wood Trunk Fawn Floor Tree


So are they real Sam Maloof Joints ?

No they are not!

The real mcCoys are three dimensional meaning there are three exposures of timber on the real joints
The front, the rear, and the side.

But I worked with the timber I had available.

Was it fun to make ? yes it was, a do again? possibly if my arm was twisted.

Enjoy
Great blog Robert and a very nice result.
 

Attachments

#52 ·
Re cycled Jarrah stool

If you read my Sledge Hammer blog I initally started making a wooden stool from all the Jarrah off cuts I recovered from my Potato Crate repairs.

Well I got active on the weekend and started.

The seat

Rectangle Wood Floor Automotive exterior Plank


I used a off cut for the joint tongue

Wood Road surface Flooring Table Floor


Once I had a reasonable fit I glued it up and began to route the rebates for the legs.

Wood Flooring Floor Gas Wood stain


The legs

I tried to make the legs from some some of the stock

Wood Wood stain Hardwood Flooring Plank


But after cutting the tenons I decide they were in fact too big and would look out of place.

Wood Wood stain Hardwood Gas Tints and shades


So I then found enough material from the boards.

Drew up a pattern, then used my table saw to cut the grooves, and then took to them with the band saw.

Wood Wood stain Rectangle Floor Flooring


Did some initial rough out sanding.

Wood Hardwood Wood stain Beige Circle


All fitted up OK so I glued them all together

Wood Gas Asphalt Road surface Automotive tire


My wife Aurora was impressed with my work and wanted a photo too

Watch Temple Plant Leisure People


To be continued.
 

Attachments

#53 ·
Re cycled Jarrah stool

If you read my Sledge Hammer blog I initally started making a wooden stool from all the Jarrah off cuts I recovered from my Potato Crate repairs.

Well I got active on the weekend and started.

The seat

Rectangle Wood Floor Automotive exterior Plank


I used a off cut for the joint tongue

Wood Road surface Flooring Table Floor


Once I had a reasonable fit I glued it up and began to route the rebates for the legs.

Wood Flooring Floor Gas Wood stain


The legs

I tried to make the legs from some some of the stock

Wood Wood stain Hardwood Flooring Plank


But after cutting the tenons I decide they were in fact too big and would look out of place.

Wood Wood stain Hardwood Gas Tints and shades


So I then found enough material from the boards.

Drew up a pattern, then used my table saw to cut the grooves, and then took to them with the band saw.

Wood Wood stain Rectangle Floor Flooring


Did some initial rough out sanding.

Wood Hardwood Wood stain Beige Circle


All fitted up OK so I glued them all together

Wood Gas Asphalt Road surface Automotive tire


My wife Aurora was impressed with my work and wanted a photo too

Watch Temple Plant Leisure People


To be continued.
Very nice Robert, you are getting quite good with this very useful and nice looking joint. You know you are doing something right when your lovely wife willingly poses with your work!
 

Attachments

#58 ·
Re cycled Jarrah stool Sculpted and sanded stage 1

I am a day behind with the progress postings but anyway here we go

I used the bandsaw to cut the curves, a sanding disk to do the bits I couldnt reach with the bandsaw then the and Oscillating sander to smooth out everything.

Due to the seat being a bit on the thin side I thought it best to add some stiffening, just in case somebody decides to stand on it, not that it would break but hey why take the chance.

Wood Flooring Tints and shades Mesh Pattern


I didnt take any pictures of the actual rough shaping.

Once I had that done I used the same round over bit used for the joints to do the again accessable areas of the top of the seat and then the legs..

Tiding again the non accesable areas with the Osc sander freehand.

Then a few hours sanding from 80 Grit finishing up with 320 Grit.

The light was again beating me so I will continue tomorrow.

A couple of sanding finish shots.

Outdoor bench Table Wood Plant Street furniture


Furniture Comfort Wood Outdoor furniture Rectangle


I have a few gap lines showing so I may have to do some filling before contuining.

Its getting there !!
 

Attachments

#59 ·
Re cycled Jarrah stool Sculpted and sanded stage 1

I am a day behind with the progress postings but anyway here we go

I used the bandsaw to cut the curves, a sanding disk to do the bits I couldnt reach with the bandsaw then the and Oscillating sander to smooth out everything.

Due to the seat being a bit on the thin side I thought it best to add some stiffening, just in case somebody decides to stand on it, not that it would break but hey why take the chance.

Wood Flooring Tints and shades Mesh Pattern


I didnt take any pictures of the actual rough shaping.

Once I had that done I used the same round over bit used for the joints to do the again accessable areas of the top of the seat and then the legs..

Tiding again the non accesable areas with the Osc sander freehand.

Then a few hours sanding from 80 Grit finishing up with 320 Grit.

The light was again beating me so I will continue tomorrow.

A couple of sanding finish shots.

Outdoor bench Table Wood Plant Street furniture


Furniture Comfort Wood Outdoor furniture Rectangle


I have a few gap lines showing so I may have to do some filling before contuining.

Its getting there !!
My Gosh that looks nice Robert.
I bet a finish will really make that pop.

Steve
 

Attachments

#61 ·
Re cycled Jarrah stool Sculpted and sanded stage 1

I am a day behind with the progress postings but anyway here we go

I used the bandsaw to cut the curves, a sanding disk to do the bits I couldnt reach with the bandsaw then the and Oscillating sander to smooth out everything.

Due to the seat being a bit on the thin side I thought it best to add some stiffening, just in case somebody decides to stand on it, not that it would break but hey why take the chance.

Wood Flooring Tints and shades Mesh Pattern


I didnt take any pictures of the actual rough shaping.

Once I had that done I used the same round over bit used for the joints to do the again accessable areas of the top of the seat and then the legs..

Tiding again the non accesable areas with the Osc sander freehand.

Then a few hours sanding from 80 Grit finishing up with 320 Grit.

The light was again beating me so I will continue tomorrow.

A couple of sanding finish shots.

Outdoor bench Table Wood Plant Street furniture


Furniture Comfort Wood Outdoor furniture Rectangle


I have a few gap lines showing so I may have to do some filling before contuining.

Its getting there !!
Very Nice!

COOL STOOL…

I love it!
 

Attachments

#65 ·
Table top 1500mm x1500mm Part 1

Number one Son Adam has just bought a bigger family home in Sydney.

The Dining room is squarish, not too sure of the overall dimensions but it looks square to me.
Anyway while I was there helping move in he asked me if I could make him a wooden table top as he wanted to make a steel frame to mount it in for the room.

Something similar in design to this one.



Anyway the room was measured up and decided a table 1500mm x 1500mm was the size they wanted.

Upon my return home I ferreted around in my various timber stashes and found some Yellow Stringbark which I though would be suitable.



