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2nd Update on the Church Hymn Number Board Commission Project

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Blog entry by Mark A. DeCou posted 2544 days ago 2043 reads 0 times favorited 11 comments Add to Favorites Watch

Today, Monday, I took photos of what I have accomplished on my Hymn Number Board that I am building for the St. Anthony Church in Strong City, KS.

On one hand, it seems like I made a lot of progress since my last blog late last week, but when I look back over the photos tonight, I can see that the number of hours it takes me to do this tedious work is mounting.

I started the project with the previous blog: http://lumberjocks.com/jocks/decoustudio/blog/1508

Also, since I had enough interest shown in the Legacy Ornamental Mill in the last update, I took some more photos of other ways I have used this unique tool during the project.

Their website is www.legacywoodworking.com
I receive nothing for the promotion of their equipment, I’m just a happy and satifisfied user.

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Here is a photo showing the Dry Fit Assembly of the major pieces that I had ready by the end of work on Saturday Evening.

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Monday’s Work Update 7-23-2007

Legacy Mill Turnings:
I have a very nice heavy duty old variable frequency drive Oliver Lathe that I use inconjunction with the Legacy Ornamental Mill to do whatever steps make the most sense, and the most efficient use for each project. I enjoy using both tools, and so I choose which steps to do on each machine based on the best way to accomplish the task. The Legacy has added a lot of unique capability to my work, and it is fun to use.

This Photo shows some turned discs that I am using to join the sectioned side posts together. This type of work on a Legacy takes about 15 minutes from square block to ready to cut apart and sand.


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Here are the turned discs after they have been cut apart. I just use a Dozuki hand saw and carefully cut the remaining tenon apart into the sections. I could do these discs on my Oliver lathe, but I am more consistent and faster on the Legacy with this type of work.


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These turnings are column bottoms, which are shown installed below.
These parts are also turned in about 15 minutes. I took the workpiece out of the Legacy and hand cut the pieces apart with the Dozuki. Then, I took them to the Old Oliver Lathe and turned the tip to a round point. Then, while spinning on the lathe, I sanded them quickly with a Klingspor Sanding Mop in an electric drill motor.


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Here are the turnings after they have been cut apart with the Dozuki

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Here are the turnings after the tip has been turned on the Oliver, and after sanding.

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Attaching Brass Roller Feet to the Legs:
I ordered solid brass roller feet for the legs. I gave some thought as to whether I could build some on my own, but I thought my version might look more rustic than I wanted for the style of this project. Maybe another time I will try that.

I ordered these Rollers from Vandykes.com

The leg tip had to be shaped to fit the roller, but I figured out how to do that, and it only took about an hour a piece to get the legs all finished with the roller installed.

Top view showing the shaping required.

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Side View showing the profile.


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Here is the final view of the attached leg.

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Joinery: Sliding Dovetail on a Tripod Base
This is my first attempt at doing a sliding dovetail joint, and first time at doing a tripod base style foot and joint. I’m happy with the result, and next time I will be much faster.

This photo shows the sliding joint after all triming, fitting and prep work has been done.

The Next step is to glue the joint. I used 2-part 5-minute epoxy, because I couldn’t wait to see it all glued up. Also, the epoxy will fill any looseness in the joint, which no other glue will do.

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Here is the joint with all four components glued in place on one side of the base.

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I decided to reinforce the bottom of the joint, as I have seen antique tables with steel reinforcement. I think it will allow a much longer life for the base of the project. I couldn’t find a suitable premade piece in a catalog.

So, I enjoy doing metal work anyway, and I had some brass sheeting, so I laid out the full scale drawing, made a plastic template, and then cut out the shape in the brass sheeting using my bandsaw.

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Then, I sanded the brass to give it a consistent brushed looking finish.
Then I drilled the screw holes and countersunk the holes.

Here is a Photo with the brass reinforcement in place.

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Here is a photo showing the joint with the Turned Tip covering up the brass reinforcement. I nailed the turning in place with three finish nails through drilled holes, so that the turnings could be removed at some point, should they ever need to be during some future refinishing, or repair of the project.

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Here is a Photo showing the finished, and glued Base, with the Brass Roller Feet Installed.


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Next step is to work my way up the side posts, assembling as I go.

Thanks for checking in on me,

Mark DeCou
www.decoustudio.com

-- Mark DeCou - American Contemporary Craft Artisan - www.decoustudio.com



11 comments so far

View DocK16's profile

DocK16

1139 posts in 2671 days


#1 posted 2544 days ago

Mark
The level of your skill and attention to detail never ceases to amaze me. I strive for that level.

-- Common sense is so rare anymore when you do see it, it looks like pure genius.

View dennis mitchell's profile

dennis mitchell

3994 posts in 2898 days


#2 posted 2544 days ago

Thanks for the update!

View Karson's profile

Karson

34842 posts in 2984 days


#3 posted 2544 days ago

Great work Mark. I assume it will be all finished by the time I hit your shop for a visit.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View TomFran's profile

TomFran

2940 posts in 2578 days


#4 posted 2544 days ago

Mark,
You are a true artist and craftsman. Guys like you on this forum will keep me plenty humble. Thanks for showing us what real woodwork looks like.

-- Tom, Surfside Beach, SC - Romans 8:28

View PanamaJack's profile

PanamaJack

4469 posts in 2661 days


#5 posted 2544 days ago

Just great art work in wood Mark.

-- Carpe Lignum; Tornare Lignum (Seize the wood, to Turn the wood)

View rentman's profile

rentman

230 posts in 2678 days


#6 posted 2544 days ago

thanks for showing this mark.and great work as always

-- Phil, Chattanooga,TN

View Thos. Angle's profile

Thos. Angle

4435 posts in 2546 days


#7 posted 2544 days ago

Thanks, Mark. It’s always good to study with someone else, especially someone as good as you are.

-- Thos. Angle, Jordan Valley, Oregon

View Don's profile

Don

2599 posts in 2761 days


#8 posted 2544 days ago

Mark, this was most interesting and inspiring.

As Tom has so correctly stated, it’s guys like you a a few other in this community that do such high quality work yet are willing to take the time to detail this work to us ordinary wood enthusiasts.

Bless you, brother.

-- CanuckDon "I just love small wooden boxes!" http://dpb-photography.me/

View Joel Tille's profile

Joel Tille

213 posts in 2828 days


#9 posted 2543 days ago

Mark – what more can be said, previous posts hit the nail on the head. As some have mentiond, its like when i golfed alot, I tried to always get with people who golfed better than I did. This made me try that much harder to improve. You and others with the artisan flare do that for many of us. I may never get to the true artisan side of woodworking, but hope through everyones projects, blog and podcast i can become a better woodworker.

Thanks always,

-- Joel Tille

View Roger Strautman's profile

Roger Strautman

642 posts in 2718 days


#10 posted 2539 days ago

Those are very nice carvings, Mark!

-- " All Things At First Appear Difficult"

View Steffen's profile

Steffen

326 posts in 2619 days


#11 posted 2532 days ago

You are one gifted man Mark.

-- Steffen - Kirkland, WA

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