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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.
 

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#147 ·
Maloof Medium Chair continues I got the timber!

OK I am back, I left off with the activity needing some more Walnut to continue with the chairs.

I rang Degoose and he invited me to come see him, adding he didnt have any Walnut but we could go see his fellow woodworker Trevor Gaskill afterwards.

Lots of exciting things are happening at Lazy larrys Wood Works, so if Larry is a buddy you may want to give him a call to get the good goss.

Anyway Larry showed me some New Guinea Rosewood pieces he had which were exactly what I needed.

Plant Wood Chair Folding chair Outdoor furniture


He had two lengths about 3m and as NGR is a good furniture wood each I took both, then with a little arm twisting I also loaded up about half a ute load of timber mostly NGR.

I was starting to run out of loot so bidded Larry farewell and I headed home with my new found booty.

So a redesign on the chairs came about instead of Walnut legs and back, the prefered timber of Sam, I decided to make all the legs and back from NGR.

Today saw quite a lot of progress.

The legs were roughed out the joints prepared and fitup of chair No1 progressed to a stage where now I need to pay attention to fine tuning the precision fitting of the components.

It has been some years since I made the first Maloof style kids chairs and with a complete dimensional change came some confusion as to how to go about the bigger joints.

I sent Paul Lemiski a PM asking his advice on what he does, Paul was most helpful and replied he was using 3 to 4 inch joints, Wow! way bigger then I needed, so I watched his video presentation on the plans he sells.
His presentation is well worth the 26 minutes if you are considering building full size furniture.

A little different to what I am doing but never the less still very informative.

I again made the same mistake as last time and bandsawed the legs before finishing the joints first, only this time I made a box jig to overcome my senility.

Wood Plant Rectangle Outdoor furniture Wood stain


It wasnt that easy either, I had to make block spacer jigs to support the legs so I could cut everything exactly.

Wood Flooring Floor Wood stain Composite material


Ploding away I managed to get everything done, even if it was the hard way

Wood Hardwood Wood stain Desk Flooring


Got all the component joints finished.

Wood Grass Wood stain Hardwood Wooden block


Then started with the tuneing of the joints to get precision fitting of everything.

I got to this stage before the light started to beat me, plus I thought I heard a beer calling!

Wood Plant Outdoor furniture Gas Hardwood


Packing up for the day I took a final shot with one of the Maloof Kids chairs I still had, simply to show the differences in size.

Furniture Wood Plant Chair Floor


More to follow.
 

Attachments

#148 ·
Maloof Medium Chair continues I got the timber!

OK I am back, I left off with the activity needing some more Walnut to continue with the chairs.

I rang Degoose and he invited me to come see him, adding he didnt have any Walnut but we could go see his fellow woodworker Trevor Gaskill afterwards.

Lots of exciting things are happening at Lazy larrys Wood Works, so if Larry is a buddy you may want to give him a call to get the good goss.

Anyway Larry showed me some New Guinea Rosewood pieces he had which were exactly what I needed.



He had two lengths about 3m and as NGR is a good furniture wood each I took both, then with a little arm twisting I also loaded up about half a ute load of timber mostly NGR.

I was starting to run out of loot so bidded Larry farewell and I headed home with my new found booty.

So a redesign on the chairs came about instead of Walnut legs and back, the prefered timber of Sam, I decided to make all the legs and back from NGR.

Today saw quite a lot of progress.

The legs were roughed out the joints prepared and fitup of chair No1 progressed to a stage where now I need to pay attention to fine tuning the precision fitting of the components.

It has been some years since I made the first Maloof style kids chairs and with a complete dimensional change came some confusion as to how to go about the bigger joints.

I sent Paul Lemiski a PM asking his advice on what he does, Paul was most helpful and replied he was using 3 to 4 inch joints, Wow! way bigger then I needed, so I watched his video presentation on the plans he sells.
His presentation is well worth the 26 minutes if you are considering building full size furniture.

A little different to what I am doing but never the less still very informative.

I again made the same mistake as last time and bandsawed the legs before finishing the joints first, only this time I made a box jig to overcome my senility.