Yellow Stringy bark is a hardwood used in flooring so I thought it should fit the bill as he wanted a rustic look

So I set to work dimensioning the rough sawn timber and managed to dress enough to do the job.



Once I had everything finished I laid the boards out to do a dimension and appearance check.



Now this timber is quite large and I might add heavy about 7 to 8 Kgs per board its now about 28 mm thick and around 160mm in width, the lengths I had to to dock to 500 or 600 mm and 1.1M to achieve the desired size.

One of the problems I see is the fact I have never handled anyything so big before, and the fact I am not really into making furniture, however as its for a family member one has to do their best, its going to be tricky to complete.

My first challenge was to make a Jig to cut everything accurately.



The layout was approved so I am off on a new adventure !!
 

Attachments

#66 ·
Table top 1500mm x1500mm Part 1

Number one Son Adam has just bought a bigger family home in Sydney.

The Dining room is squarish, not too sure of the overall dimensions but it looks square to me.
Anyway while I was there helping move in he asked me if I could make him a wooden table top as he wanted to make a steel frame to mount it in for the room.

Something similar in design to this one.

Table Rectangle Wood Floor Flooring


Anyway the room was measured up and decided a table 1500mm x 1500mm was the size they wanted.

Upon my return home I ferreted around in my various timber stashes and found some Yellow Stringbark which I though would be suitable.

Table Wood Rectangle Flooring Floor


Yellow Stringy bark is a hardwood used in flooring so I thought it should fit the bill as he wanted a rustic look

So I set to work dimensioning the rough sawn timber and managed to dress enough to do the job.

Wood Wood stain Plank Hardwood Rectangle


Once I had everything finished I laid the boards out to do a dimension and appearance check.

Wood Rectangle Composite material Hardwood Wood stain


Now this timber is quite large and I might add heavy about 7 to 8 Kgs per board its now about 28 mm thick and around 160mm in width, the lengths I had to to dock to 500 or 600 mm and 1.1M to achieve the desired size.

One of the problems I see is the fact I have never handled anyything so big before, and the fact I am not really into making furniture, however as its for a family member one has to do their best, its going to be tricky to complete.

My first challenge was to make a Jig to cut everything accurately.

Wood Automotive exterior Bumper Gas Machine


The layout was approved so I am off on a new adventure !!
That'll be one pretty table when completed…
 

Attachments

#76 ·
1500 mm Table Top a short diversion while I make Jigs and a shopping list

My intention was to biscuit joint all the boards together using 6 in the edges and 2 in the ends, however clamping material 1.6m in length was a challenge along with holding two boards flat.

So I made a purpose built Jig to biscuit the timber and then to allow me to clamp 4 boards up together.
This means I can now biscuit join 2 sets of boards and stilll have the width ability to drum sand them if required.
To over come the length issues I daisy chained 4 sash clamps in pairs to do the job. Its far from satisfactory but works untill I go shopping for more.

The saw Jig construction:
I made two hardwood rails for my table saw and mounted a piece of particle board on them as close to square as I could get them.



Then using a building square on the table bed I them mounted a large jointed piece of timber as a guide.



From this guide on the left I screwed an arm out at 1050 mm from the saw blade on the left.


First up I squared one end of each board and cut off any checking, any that finished less than 1050 became 550 mm pieces. The reason I was so particular with the lengths was so that I had at least one edge as a datum for later work.

I simply used a block on the fence to obtain the 550mm. This will give me an length of 1600 allowing 100 mm or 50 mm each side for squaring later.

I used a square to check on the cuts, and they were very close to 90 degrees, I could see some light through a slight gap which glue will cover anyway so I was happy with that. The reason for this Jig was due to the fact my Incra gauge was too light for this type of work and I was getting errors initally, Plus I didnt have a sled anyway.

The clamping and biscuit cutting Jig:



I had to use a spacer under the biscuit cutter to centralise the biscuits, it all went well.

The Clamping Jig was big enough to clamp four boards, two short and two long staggered together.

For this jig I used a piece of bench top off cut which had a melamine or laminex finish which was good as the glue would not stick very well to it.
Again using my builders square I made a 90 degree anged frame on one side and one end, put heaps of screws in it and then used some "Good Hand" Clamps I had, these were supposed to push the edges together, (fail) (they were too light duty for the job) so I ended up using F clamps.

As soon as I applied the F Clamps the boards rose up off the jig, so I had to add a Big Good Hand Clamp to push them back down. Not visible in the pictures !! BTW the clamps are not bent or curved its a illusion.



The shortage of full length sash clamps posed a bit of a problem but I overcame it this time, will not be possible later though… go shopping!! ( I took one set off for the photo.)

So I set to biscuiting, glueing and clamping up all the boards, it took 2 days as I could only do 2 sets at a time and then had to wait for the glue to set, by the end of the weekend I had them complete.



Here they are stickered and left overnight to completly set



I thought they all joined well no cupping or bowing so I set them up loosley against the fence and took a picture of them to send to my Son.



To be continued.
 

Attachments

#77 ·
1500 mm Table Top a short diversion while I make Jigs and a shopping list

My intention was to biscuit joint all the boards together using 6 in the edges and 2 in the ends, however clamping material 1.6m in length was a challenge along with holding two boards flat.

So I made a purpose built Jig to biscuit the timber and then to allow me to clamp 4 boards up together.
This means I can now biscuit join 2 sets of boards and stilll have the width ability to drum sand them if required.
To over come the length issues I daisy chained 4 sash clamps in pairs to do the job. Its far from satisfactory but works untill I go shopping for more.

The saw Jig construction:
I made two hardwood rails for my table saw and mounted a piece of particle board on them as close to square as I could get them.

Wood Wood stain Rectangle Hardwood Gas


Then using a building square on the table bed I them mounted a large jointed piece of timber as a guide.

Wood Bumper Plant Automotive exterior Automotive tire


From this guide on the left I screwed an arm out at 1050 mm from the saw blade on the left.

Table saws Plant Wood Gas Folding table

First up I squared one end of each board and cut off any checking, any that finished less than 1050 became 550 mm pieces. The reason I was so particular with the lengths was so that I had at least one edge as a datum for later work.

I simply used a block on the fence to obtain the 550mm. This will give me an length of 1600 allowing 100 mm or 50 mm each side for squaring later.

I used a square to check on the cuts, and they were very close to 90 degrees, I could see some light through a slight gap which glue will cover anyway so I was happy with that. The reason for this Jig was due to the fact my Incra gauge was too light for this type of work and I was getting errors initally, Plus I didnt have a sled anyway.

The clamping and biscuit cutting Jig:

Wood Floor Flooring Gas Bumper


I had to use a spacer under the biscuit cutter to centralise the biscuits, it all went well.

The Clamping Jig was big enough to clamp four boards, two short and two long staggered together.

