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Replacement Village Notice Board

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Project by Don Johnson posted 12-11-2016 02:32 PM 847 views 0 times favorited 1 comment Add to Favorites Watch

Our village notice board had been in place for a number of years, but finally gave up the ghost a couple of months ago, when the softwood frame had rotted enough to start to fall to pieces. Luckily I spotted what was happening before the doors fell off and smashed the glass. The third, fourth and fifth pictures give some idea of the condition of the board.

I advised the situation to the Clerk of the Parish Council, indicating that a new hardwood board of similar design was likely to cost well in excess of £1,000, but if the wood was paid for, I would be willing to make the board myself as a contribution to the village. Luckily, one of our villagers runs a woodturning business – making items as small as bannister spindles up to columns over two feet in diameter – and he said he had some Sapele off-cuts from one of his larger jobs that were not suitable for making anything else, which I might be able to use. With quite a lot of re-sawing and extensive use of my planer/thicknesser (jointer/planer), I was able to squeeze the necessary components out of the supplied wood, although I did have to use a finger joint to make one piece of the frame long enough.

Luckily, the window panes could be re-used – which was handy because they were made of Pilkington’s safety glass – so my design was pretty much the same size as the original. The old window frames had used mortice and tenon joints, but I did not feel that I could achieve the same quality, so I considered using my dowelling jig. However, when I tested the way of setting the jig for the component parts of the joints, I realised that it was going to be very fiddly, and – in my case – prone to error! I pondered on the situation for some days, but finally ‘bit the bullet’ and decided to buy a Festool Domino – the FD500. The salesman at Axminster tools was very helpful in demonstrating the machine, and luckily mentioned that the normal dominoes were NOT suitable for outdoor use – so I made my own from some of Sapele left-overs.

The door frames went together beautifully – probably because for the first time I had made full and proper use of the thicknesser/planer, and all the parts were straight and square, unlike the pre-planed timber I usually purchase. The outer frame initially came out all wrong, until I realised that I had cut the mortices in the ends of the sides instead of the inner faces (and vice-versa on the horizontals) !! There was no more Sapele available, so I had to make a new set of tenons to replace the first lot which I cut in half and used to fill the unwanted mortices. It just goes to show, that no matter how efficient and sophisticated the tools one uses, it is still possible to do something stupid with them.

Some outdoor plywood was rebated into the frame, and after a coat of varnish on the inside, self-adhesive cork wall tiles were stuck on – I hope that they will not fall off because they are outside. Three coats of exterior wood protection seemed to finished off the job, until my wife pointed out that the support legs – which were still fine and solid – did not match the board itself, so they had to be brushed and coated as well.

I’ve received a number of complimentary remarks, and must say that I am pleased with the outcome – especially as the ‘fill in’ tenons are out of sight!

-- Don, Somerset UK, http://www.donjohnson24.co.uk





1 comment so far

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pottz

1756 posts in 703 days


#1 posted 12-11-2016 10:17 PM

don id say you rescued that board with no time to spare,pretty bad shape.hopefully your new board will last for many years,great job.

-- sawdust the bigger the pile the bigger my smile-larry,so cal.

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