It wasnt that easy either, I had to make block spacer jigs to support the legs so I could cut everything exactly.



Ploding away I managed to get everything done, even if it was the hard way



Got all the component joints finished.



Then started with the tuneing of the joints to get precision fitting of everything.

I got to this stage before the light started to beat me, plus I thought I heard a beer calling!



Packing up for the day I took a final shot with one of the Maloof Kids chairs I still had, simply to show the differences in size.



More to follow.
Rob, I always enjoy your projects. Thanks for sharing. We're off on another of your wood adventures.
 

Attachments

#153 ·
GN Prototype Chair (or Pottz made me do it)

Pottz spotted a Sam Maloof chair I was making for the family and wanted a picture, so I sent him a few attached to one of my replies.
Anyway he educated me about a person called George Nakashima in the process, so being a bit of an inquisitive sort of person I went off and researched George myself.

Now this guy is a fellow Americian, and obviously of japanese heritage and he had an engineering background but ended up in a Internment Camp in the USA during WWII.

His life story is a very interesting one (well it was to me anyway) and his furniture creations took my interest.
In particular his two legged chair the "Coniod"

At first I just admired his work and marveled over the natural lines and simplicity he used obviously calling on and using his engineering skills to make the products.

Being a simple person myself I decided to see if I could make the Conoid chair.

As it was a first off for me I decided to make a prototype just in case it ended up in the Otto bin.
So its Sunday morning I set to work, its now early AM Sun and this is my result so far.

The basic frame.

Wood Gas Tints and shades Plant Metal


It seemed to be too easy, the feet and supports are Morticed so I clamped up some cross braces and made a temporary seat and inserted some seat supports and clamped them in position.

Wood Gas Flooring Composite material Tints and shades


Well it didnt fall over so I guess thats a good start, curious as to how well balanced it was I sat in it.

The Stability Test

Plant Sleeve Wood Tints and shades T-shirt


To my surprise it was quite comportable albeit a bit wobbly, but it was not too unstable tipping wise.

So I decide to stand on it , now its not really a good idea but sure enough it held me OK, mind you I would not recommend standing on the very front as I think it may tip forward.

Footwear Leg Wood Grey Finger


Summary

Well in summary its well worth continuing with, and I wanted a decent picture to demonstrate it so I asked my wife Aurora to "come take a look" she looked at it and asked where the other two legs were.

I then coaxed her to try it out and she reluctantly did saying it looked very wobbly upon sitting it it she was also surprised!

So I got some decent pictures to show you all!

Better Pictures

Smile Sleeve Knee Waist Wood


and another

Wood Plant Smile Leisure Thigh


Well thats something well worth persuing and turning into a project !
 

Attachments

#154 ·
GN Prototype Chair (or Pottz made me do it)

Pottz spotted a Sam Maloof chair I was making for the family and wanted a picture, so I sent him a few attached to one of my replies.
Anyway he educated me about a person called George Nakashima in the process, so being a bit of an inquisitive sort of person I went off and researched George myself.

Now this guy is a fellow Americian, and obviously of japanese heritage and he had an engineering background but ended up in a Internment Camp in the USA during WWII.

His life story is a very interesting one (well it was to me anyway) and his furniture creations took my interest.
In particular his two legged chair the "Coniod"

At first I just admired his work and marveled over the natural lines and simplicity he used obviously calling on and using his engineering skills to make the products.

Being a simple person myself I decided to see if I could make the Conoid chair.

As it was a first off for me I decided to make a prototype just in case it ended up in the Otto bin.
So its Sunday morning I set to work, its now early AM Sun and this is my result so far.

The basic frame.

Wood Gas Tints and shades Plant Metal


It seemed to be too easy, the feet and supports are Morticed so I clamped up some cross braces and made a temporary seat and inserted some seat supports and clamped them in position.

Wood Gas Flooring Composite material Tints and shades


Well it didnt fall over so I guess thats a good start, curious as to how well balanced it was I sat in it.

The Stability Test

Plant Sleeve Wood Tints and shades T-shirt


To my surprise it was quite comportable albeit a bit wobbly, but it was not too unstable tipping wise.