For this jig I used a piece of bench top off cut which had a melamine or laminex finish which was good as the glue would not stick very well to it.
Again using my builders square I made a 90 degree anged frame on one side and one end, put heaps of screws in it and then used some "Good Hand" Clamps I had, these were supposed to push the edges together, (fail) (they were too light duty for the job) so I ended up using F clamps.

As soon as I applied the F Clamps the boards rose up off the jig, so I had to add a Big Good Hand Clamp to push them back down. Not visible in the pictures !! BTW the clamps are not bent or curved its a illusion.

Wood Plant Hardwood Wood stain Plank


The shortage of full length sash clamps posed a bit of a problem but I overcame it this time, will not be possible later though… go shopping!! ( I took one set off for the photo.)

So I set to biscuiting, glueing and clamping up all the boards, it took 2 days as I could only do 2 sets at a time and then had to wait for the glue to set, by the end of the weekend I had them complete.

Wood Road surface Grass Wood stain Hardwood


Here they are stickered and left overnight to completly set

Rectangle Wood Flooring Hardwood Wood stain


I thought they all joined well no cupping or bowing so I set them up loosley against the fence and took a picture of them to send to my Son.

Wood Fixture Wood stain Wall Hardwood


To be continued.
Lot of work in that table but it's sure looking good sir….
 

Attachments

#82 ·
1500mm Table Top clamping the sections up

Once the five sections were ready to glue together as one table top I checked the edges and any that were not going to close on glue up were recut with my table saw to make them parallel.

Then I set off looking for panel clamps to hold the sections together for the glue up.
I had in mind using Plano brand panel clamps but at (shock horror) $460 per clamp and then they were only 1200 in length I decided that not only would they not be able to do the job in regard to size or price for that matter I soon gave that idea away.

So next trip was to my local electrical distribuitor and I buy 2 x lenghts of unistrut at 6m lengths, no sooner then I had hauled them home I realised I did not have any way of cutting them into 2M lengths.

So I called on my friend Michael who is a metal Fabricator knowing he had a friction saw, he had no problem in lend me the saw but as I loaded it he wanted to know what I was doing with it.
As the conversation progressed he told me he had two clamps over 1600mm long so I borrowed them also.

I got everyting home cut up the unistrut and bought a heap of bolts, wing nuts and washers so I could use them as a set of three poor mans Panel clamps.

I layed everything out on the floor again an and marked each section up to cut more biscuit recesses.
Then using the Biscuit jig I cut them in preparation for more biscuits.

Here is a series of pictures I took in the glue up process, some are a bit blurred, (sorry about that)



Even with the three Unistrut sections I needed to daisy chain my existing sash clamps again

Wood Composite material Hardwood Plank Flooring


You can see Michaels life saving Orange sash clamps at work.

Musical instrument Wood Folk instrument String instrument Wood stain


I had a bit of a problem with one edge side that didnt want to cooperate so I applied blocks and F clamps to hold the boards straight.

Well after wasting almost half a day trying to buy panel clamps bolts etc this was all I achieved today.
I hope all goes well overnight.

Additional Notes (as a result of feedback)
The table top is in five sections (each section being two boards wide) the were biscuited and then glued,
the glue sections are delineated by the additional clamps I have on the edges every where there is a block and clamp there is a new glue joint underneath.

Getting there
 

Attachments

#83 ·
1500mm Table Top clamping the sections up

Once the five sections were ready to glue together as one table top I checked the edges and any that were not going to close on glue up were recut with my table saw to make them parallel.

Then I set off looking for panel clamps to hold the sections together for the glue up.
I had in mind using Plano brand panel clamps but at (shock horror) $460 per clamp and then they were only 1200 in length I decided that not only would they not be able to do the job in regard to size or price for that matter I soon gave that idea away.

So next trip was to my local electrical distribuitor and I buy 2 x lenghts of unistrut at 6m lengths, no sooner then I had hauled them home I realised I did not have any way of cutting them into 2M lengths.

So I called on my friend Michael who is a metal Fabricator knowing he had a friction saw, he had no problem in lend me the saw but as I loaded it he wanted to know what I was doing with it.
As the conversation progressed he told me he had two clamps over 1600mm long so I borrowed them also.

I got everyting home cut up the unistrut and bought a heap of bolts, wing nuts and washers so I could use them as a set of three poor mans Panel clamps.

I layed everything out on the floor again an and marked each section up to cut more biscuit recesses.
Then using the Biscuit jig I cut them in preparation for more biscuits.

Here is a series of pictures I took in the glue up process, some are a bit blurred, (sorry about that)

Wood Floor Flooring Composite material Hardwood


Even with the three Unistrut sections I needed to daisy chain my existing sash clamps again

Wood Composite material Hardwood Plank Flooring


You can see Michaels life saving Orange sash clamps at work.

Musical instrument Wood Folk instrument String instrument Wood stain


I had a bit of a problem with one edge side that didnt want to cooperate so I applied blocks and F clamps to hold the boards straight.

Well after wasting almost half a day trying to buy panel clamps bolts etc this was all I achieved today.
I hope all goes well overnight.

Additional Notes (as a result of feedback)
The table top is in five sections (each section being two boards wide) the were biscuited and then glued,
the glue sections are delineated by the additional clamps I have on the edges every where there is a block and clamp there is a new glue joint underneath.

Getting there
Just one step at a time. But, you're making long strides so far. Keep up the ambitition.
 

Attachments

#90 ·
1500 mm Table Top Squaring and edging work

I released the clamps this morning and with the help of my wife got the table top up onto some temporary stands, they are simply four metal table frames 600mm x 600mm each so I just taped the four center legs together to make a work platform

Table Wood Road surface Outdoor furniture Outdoor table


Using my building square and tape measure I checked the table for overall dimensions and squarness.
Sure enough the diagonal measurements showed it was out of square by about 10mm.
So after doing some more precise measurements I set up my saw guide and used my 7 1/4 circular saw to trim the table top and square it.

A note here I had to invert the table face down to remove any chance of splintering by the circular saw as it rotates the same as a table saw but up upside down.

I didnt take any pictures of this process, maybe beacuse I was a bit nervous doing it.
However as a result I was able to achieve squareness to about 1mm so I was happy to leave it alone at that amount of error.

A note added: If you are wondering what I have on the corner I was experinenting with some timber to see how the edging would look.

Tire Wood Wheel Gas Bicycle


I then set up my 1/2" Router and rabbet bit to cut the "tongue" profile edge I did a test cut on some of the offcuts and determined 8mm was a good division of the timber,
I "flipped" it over and did the oppisite edge, mind you it was no easy feat as it was so big and risked breaking it in half if I tried to turn it by its side rather than its edge however with the help of my "assistant" again we did it.

