A week ago I saw the Locker Docker video from Steve Ramsey over at woodworking for mere mortals and thought that my 15 year old sister might like it. So I sent her a picture and asked if she wanted me to build her one she said yes, but gave her own take on colors :)
I started working on it last weekend, got a mirror and a white board at the dollar store. I ended up getting a square candle holder mirror it was 5’‘x5’’ and I figured would be easier to work with than a round mirror. I got all the parts cut and sorted out last weekend. I ended up using 1/2’’ plywood for the sides and shelves and this thin strip of pine that I had as scrap that turned out to be just right for the job.
Since the mirror and white board weren’t going to have any edging on them the door was just going to be 1/4’’ thick, so I had to figure out something different to do with the hinges. I decided that I would attach the hinges with the knuckled buried into the side. I marked out all the hinge locations and clamped the side in my vice.
I used chisels to cut away the knuckle mortise but it was a bit difficult, I had to be careful not to split the plywood laminates and I was mostly going against end grain it seemed like. With enough patience and persistance though I was able to get the knuckle to fit into the side.
By time I got to the 3rd one, I was getting better and was ready to do the 4th and when I went to clamp down the side at a better angle the screws holding the wood to my vice stripped out.
Now to be fair, this was a long time coming. It has been loose for a while now, but I was debating on building another bench and would fix it then. The wood I used was poplar (it’s what I had at the time that was thick enough) and I just drove in some screws into the wood thinking that it would be enough. Obviously it wasn’t I figured I’d get some bolts later and bolt it back in.
In the mean time I had 1 more mortise to make for a hinge so I just clamped the side down to my bench and worked slowly until I got that one all cleaned up as well. I didn’t get much else done that weekend or at all during the week.
I wanted to do a lot of woodworking this weekend, but a last minute project came up and I spent all night friday and most of the day on saturday working on it. Though I did pick up some bolts and such from the hardware store yesterday when I took a break and went grocery shopping. (Hardware store is right next to the grocery store, makes it really easy)
I spent a good bit of today in my shop though and started working on glueing up the locker docker. I wasn’t sure how I was going to glue the strip of pine to the plywood for the shelves. In the end I decided on just clamping it with blue tape.
It made it pretty easy instead of fussing with clamps, I was able to tape the pine strip to the plywood, then fold open the glue joint and apply glue.
Then I just have to fold the tape over and wrap it tightly around the plywood and it held it good enough for the glue to try.
After those dried I sanded off the squeeze out and glued all the sides and shelves together. I used the bottom plywood to help light everything up and applied the glue only to the side of the shelves, not the bottom. After I got it all clamped up I flipped it over and let it dry.
After that glue was dry I made sure the bottom was smooth, applied more glue and clamped the 1/4’’ plywood bottom though I think I applied too much glue, I got a lot more squeeze out than I wanted.
After the glue set on the bottom I tried using a chisel to get as much as the glue squeeze out on the inside as I could. My glue scrapper just wouldn’t fit inside very well. Here is a picture of my progress by the end of today.
While the glue was drying I also fixed my bench vice.
And I finished my band saw tune up I started a few weeks back when I discovered the broken bearing. Powermatic sent me a replacement bearing since the band saw was still under warranty. I also decided since I was getting a new blade anyways, I got a highland woodworking 1/2’’ wood slicer blade for resawing.
I was following this youtube video from the guys at carter, it was a presentation at one of the woodworking shows and the video is great.
I adjusted the blade the way he recommends with the gullet being in the center, and I start working on the bearing adjustments and I notice that the bottom bearing is impossible to be set the way he describes (just barely not touching the blade).
The problem is, I can’t back the bottom bearing back far enough it gets stuck against the back and won’t rotate at all, and the blade is still touching the bearing. I am sure this is exactly what caused the previous bearing to burn up like it did. I don’t know if the saw came like this, or if I just assembled it wrong, regardless I had to fix it. Fortunately the entire bearing unit can be adjusted back by unscrewing it and sliding it back. Unfortunately I have to remove the trunnion to unscrew the lower bearing assembly.
It was only two bolts and I got the trunnion off, then pulled the entire lower bearing assembly back far enough to allow me to adjust the thrust bearing some for a 1/2’’ blade. After that was done I finished the carter video and adjusted all the bearings as stated in the video.
Then I put the trunnion back on, and put the table back on as well. I was concerned that removing and re-adding the trunnion would have knocked out the 90 degree stop, so I had to double check the angle of everything. I used my wixey digital gauge and attached it to the blade and zero’d it out. It’s magnetic to it sticks to the blade easily, then I just have to set it on the table and check the angle.
The good news is, the stop was still good for 90 degrees and my table was all set. My final setup was to re-adjust the fence for the new setup. The carter video says that you shouldn’t have any blade drift if set up properly, and my fence was set for the really bad drift I had before (and still didn’t work good) .. so I needed to re square it up.
Using a framing square and several test cuts (checking for drift etc..) I was able to get the fence to produce a good straight cut. I cut a strip of plywood and measured both ends of the strip and both sides came out at 19/32’‘
It wasn’t a very long piece so there still might be a slight margin of error in there, but I’m satisfied as it is, I won’t be doing any ripping with my band saw anyways I just wanted it to be as straight as I could get it for resawing.
Next weekend I hope to get the doors of the locker docker done, and have the whole thing sanded and ready for painting.
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