So I decide to stand on it , now its not really a good idea but sure enough it held me OK, mind you I would not recommend standing on the very front as I think it may tip forward.

Footwear Leg Wood Grey Finger


Summary

Well in summary its well worth continuing with, and I wanted a decent picture to demonstrate it so I asked my wife Aurora to "come take a look" she looked at it and asked where the other two legs were.

I then coaxed her to try it out and she reluctantly did saying it looked very wobbly upon sitting it it she was also surprised!

So I got some decent pictures to show you all!

Better Pictures

Smile Sleeve Knee Waist Wood


and another

Wood Plant Smile Leisure Thigh


Well thats something well worth persuing and turning into a project !
always nice to find new ways to enjoy the craft

aurora seems happy too
add more chairs to the honey do list
and start thinking about the matching table
while you are at it
 

Attachments

#164 ·
GN Prototype chair Making the seat and assemblying most parts

I continued after lunch and made the seat cut out the joints and dry assembled everything.

Construction process

I used a contractors saw with a miter sled rip fence and my tenoning jig to cut all the timbers

To make the seat I cut up some pallet frames, cut a taper on the underside to 30mm and glued them all together.

Wood Plant Table Tool Wheel


The overall thickness at the back was not 50mm so I added a section to achieve the 50mm thickness.

I cut the seat joints on the saw and fine tuned the fit with a Rasp.

Wood Composite material Hardwood Flooring Plywood


I then marked out the top post tenons and cut them, again using the table saw and tenoning jig.

Wood Machine tool Gas Engineering Machine


Here is a few shots of the joints.

Wood Rectangle Wood stain Natural material Hardwood


Wood Road surface Floor Flooring Asphalt


That was enough for the day so work stopped at this stage.
 

Attachments

#165 ·
GN Prototype chair Making the seat and assemblying most parts

I continued after lunch and made the seat cut out the joints and dry assembled everything.

Construction process

I used a contractors saw with a miter sled rip fence and my tenoning jig to cut all the timbers

To make the seat I cut up some pallet frames, cut a taper on the underside to 30mm and glued them all together.

Wood Plant Table Tool Wheel


The overall thickness at the back was not 50mm so I added a section to achieve the 50mm thickness.

I cut the seat joints on the saw and fine tuned the fit with a Rasp.

Wood Composite material Hardwood Flooring Plywood


I then marked out the top post tenons and cut them, again using the table saw and tenoning jig.

Wood Machine tool Gas Engineering Machine


Here is a few shots of the joints.

Wood Rectangle Wood stain Natural material Hardwood


Wood Road surface Floor Flooring Asphalt


That was enough for the day so work stopped at this stage.
Just a thought…

Could you leave the final pieces of the sides OFF the seat, with just the notches cut in the seat…
Place an outside SIDES, also notched, into leg and glued & clamped to seat…
... auto Perfect Fit??
... why cut & fit it??

This is interesting…

Could it handle the weight of 210 lbs+??

COOL… Thank you…
 

Attachments

#174 ·
GN Prototype chair redesign and final assembly

Hey its ANZAC Day public holiday here in Australia so in Remembrance of our fallen I manned the trenches this morning, the wooden trenches that is.

First up I took the advice of our learned LJs and redesigned the seat and legs to suit their suggestions.

Here is the rebuild.

Wood Public space Leisure Smile Outdoor furniture


OK now back to the past.

The seat sculpting commenced.

Table Wood Tool Power tool Workbench


I made a couple of jigs to shape the seat

Wood Font Handwriting Plant Triangle


Then powering up the grinder and I had the chips flying big time.

Outdoor bench Wood Outdoor furniture Bench Hardwood


Next was the morticing of the top cross support, this proved to be a bit tricky as it had to be held at 11 deg in the Hollow Chisel Morticer clamp so the mortice could conform to the support tenon angle.

Saw Milling Wood Machine tool Gas


I am not sure exactly how this is done but I just bunged a dowel in the back and clamped it.
All a bit raggedy but it worked for me.

Wood Composite material Gas Bumper Asphalt


Next was the back support dowels.