As I was rabbeting the other edge all went went until I felt the router kick a bit.
Upon stopping and checking I found the tongue of which the bearing was using as a guide had splintered out and ruined the edge.

Furniture Table Wood Road surface Flooring


This completely deflated me and I wondered what I could do

Upon checking close by I saw a lesser splinter effect as well (no doubt the grain was reversed on this piece)

Table Wood Window Wood stain Floor


I stopped work and went and made a coffee pondering as to just how I was going to fix it.
It really got to me and I lost a lot of my motivation when it happened, however after walking away for a while I considered the only possible fix was to carefully reroute the tongue to remove the defect divot and then re rabbet the edge again.

I spent quite a lot of time measuring/checking and setting up before I was confident my fix would work

Sure enough I managed to fix it but decided to put it all away for the day and continue later.

Wood Flooring Floor Hardwood Wood stain


I am used to moving sheet material around on my own and had the little "skateboard" under it to get it back inside and then put it into the wedge clamps.

well tomorrows is another day I guess, boo hiss!!
 

Attachments

#91 ·
1500 mm Table Top Squaring and edging work

I released the clamps this morning and with the help of my wife got the table top up onto some temporary stands, they are simply four metal table frames 600mm x 600mm each so I just taped the four center legs together to make a work platform

Table Wood Road surface Outdoor furniture Outdoor table


Using my building square and tape measure I checked the table for overall dimensions and squarness.
Sure enough the diagonal measurements showed it was out of square by about 10mm.
So after doing some more precise measurements I set up my saw guide and used my 7 1/4 circular saw to trim the table top and square it.

A note here I had to invert the table face down to remove any chance of splintering by the circular saw as it rotates the same as a table saw but up upside down.

I didnt take any pictures of this process, maybe beacuse I was a bit nervous doing it.
However as a result I was able to achieve squareness to about 1mm so I was happy to leave it alone at that amount of error.

A note added: If you are wondering what I have on the corner I was experinenting with some timber to see how the edging would look.

Tire Wood Wheel Gas Bicycle


I then set up my 1/2" Router and rabbet bit to cut the "tongue" profile edge I did a test cut on some of the offcuts and determined 8mm was a good division of the timber,
I "flipped" it over and did the oppisite edge, mind you it was no easy feat as it was so big and risked breaking it in half if I tried to turn it by its side rather than its edge however with the help of my "assistant" again we did it.

As I was rabbeting the other edge all went went until I felt the router kick a bit.
Upon stopping and checking I found the tongue of which the bearing was using as a guide had splintered out and ruined the edge.

Furniture Table Wood Road surface Flooring


This completely deflated me and I wondered what I could do

Upon checking close by I saw a lesser splinter effect as well (no doubt the grain was reversed on this piece)

Table Wood Window Wood stain Floor


I stopped work and went and made a coffee pondering as to just how I was going to fix it.
It really got to me and I lost a lot of my motivation when it happened, however after walking away for a while I considered the only possible fix was to carefully reroute the tongue to remove the defect divot and then re rabbet the edge again.

I spent quite a lot of time measuring/checking and setting up before I was confident my fix would work

Sure enough I managed to fix it but decided to put it all away for the day and continue later.

Wood Flooring Floor Hardwood Wood stain


I am used to moving sheet material around on my own and had the little "skateboard" under it to get it back inside and then put it into the wedge clamps.

well tomorrows is another day I guess, boo hiss!!
Closer & closer…

Nice SAVE…

Little by little…

Step by step…

Looking GOOD!

Thank you!
 

Attachments

#96 ·
1500 mm Table attaching the edges

Well I went shopping again today, on my list was two more sash clamps and timber suitable for edging the table, the reason for this was because the edging was bigger than the table profile my unistrut clamps could not be used as sucessfully.
I managed to buy two clamps, from Trade Tools 1Ă—1680 mm ($59) and 1Ă—1980 mm ($69) these were exactly the same as the pair from my friend Michael.
The edging timber was a different matter I bought a 3 m piece for $32 but when I milled it and cut off the rubbish I lost almost 50% of it, so much for buying timber at Bunnings! A total wase for what I wanted to do.

So with this setback I again dithered about wondering what to do.
Eventually sanity took hold again and I rang my woodworking friend Wally who lives around the corner from me.

Wally is about 95+ and has an area under his house packed with wood and wood working parafanalia of all descriptions. Sure enough he had some Merbau posts of which he gave me in return for me doing some leaking tap plumbing work. That was fine with me so I hauled the post home

Here it is on the saw.

Saw Wood Plant Gas Outdoor bench


My plan is to dock it and then quarter it so its suitable for edging.
Here is the end docked off

Table Wood Rectangle Wood stain Flooring


Next it was into the table saw for ripping.

Brown Wood Rectangle Beige Brickwork


Then again back on the saw for quartering.

Wood Table Wood stain Rectangle Hardwood


Here is a close up shot of the distinctive fleck grain

Brown Wood Rectangle Road surface Wood stain


I then thicknessed them and then using an off cut to do a precise test sawed in a groove to match the table tongue

Cut one end 45 deg and dry clamped them onto the table to ensure I had an exact measurement for the glue up.

All went well and I pulled it all apart again, applied glue and clamped everything up and left it to dry.

Wood Table Floor Tradesman Wood stain


I then applied all of the edge clamps I had to ensure all was fully contacted and a couple of F clamps to ensure the corners were level

Wood Composite material Wood stain Engineering Plank


I deliberately left about 1mm proud at the top surface so I would end up with a even surface in the next phase.

Nothing too exciting about work today apart from some very satisfying results for a change !!

My new clamps are the red ones, and they match exactly the pair I borrowed.
 

Attachments

#97 ·
1500 mm Table attaching the edges

Well I went shopping again today, on my list was two more sash clamps and timber suitable for edging the table, the reason for this was because the edging was bigger than the table profile my unistrut clamps could not be used as sucessfully.
I managed to buy two clamps, from Trade Tools 1Ă—1680 mm ($59) and 1Ă—1980 mm ($69) these were exactly the same as the pair from my friend Michael.
The edging timber was a different matter I bought a 3 m piece for $32 but when I milled it and cut off the rubbish I lost almost 50% of it, so much for buying timber at Bunnings! A total wase for what I wanted to do.

So with this setback I again dithered about wondering what to do.
Eventually sanity took hold again and I rang my woodworking friend Wally who lives around the corner from me.

Wally is about 95+ and has an area under his house packed with wood and wood working parafanalia of all descriptions. Sure enough he had some Merbau posts of which he gave me in return for me doing some leaking tap plumbing work. That was fine with me so I hauled the post home

Here it is on the saw.

Saw Wood Plant Gas Outdoor bench


My plan is to dock it and then quarter it so its suitable for edging.
Here is the end docked off

Table Wood Rectangle Wood stain Flooring


Next it was into the table saw for ripping.