Wood Table Composite material Wood stain Plank


I made these from bits I ripped off when making the support legs

Wood Natural material Outdoor furniture Wood stain Gas


The chair is now complete, apart from some cosmetic finishing work to make more accurate and possibly glueing everything together.

Plant Wood Natural material Outdoor furniture Chair


And another shot

Chair Wood Natural material Grass Gas


Closure:

Are they worth building? In my mind yes,
Why is it not glued up? A couple of reasons
1. From information I found relating to the build the real test of its construction is the fact it can support a person in its dry assembled only state.
2. There are some additional tapering tasks and shaping of parts needing to be done that I picked up from Joe Lyddon's posts.

General info: There is a lot of banter about the building of these type of chairs and some tend to digress from the original George Nakashima design, so beware if you do research it the limited information available detailing the build is sometimes not "original design" accurate.
Incidently I emailed Mira Nakashima asking advice on the build and I am yet to hear back.

ANZAC Day: Just in case you thought I was taking the piss about ANZAC Day I had my eldest brother David in Vietnam with 9 RAR in 1969 and sadly he did not return alive.

Lest we forget

Chin Hat Flash photography Cap Headgear


That ends the George Nakishima Conoid Chair build blog.
 

Attachments

#175 ·
GN Prototype chair redesign and final assembly

Hey its ANZAC Day public holiday here in Australia so in Remembrance of our fallen I manned the trenches this morning, the wooden trenches that is.

First up I took the advice of our learned LJs and redesigned the seat and legs to suit their suggestions.

Here is the rebuild.

Wood Public space Leisure Smile Outdoor furniture


OK now back to the past.

The seat sculpting commenced.

Table Wood Tool Power tool Workbench


I made a couple of jigs to shape the seat

Wood Font Handwriting Plant Triangle


Then powering up the grinder and I had the chips flying big time.

Outdoor bench Wood Outdoor furniture Bench Hardwood


Next was the morticing of the top cross support, this proved to be a bit tricky as it had to be held at 11 deg in the Hollow Chisel Morticer clamp so the mortice could conform to the support tenon angle.

Saw Milling Wood Machine tool Gas


I am not sure exactly how this is done but I just bunged a dowel in the back and clamped it.
All a bit raggedy but it worked for me.

Wood Composite material Gas Bumper Asphalt


Next was the back support dowels.

Wood Table Composite material Wood stain Plank


I made these from bits I ripped off when making the support legs

Wood Natural material Outdoor furniture Wood stain Gas


The chair is now complete, apart from some cosmetic finishing work to make more accurate and possibly glueing everything together.

Plant Wood Natural material Outdoor furniture Chair


And another shot

Chair Wood Natural material Grass Gas


Closure:

Are they worth building? In my mind yes,
Why is it not glued up? A couple of reasons
1. From information I found relating to the build the real test of its construction is the fact it can support a person in its dry assembled only state.
2. There are some additional tapering tasks and shaping of parts needing to be done that I picked up from Joe Lyddon's posts.

General info: There is a lot of banter about the building of these type of chairs and some tend to digress from the original George Nakashima design, so beware if you do research it the limited information available detailing the build is sometimes not "original design" accurate.
Incidently I emailed Mira Nakashima asking advice on the build and I am yet to hear back.

ANZAC Day: Just in case you thought I was taking the piss about ANZAC Day I had my eldest brother David in Vietnam with 9 RAR in 1969 and sadly he did not return alive.

Lest we forget

Chin Hat Flash photography Cap Headgear


That ends the George Nakishima Conoid Chair build blog.
Hi Rob,

Sorry about the loss of your brother in Vietnam… A very sad day for sure… an you will never forget it.

I didn't know the chair was built WITHOUT gluing it up… Really?
I thought it was standard procedure to glue it up… :)
What parts are glued and NOT glued?

I think I would try to place a "lower back rest" across the bottom area of the back… with the dowels going up from there.

I agree… I think it's positively worth building… trying… Very unique…
I like the extra Leg Room!!

Thank you for keeping us updated on your progress… Have a good one!
 