Brown Wood Rectangle Beige Brickwork


Then again back on the saw for quartering.

Wood Table Wood stain Rectangle Hardwood


Here is a close up shot of the distinctive fleck grain

Brown Wood Rectangle Road surface Wood stain


I then thicknessed them and then using an off cut to do a precise test sawed in a groove to match the table tongue

Cut one end 45 deg and dry clamped them onto the table to ensure I had an exact measurement for the glue up.

All went well and I pulled it all apart again, applied glue and clamped everything up and left it to dry.

Wood Table Floor Tradesman Wood stain


I then applied all of the edge clamps I had to ensure all was fully contacted and a couple of F clamps to ensure the corners were level

Wood Composite material Wood stain Engineering Plank


I deliberately left about 1mm proud at the top surface so I would end up with a even surface in the next phase.

Nothing too exciting about work today apart from some very satisfying results for a change !!

My new clamps are the red ones, and they match exactly the pair I borrowed.
Looking better… & better…

Thanks for the Update…
 

Attachments

#98 ·
1500 mm Table top working the top

Well the table progress is advancing well, I am now up to surfacing the top and edges

Due to very overcast weather I had to set up in the garage as I was keen again to get on with it without having to wait for the weather to clear

Table Tableware Wood Food Staple food


So my trusty plane was awoken from its slumber and away we went together around around and around.

Wood Tints and shades Road surface Soil Asphalt


After about an hour or so of work I had the edges level with the table top and was reasonably happy with the finish.

The weather cleared amd I moved everything back out into the fresh air, Now it was only a matter of sanding everthing to an acceptable finish.

Before sanding I hand scraped all the glue joins and removed any glue residue along with any high spots in the timber

I then started off with 80 grit on my half sheet sander and way I went again, in the process I exhausted all my 80 Grit supplies doing the first sanding, this was about 10 to 15 or so half sheets consumed in the process, It seemed as though the sandpaper was not lasting as long as it normally does.
Anyway then it was out with the 120 grit and repeat the process all over again.

The following shots show the results. ( The iight was not really kind to me but I think the basic result is there)

Table Furniture Outdoor table Rectangle Outdoor furniture


Light Rectangle Wood Wood stain Flooring


Table Furniture Wood Rectangle Wood stain


There is nothing really exciting about sanding apart from the finish you achieve as a result of your work.

It looked OK to me.

Well thats it for a while now as all that remains is the under bracing of which will not happen until my son visits at the end of the month.

I had a couple of ideas but the final layout will be dependent on his design concept for the frame.

Outdoor bench Street furniture Plant Outdoor furniture Wood


Thank for watching and all the great commenting !!
 

Attachments

#99 ·
1500 mm Table top working the top

Well the table progress is advancing well, I am now up to surfacing the top and edges

Due to very overcast weather I had to set up in the garage as I was keen again to get on with it without having to wait for the weather to clear

Table Tableware Wood Food Staple food


So my trusty plane was awoken from its slumber and away we went together around around and around.

Wood Tints and shades Road surface Soil Asphalt


After about an hour or so of work I had the edges level with the table top and was reasonably happy with the finish.

The weather cleared amd I moved everything back out into the fresh air, Now it was only a matter of sanding everthing to an acceptable finish.

Before sanding I hand scraped all the glue joins and removed any glue residue along with any high spots in the timber

I then started off with 80 grit on my half sheet sander and way I went again, in the process I exhausted all my 80 Grit supplies doing the first sanding, this was about 10 to 15 or so half sheets consumed in the process, It seemed as though the sandpaper was not lasting as long as it normally does.
Anyway then it was out with the 120 grit and repeat the process all over again.

The following shots show the results. ( The iight was not really kind to me but I think the basic result is there)







There is nothing really exciting about sanding apart from the finish you achieve as a result of your work.

It looked OK to me.

Well thats it for a while now as all that remains is the under bracing of which will not happen until my son visits at the end of the month.

I had a couple of ideas but the final layout will be dependent on his design concept for the frame.



Thank for watching and all the great commenting !!
NICE!

Any idea of how much it weighs?

Looks like you will keep it all together… using Help to move, etc.

It's not as thick as it looked at the very beginning…

Coming along very nicely… Super COOL!

COOL work!
 

Attachments

#108 ·
1500mm Table under Bracing and shrinkage management

I installed the underbracing for the table top today, I had the work on hold whilst the table underwent some stress changes over the last couple of weeks.

Some Shrinkage.

I had it stored away near where I was working and heard on numerous occasions a sharp crack from it.
I was sitting quietly near it when I heard it again and observed over the week a shrinkage crack appearing on one of the sets of edge jointed boards, at first it only barely visible but eventually grew to about 4mm wide.
I didnt do to much untill it settled and stopped the "cracking" noise and the gap widening.

I didnt even bother to take any pictures at the time as it was not entierly unexpected.

However once it settled down I brought it out to see what I could do.

Tape measure Tool Office ruler Ruler Wood


There was no other effect on the Table so it was definately shrinkage, what surprised me was it was only in one section as well.

Wood Rectangle Hardwood Wood stain Flooring


As it occured completely along the glue line it made it reasonably easy to repair.

First of all I cut the glue away with a trimming Knife and then cleaned the entire length out with a small rasp.
Then cut a "shrinkage strip to repair the gap. This strip consists of a length of timber cut and trimmed to size and then spot glued in place resting on the top of the biscuits, no attempt was made to close the underside.

Brown Wood Rectangle Flooring Wood stain


If any more movement occurs its simply a matter of knocking the strip out from underneath and replace it.

The Under Bracing

Upon discussion with my Son and the metal fabricator the center frames will sit on 600mm centers
So a half lap jointed frame was constructed under the table in the center and extending from each side was a support frame and support blocks in each of the corners.

I used my box cutter blade to fabricate the half lap joints.

Wood Font Office supplies Metal Kitchen utensil


This is the bracing in progress

Rectangle Wood Flooring Floor Wood stain


And now all complete.

Wood Road surface Flooring Floor Plant


The corner pads? they are here simply if required otherwise they can be removed later.

All the timber near the edges was chamfered to avoid any injury to hands / knees under the table.

Every lap joints on the bracing is free to move if the table experiences any more movement.

Weights: A couple of LJs comment on the Mass or weights I posted being a bit Heiferish , so a re-weigh was conducted.

The Results:

Each Board weighs approx 4.5 Kgs at 1500 mm and there are ten of them so we are looking at 45 Kgs for the boards plus the edging. I cannot physically check the completed top.

So my revised esimate is about 55 to 65 Kgs not 100Kgs as previously reported.

Here is a section of dressed board about 1M in length on the scales.

Watch Satellite phone Wood Gesture Finger


Now that should do it for the time being,... stand by for the completed Project possibly in the New Year as its due for delivery Dec 2016.
 

Attachments

#109 ·
1500mm Table under Bracing and shrinkage management

I installed the underbracing for the table top today, I had the work on hold whilst the table underwent some stress changes over the last couple of weeks.

Some Shrinkage.

I had it stored away near where I was working and heard on numerous occasions a sharp crack from it.
I was sitting quietly near it when I heard it again and observed over the week a shrinkage crack appearing on one of the sets of edge jointed boards, at first it only barely visible but eventually grew to about 4mm wide.
I didnt do to much untill it settled and stopped the "cracking" noise and the gap widening.

I didnt even bother to take any pictures at the time as it was not entierly unexpected.

However once it settled down I brought it out to see what I could do.

Tape measure Tool Office ruler Ruler Wood


There was no other effect on the Table so it was definately shrinkage, what surprised me was it was only in one section as well.

Wood Rectangle Hardwood Wood stain Flooring


As it occured completely along the glue line it made it reasonably easy to repair.

First of all I cut the glue away with a trimming Knife and then cleaned the entire length out with a small rasp.
Then cut a "shrinkage strip to repair the gap. This strip consists of a length of timber cut and trimmed to size and then spot glued in place resting on the top of the biscuits, no attempt was made to close the underside.

Brown Wood Rectangle Flooring Wood stain


If any more movement occurs its simply a matter of knocking the strip out from underneath and replace it.

The Under Bracing

Upon discussion with my Son and the metal fabricator the center frames will sit on 600mm centers
So a half lap jointed frame was constructed under the table in the center and extending from each side was a support frame and support blocks in each of the corners.

I used my box cutter blade to fabricate the half lap joints.

Wood Font Office supplies Metal Kitchen utensil


This is the bracing in progress

Rectangle Wood Flooring Floor Wood stain


And now all complete.

Wood Road surface Flooring Floor Plant


The corner pads? they are here simply if required otherwise they can be removed later.

All the timber near the edges was chamfered to avoid any injury to hands / knees under the table.

Every lap joints on the bracing is free to move if the table experiences any more movement.

Weights: A couple of LJs comment on the Mass or weights I posted being a bit Heiferish , so a re-weigh was conducted.

The Results:

Each Board weighs approx 4.5 Kgs at 1500 mm and there are ten of them so we are looking at 45 Kgs for the boards plus the edging. I cannot physically check the completed top.

So my revised esimate is about 55 to 65 Kgs not 100Kgs as previously reported.

Here is a section of dressed board about 1M in length on the scales.

Watch Satellite phone Wood Gesture Finger


Now that should do it for the time being,... stand by for the completed Project possibly in the New Year as its due for delivery Dec 2016.
Rob, keep at it.
 

Attachments

#114 ·
Base for the 1500mm x1500mm Table top

Today I commenced making a base for my sons New 1500 mm x 1500mm Dining Table.

Originally he was going to fabricate a metal base however after seeing "Wally's Huon Beams" he decided I should do it instead!

He sent me the design of what he was going to build and asked it I could use the beams and make it in wood.
making the vertical post 150mm x 150mm the legs 1m x 150mm x 75mm and the support braces 100mm x 70mm.

I agreed of course, what else had I to do but work out with these beams at my age!

I wrestled the beam up onto my combination saw and set it up to cut it so I had the pieces into more managable sizes

Wood Plant Automotive tire Motor vehicle Gas


Now this turned out to be quite a challange due to the size of my saw and the material I was trying to cut.

Wood Floor Composite material Hardwood Gas


I needed to make three cuts so I had a datum point to reset the position of the blade accurately as I turned the beam, it took quite a lot of positioning and checking to get the most accurate cut possible.

Automotive tire Wood Saw Plant Grass


I achieved about half a kerf accuracy and reasonable squareness in the process.

Next just to really push the envelope I needed 45 degree cuts on each of the two base pieces.

The results were not quite as accurate this time adding also an extra step as well which required final cutting with a hand saw to complete the cuts.

Wood Gas Lumber Wood stain Hardwood


and another view

Wood Wood stain Plank Hardwood Plant


Then it was on to cutting the Half Lap Joint.

I used my table saw to do this mainly for accuracy and ease of cutting.

Plant Wood Table Rectangle Wood stain


This task took quite a bit of time and needed some fine tuning to get the fit I wanted.

Outdoor bench Wood Outdoor furniture Wood stain Picnic table


I then dry assembled the legs and sat the vertical post in place.

Wood Flooring Floor Gas Hardwood


I looked at it and thought it was too big and too ugly and was a waste of timber.

However I pressed on and cut the feet in and reduced the overall height of the feet.
To cut the feet pads I used the table saw to make four rip cuts and two cross cuts again finishing with a panel saw. As I worked away thinking how hard it was a thought entered my head as to how Noah managed to make his Ark, this made me feel a bit more confident and I pressed on.

After that I then dry assembled everything again and looked at it, thinking ithis time it was begining to look OK after all.

Wood Floor Flooring Wood stain Hardwood


Next I cut the vertical post to size and started on the diagonal braces.

Again this process required duplicated work, cutting the 45 deg angles on the combination saw, then using the panel saw to complete the cut, then and added step of sanding off the differences in kerfs.

I again dry assembled the base and tacked the diagonals in place to check what it would look like.

Wood Flooring Floor Hardwood Plywood


This time I was more impressed with the build

Wood Natural material Tape measure Line Material property


I think it had turned out OK after all

Conclusion:

The work again exceeded my skills and definately pushed my basic tools to the limit.
I now have to figure out how to fasten everything together, all a bit beyond my 25 to 32mm screws!!
I must say my Ozito combination saw worked really well for a el cheapo DIY item!
Needless tosay if this was timber other than Huon pine the results would have been some what different.
 

Attachments

#115 ·
Base for the 1500mm x1500mm Table top

Today I commenced making a base for my sons New 1500 mm x 1500mm Dining Table.

Originally he was going to fabricate a metal base however after seeing "Wally's Huon Beams" he decided I should do it instead!

He sent me the design of what he was going to build and asked it I could use the beams and make it in wood.
making the vertical post 150mm x 150mm the legs 1m x 150mm x 75mm and the support braces 100mm x 70mm.

I agreed of course, what else had I to do but work out with these beams at my age!

I wrestled the beam up onto my combination saw and set it up to cut it so I had the pieces into more managable sizes

Wood Plant Automotive tire Motor vehicle Gas


Now this turned out to be quite a challange due to the size of my saw and the material I was trying to cut.

Wood Floor Composite material Hardwood Gas


I needed to make three cuts so I had a datum point to reset the position of the blade accurately as I turned the beam, it took quite a lot of positioning and checking to get the most accurate cut possible.