Attachments

#179 ·
Shoe Rack cabinet Concept

I am going to make a shoe rack cabinet based on the project David Dean posted in Oct 2012
It will only have one tilt out section as I need to have room for work boots and other formal high heel boots of which all need hiding away.

So whats prompted this?

Here is the situation at our front entrance as we speak.

Brown Wood Flooring Floor Wood stain


Although we have a cupboard its outlived its usefullness, and there are shoes and boots scattered about.

Furniture Wood Comfort Chair Flooring


This is the timber I am going to use.

Some swamp Gum and,

Outdoor bench Wood Outdoor furniture Wood stain Bench


Red Ironbark

Wood Grass Gas Rectangle Mesh


The design/plan will be Swamp Gum frame with red Ironbark raised panels and possibly plywood backing and areas not imediately visible.
 

Attachments

#180 ·
Shoe Rack cabinet Concept

I am going to make a shoe rack cabinet based on the project David Dean posted in Oct 2012
It will only have one tilt out section as I need to have room for work boots and other formal high heel boots of which all need hiding away.

So whats prompted this?

Here is the situation at our front entrance as we speak.

Brown Wood Flooring Floor Wood stain


Although we have a cupboard its outlived its usefullness, and there are shoes and boots scattered about.

Furniture Wood Comfort Chair Flooring


This is the timber I am going to use.

Some swamp Gum and,

Outdoor bench Wood Outdoor furniture Wood stain Bench


Red Ironbark

Wood Grass Gas Rectangle Mesh


The design/plan will be Swamp Gum frame with red Ironbark raised panels and possibly plywood backing and areas not imediately visible.
Cool….
 

Attachments

#196 ·
Shoe Rack Cabinet The work begins

The Red Ironbark

The 30Kg plus piece of Red Ironbark was first in line for working, mainly because of its sheer weight alone,

I set the Table saw up and then wrestled the post onto the table.

Wood Flooring Hardwood Composite material Machine


I estimated that I could get a series of pieces about 25mm each from the post
Plant Wood Road surface Automotive tire Tree


I was surprised just how flat the timber is and layed them all out for the thicknesser, as I believed the jointer could not improve on much.

Wood Outdoor furniture Bumper Automotive exterior Table


Sure enough I got five pieces from it. I had to make two cuts for each piece as the timber was 150 mm x 150 mm so I set the blade at DOC = 80mm.

Sawing away I ended up with a very neat package of usable timber, The saw cut OK and I took it easy and just fed it as it progressed through, A few puffs of smoke every now and then but no other worries.

Wood Road surface Rectangle Flooring Floor


I then ran them through the thicknesser/planer and they were ready for their role as raised panels.

Wood Rectangle Composite material Flooring Hardwood


I am still amazed somebody would just dump this wood.

The Swamp Gum
No prizes for guessing where it came from, ....LLWW, AKA degoose and now as Laser Creations by Larry

You can find him here: lasercreationsbylarry.com.au (I think he might be partial to Blue M&Ms)

Again this timber was introduced to the table saw and sawn up as follows:
In half width wise then I cut a length 1.2m (The 1.2 being the side Stiles for the cupboard) off the end to make it a little more managable.

Wood Flooring Floor Rectangle Plank


Then I cut the remaining four pieces in half again giving me pieces about 90mm x 25mm

Wood Rectangle Urban design Composite material Art


I ended up with 10 pieces of timber, the Swamp Gum will be for the Cupboard framework.

The two separate lengthsI didnt take any pictures of it getting processed. They will be dividers for the Raised Panels

Table Furniture Wood Rectangle Wood stain


Again I was impressed with the flatness of the Gum so it went straight into the thicknesser.

I am not sure if Red Ironbark and Swamp Gum are used for "fine" furniture but they certailny lend themselves to it.
I do know outdoor furniture is made from it and commands big $ at sales.

Overall I was pleased with the results and when I finished I gave the Table saw a good check over, maybe two new belts for its effort are in order, so they were ordered, the blade will need chainging out if I cut more stock that size but its OK to do the ongoing cut work.

Its clean up time and a task to find out where to hide all the sawdust!
 

Attachments

#197 ·
Shoe Rack Cabinet The work begins

The Red Ironbark

The 30Kg plus piece of Red Ironbark was first in line for working, mainly because of its sheer weight alone,

I set the Table saw up and then wrestled the post onto the table.

Wood Flooring Hardwood Composite material Machine


I estimated that I could get a series of pieces about 25mm each from the post
Plant Wood Road surface Automotive tire Tree


I was surprised just how flat the timber is and layed them all out for the thicknesser, as I believed the jointer could not improve on much.

Wood Outdoor furniture Bumper Automotive exterior Table


Sure enough I got five pieces from it. I had to make two cuts for each piece as the timber was 150 mm x 150 mm so I set the blade at DOC = 80mm.

Sawing away I ended up with a very neat package of usable timber, The saw cut OK and I took it easy and just fed it as it progressed through, A few puffs of smoke every now and then but no other worries.

Wood Road surface Rectangle Flooring Floor


I then ran them through the thicknesser/planer and they were ready for their role as raised panels.

Wood Rectangle Composite material Flooring Hardwood


I am still amazed somebody would just dump this wood.

The Swamp Gum
No prizes for guessing where it came from, ....LLWW, AKA degoose and now as Laser Creations by Larry

You can find him here: lasercreationsbylarry.com.au (I think he might be partial to Blue M&Ms)

Again this timber was introduced to the table saw and sawn up as follows:
In half width wise then I cut a length 1.2m (The 1.2 being the side Stiles for the cupboard) off the end to make it a little more managable.

Wood Flooring Floor Rectangle Plank


Then I cut the remaining four pieces in half again giving me pieces about 90mm x 25mm

Wood Rectangle Urban design Composite material Art


I ended up with 10 pieces of timber, the Swamp Gum will be for the Cupboard framework.

The two separate lengthsI didnt take any pictures of it getting processed. They will be dividers for the Raised Panels

Table Furniture Wood Rectangle Wood stain


Again I was impressed with the flatness of the Gum so it went straight into the thicknesser.

I am not sure if Red Ironbark and Swamp Gum are used for "fine" furniture but they certailny lend themselves to it.
I do know outdoor furniture is made from it and commands big $ at sales.

Overall I was pleased with the results and when I finished I gave the Table saw a good check over, maybe two new belts for its effort are in order, so they were ordered, the blade will need chainging out if I cut more stock that size but its OK to do the ongoing cut work.

Its clean up time and a task to find out where to hide all the sawdust!
Rob, I am beginning to want to see the finished product. The wood is beautiful. Are you going to match the grain for the doors? In a few days I'll send you a pix of my shoe closet.
 

Attachments

#203 ·
Shoe Rack Cabinet some skill based results at last

With all the brute force timber cutting and preparation work over it was now time for some interesting progress

Today I achieved the following:

1. Cut up the raised panels cut the rails including Profiling all the rails and stiles
2. Profiled all the raised Panels.
3. Did a dry fit up to check everything.
4. Pulled it all apart sanded everything and Polished the raised panels and then sealed the frame work

5. Assembled and glued up the "B" Side of the cupboard.

I used my 3 bit Raised panel set to cut the stiles and rails
Some photos.

Work begins in ernest.

Table Outdoor table Outdoor furniture Wood Picnic table


Layout of the components

Rectangle Wood Flooring Wood stain Floor


Everything looked OK dimensions wise so it was now time to profile everything.

Outdoor bench Plant Table Wood Outdoor furniture


I used my shaper to do the profiles with the bit in the pictures.

Wood Wood stain Hardwood Flooring Varnish


Then assembled everything to do a final check.

The fronts:

Wood Wood stain Rectangle Hardwood Composite material


The Rears:

Wood Rectangle Cabinetry Wood stain Natural material


Then all was dismantled and final finishing carried out.

Sanding the frame stiles.

Wood Gas Audio equipment Office equipment Machine


and the rails

Automotive tire Wood Bumper Plant Automotive exterior


The Raised panels were sanded too but I had another process in store for them.

Polishing.
Wood Machine tool Gas Tool Hardwood


(I had to quickly remove my red nail polish just in case LBD spotted it)

Here is the first Panel polished beside it's mate just sanded to 320 G.