Automotive tire Wood Saw Plant Grass


I achieved about half a kerf accuracy and reasonable squareness in the process.

Next just to really push the envelope I needed 45 degree cuts on each of the two base pieces.

The results were not quite as accurate this time adding also an extra step as well which required final cutting with a hand saw to complete the cuts.

Wood Gas Lumber Wood stain Hardwood


and another view

Wood Wood stain Plank Hardwood Plant


Then it was on to cutting the Half Lap Joint.

I used my table saw to do this mainly for accuracy and ease of cutting.

Plant Wood Table Rectangle Wood stain


This task took quite a bit of time and needed some fine tuning to get the fit I wanted.

Outdoor bench Wood Outdoor furniture Wood stain Picnic table


I then dry assembled the legs and sat the vertical post in place.

Wood Flooring Floor Gas Hardwood


I looked at it and thought it was too big and too ugly and was a waste of timber.

However I pressed on and cut the feet in and reduced the overall height of the feet.
To cut the feet pads I used the table saw to make four rip cuts and two cross cuts again finishing with a panel saw. As I worked away thinking how hard it was a thought entered my head as to how Noah managed to make his Ark, this made me feel a bit more confident and I pressed on.

After that I then dry assembled everything again and looked at it, thinking ithis time it was begining to look OK after all.

Wood Floor Flooring Wood stain Hardwood


Next I cut the vertical post to size and started on the diagonal braces.

Again this process required duplicated work, cutting the 45 deg angles on the combination saw, then using the panel saw to complete the cut, then and added step of sanding off the differences in kerfs.

I again dry assembled the base and tacked the diagonals in place to check what it would look like.

Wood Flooring Floor Hardwood Plywood


This time I was more impressed with the build

Wood Natural material Tape measure Line Material property


I think it had turned out OK after all

Conclusion:

The work again exceeded my skills and definately pushed my basic tools to the limit.
I now have to figure out how to fasten everything together, all a bit beyond my 25 to 32mm screws!!
I must say my Ozito combination saw worked really well for a el cheapo DIY item!
Needless tosay if this was timber other than Huon pine the results would have been some what different.
Again good work Rob, I might have been inclined to let the upper braces into the post, and let the leg into the stand to give it more rigidity. But as it stands, I would be inclined to attach the upper braces with 1" dowels, they will be doing a balancing act for the top, rather than taking the bulk of the weight, and the base to the post, I would drill and rawl bolt. however I would first still be inclined to let the post into the base, if only 1/2" to stop it twisting… Just my two penneth!
 

Attachments

#120 ·
The 1500mm x 1500mm Table Dry Assembled

For any of the LJs interested in seeing just how big this monster is I thought I had better add these final photos before the table heads off to my Sons Place for Christmas.

Its just dry assembled at this stage hence if you spot some parts missing thats why.

The top as reported previously has suffered shrinkage all around the various spots on the edges and also across one of the table top joins.

Its nothing unexpected but I didnt think it would be as pronounced as it is

In this photo you can see a filler piece sitting in the gap completley across the top
Table Furniture Wood Outdoor table Outdoor furniture


There is also a minor shrinkage showing here but its not full length like the first picture, it will possibly just get filler.

Table Furniture Outdoor bench Wood Outdoor table


Here is some of the edge areas where shrinkage has also occured
there is not a lot I can do here until its in place and normalised then decide a fix.

Table Wood Flooring Wood stain Hardwood


So why did it happen?... natural movement of wood and possibly variances in EMC at the build stage

I do not really know apart from the fact is iis shrinkage.
 

Attachments

#121 ·
The 1500mm x 1500mm Table Dry Assembled

For any of the LJs interested in seeing just how big this monster is I thought I had better add these final photos before the table heads off to my Sons Place for Christmas.

Its just dry assembled at this stage hence if you spot some parts missing thats why.

The top as reported previously has suffered shrinkage all around the various spots on the edges and also across one of the table top joins.

Its nothing unexpected but I didnt think it would be as pronounced as it is

In this photo you can see a filler piece sitting in the gap completley across the top
Table Furniture Wood Outdoor table Outdoor furniture


There is also a minor shrinkage showing here but its not full length like the first picture, it will possibly just get filler.

Table Furniture Outdoor bench Wood Outdoor table


Here is some of the edge areas where shrinkage has also occured
there is not a lot I can do here until its in place and normalised then decide a fix.

Table Wood Flooring Wood stain Hardwood


So why did it happen?... natural movement of wood and possibly variances in EMC at the build stage

I do not really know apart from the fact is iis shrinkage.
A VERY NICE, COOL table…

Couldn't it expand back to where it was?

I'm sure you figure a way to 'fix' it… Not to worry…

He will LOVE it!

Thank you!
 

Attachments

#129 ·
1500 x 1500 Table finished and STW

Here is the completed table installed in No 1 Son (and Family) s place.

Table Furniture Computer desk Writing desk Desk


Table Furniture Chair Wood Interior design


The shrinkage I reported in previous blogs proved to be very difficult for me to repair so I bit bullet and took to it with a mallet breaking it apart in two sections and then reglueing the offending sections and triming the edging to suit.

This may seem a bit of overkill but I was at the stage of not being able to sucessfully patch it with filler strips and get a nice consistant look.

Table Furniture Outdoor table Wood Desk


Wood Tool Hardwood Musical instrument Natural material


Table Wood Rectangle Desk Outdoor furniture


How I did it.
Used a lump hammer and block of wood to break away the two edges glued on covering the ends of the timber.
Prised apart the two shrinkage sections, cleaned them up trued them andthen carefully trimmed the 45 deg remaining edges back flush.
Re cut the biscuit slots and glued every thing back together again.
Replaced the two damaged edges and its back together again.
 

Attachments

#130 ·
1500 x 1500 Table finished and STW

Here is the completed table installed in No 1 Son (and Family) s place.

Table Furniture Computer desk Writing desk Desk


Table Furniture Chair Wood Interior design


The shrinkage I reported in previous blogs proved to be very difficult for me to repair so I bit bullet and took to it with a mallet breaking it apart in two sections and then reglueing the offending sections and triming the edging to suit.

This may seem a bit of overkill but I was at the stage of not being able to sucessfully patch it with filler strips and get a nice consistant look.

Table Furniture Outdoor table Wood Desk


Wood Tool Hardwood Musical instrument Natural material


Table Wood Rectangle Desk Outdoor furniture


How I did it.
Used a lump hammer and block of wood to break away the two edges glued on covering the ends of the timber.
Prised apart the two shrinkage sections, cleaned them up trued them andthen carefully trimmed the 45 deg remaining edges back flush.
Re cut the biscuit slots and glued every thing back together again.
Replaced the two damaged edges and its back together again.
A family heirloom there Rob…well done on a beautiful family sized table…
 

Attachments

#135 ·
Medium size Maloof Chair - Preparing the seats

My * friend saw the Maloof kids chairs I made for the family and asked if I would malke her one for her grand daughter.

As I had all the templates and suitable material I accepted to make her one.
Then she added "but I want it bigger" Oh yeah I thought and asked just how much bigger?

She said about 100mm overall and I declined the request, she insisted saying she only wanted one, I thought was thats even more reason not to do it, ... then said so.

The conversation continued and without going into more details I eventually agreed.

After she left I thought about it and if I was to make one I may as well make a few so I checked my materials

I had enough bits and pieces to make the seats and then continue on with the legs.

So I started:

I designed some new templates and worked out what the overall size would be

The seat is about 400mm x 400mm and the front legs around 300mm and the back about double that.

Here is the sequence of events as the seats progressed.

I knew the material woul have to be thicker than my previous builds and I had very little Walnut left to do the job, so I used a composition of Tasmanian Blackwood Oak and Walnut.

Plant Wood Outdoor furniture Wood stain Hardwood


I cut the pieces up removing the defects and shuffeled them around to see what was left.
It was going to be a deviation from the traditional Walnut but I could do it. So I jointed and thicknesses everything (or so I thought) and started to arrange the layout

Seat 1
Will comprise of all Tasmanian Black wood
Wood Grass Automotive exterior Wood stain Hardwood


Seat 2
Will comprise of Oak sanwiched by Tasmanian Black Wood
Wood Rectangle Wood stain Hardwood Flooring


Seat 3
Will comprise of European and QLD Walnut with Tasmanian Black Wood
Plant Wood Table Wood stain Grass


They will certainly maintain Sam's unique one off style thats for sure.

So into the clamps they go.

Rectangle Wood Ruler Office ruler Wood stain


Now it was at this stage I realised I had missed one piece in the final thicknessing so it got clamped up independently.

This goof caused me a bit of stress as I dont have any way of fixing it at the moment so I just left it for the time being.

Wood Hardwood Composite material Plywood Engineering
 

Attachments

#136 ·
Medium size Maloof Chair - Preparing the seats

My * friend saw the Maloof kids chairs I made for the family and asked if I would malke her one for her grand daughter.

As I had all the templates and suitable material I accepted to make her one.
Then she added "but I want it bigger" Oh yeah I thought and asked just how much bigger?

She said about 100mm overall and I declined the request, she insisted saying she only wanted one, I thought was thats even more reason not to do it, ... then said so.

The conversation continued and without going into more details I eventually agreed.

After she left I thought about it and if I was to make one I may as well make a few so I checked my materials

I had enough bits and pieces to make the seats and then continue on with the legs.

So I started:

I designed some new templates and worked out what the overall size would be

The seat is about 400mm x 400mm and the front legs around 300mm and the back about double that.

Here is the sequence of events as the seats progressed.

I knew the material woul have to be thicker than my previous builds and I had very little Walnut left to do the job, so I used a composition of Tasmanian Blackwood Oak and Walnut.

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I cut the pieces up removing the defects and shuffeled them around to see what was left.
It was going to be a deviation from the traditional Walnut but I could do it. So I jointed and thicknesses everything (or so I thought) and started to arrange the layout

Seat 1
Will comprise of all Tasmanian Black wood
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Seat 2
Will comprise of Oak sanwiched by Tasmanian Black Wood
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Seat 3
Will comprise of European and QLD Walnut with Tasmanian Black Wood
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They will certainly maintain Sam's unique one off style thats for sure.

So into the clamps they go.

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Now it was at this stage I realised I had missed one piece in the final thicknessing so it got clamped up independently.

This goof caused me a bit of stress as I dont have any way of fixing it at the moment so I just left it for the time being.

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Hi Robert!

I don't think your 'goof' is all that bad… One thing about the Maloof seats is that a lot of the wood gets sculptured OUT… In your seat #3, the center piece looks a little thicker to me… Once you figure what is going away, you will see just a small amount that could be sanded (sculptured) away… I'm looking at it where the piece is sticking out the back as the Back which will be trimmed along the back edge… The seat will be sculptured away starting about 3", or so, from the Back & go all the way to the front, clearing away your over-thick part… So, don't sweat it… It is really very minor… I hope you can follow my brain drainage to paper as fast as I could type… :)

I started two Maloof lowback dining chairs a few years ago… have one seat sculptured (the one where the dust GOT to me)... the other seat is ready to be hogged out a little Before gluing it up where it will be ready to be sculptured out… I hope to get working on them soon… Shop is a mess & my back is killing me where I can't spend much time DOING things before I must stop & rest… BUT, I will get back to it… I have to do it… I'm NOT getting any younger! :)

So, I think you're doing good… and your thickness error is NO BIGGY… Just study my thoughts and I'm sure you will see it…

Good luck… Have fun… You WILL do it.
 

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#140 ·
MSMC out of the clamps and into the bandsaw

OK making good progress on the Medium Size Maloof Chairs (MSMC)today.

I solved the mismatched piece by using a hand plane, so afer much huffing and puffing and then later reading Joe and David's comments I could have left it there and sculpted it out oh well.

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Any way I profiled the seat edges in the bandsaw and commenced cutting out the legs as well.

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I used all Walnut this time but found I had completly consumed every piece that was a useable size and length for the rear legs and upper support.

I think I have one complete set but will need ot go see LJ degoose (Larry) to restock my Walnut stock so I can continue.

The front legs, I had heaps of material for them.

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The back legs

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I only had enough for one set so I had to stop

I considered using some maple but decided against it due to the strength differences

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Stopping for a while and off on a timber run to Caboolture.
 

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#141 ·
MSMC out of the clamps and into the bandsaw

OK making good progress on the Medium Size Maloof Chairs (MSMC)today.

I solved the mismatched piece by using a hand plane, so afer much huffing and puffing and then later reading Joe and David's comments I could have left it there and sculpted it out oh well.

Wood Wood stain Hardwood Outdoor furniture Flooring


Any way I profiled the seat edges in the bandsaw and commenced cutting out the legs as well.

Wood Plant Wood stain Hardwood Flooring


I used all Walnut this time but found I had completly consumed every piece that was a useable size and length for the rear legs and upper support.

I think I have one complete set but will need ot go see LJ degoose (Larry) to restock my Walnut stock so I can continue.

The front legs, I had heaps of material for them.

Wood Plant Wood stain Hardwood Flooring


The back legs

Wood Automotive exterior Plant Rectangle Bumper


I only had enough for one set so I had to stop

I considered using some maple but decided against it due to the strength differences

Wood Grass Gas Electrical wiring Electrical supply


Stopping for a while and off on a timber run to Caboolture.
Are there still mills up that way Rob??
 

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