Rectangle Wood Flooring Floor Wood stain


A shot of the original post just in case there was some concern about me pulling a hoax about just what this timber gives up with some TLC.

Plant Wood Table Wood stain Hardwood


The B Side re assembled and glued up.

Whats with the B side reference?

As the shoe cuboard will be free standing and the right hand side will face the wall and never be seen until its removal, and by that stage I will not be around to explain all the dodgy work. So when I prepared all the parts I graded all the best features into the left hand side, so that the natural defects and those man made were religated to "The Wall".

Have a look and see how many defects you can spot. there are about five but I think one is hidden by a rail.

Pic 1
Brown Wood Stairs Rectangle Flooring

The sides are yet to be trimmed to size hence the raggedy end.

Pic 2
Brown Stairs Wood Table Flooring

Check out that finish shine ! nothing more than friction polished.

Pic 3
Wood Plant Wood stain Hardwood Plank

I included picture three as it showed the stock pile of posts remaining, these brutes weigh in at about 35 to 40 kgs each, and patiently await my son to arrive to assist in their movement.

Now on to the second side.
 

Attachments

#204 ·
Shoe Rack Cabinet some skill based results at last

With all the brute force timber cutting and preparation work over it was now time for some interesting progress

Today I achieved the following:

1. Cut up the raised panels cut the rails including Profiling all the rails and stiles
2. Profiled all the raised Panels.
3. Did a dry fit up to check everything.
4. Pulled it all apart sanded everything and Polished the raised panels and then sealed the frame work

5. Assembled and glued up the "B" Side of the cupboard.

I used my 3 bit Raised panel set to cut the stiles and rails
Some photos.

Work begins in ernest.

Table Outdoor table Outdoor furniture Wood Picnic table


Layout of the components

Rectangle Wood Flooring Wood stain Floor


Everything looked OK dimensions wise so it was now time to profile everything.

Outdoor bench Plant Table Wood Outdoor furniture


I used my shaper to do the profiles with the bit in the pictures.

Wood Wood stain Hardwood Flooring Varnish


Then assembled everything to do a final check.

The fronts:

Wood Wood stain Rectangle Hardwood Composite material


The Rears:

Wood Rectangle Cabinetry Wood stain Natural material


Then all was dismantled and final finishing carried out.

Sanding the frame stiles.

Wood Gas Audio equipment Office equipment Machine


and the rails

Automotive tire Wood Bumper Plant Automotive exterior


The Raised panels were sanded too but I had another process in store for them.

Polishing.
Wood Machine tool Gas Tool Hardwood


(I had to quickly remove my red nail polish just in case LBD spotted it)

Here is the first Panel polished beside it's mate just sanded to 320 G.

Rectangle Wood Flooring Floor Wood stain


A shot of the original post just in case there was some concern about me pulling a hoax about just what this timber gives up with some TLC.

Plant Wood Table Wood stain Hardwood


The B Side re assembled and glued up.

Whats with the B side reference?

As the shoe cuboard will be free standing and the right hand side will face the wall and never be seen until its removal, and by that stage I will not be around to explain all the dodgy work. So when I prepared all the parts I graded all the best features into the left hand side, so that the natural defects and those man made were religated to "The Wall".

Have a look and see how many defects you can spot. there are about five but I think one is hidden by a rail.

Pic 1
Brown Wood Stairs Rectangle Flooring

The sides are yet to be trimmed to size hence the raggedy end.

Pic 2
Brown Stairs Wood Table Flooring

Check out that finish shine ! nothing more than friction polished.

Pic 3
Wood Plant Wood stain Hardwood Plank

I included picture three as it showed the stock pile of posts remaining, these brutes weigh in at about 35 to 40 kgs each, and patiently await my son to arrive to assist in their movement.

Now on to the second side.
sweet my friend,i like the progress so far.lso i gotta say im envious of the timber you aussies have to work with,i mean i can get it here but for a hell of a lot more than you pay.so rob how about sending a buddy in the states a little care package of lets say 500 board feet of your nice australian timber.it would make a nice jesture!peace .
 

Attachments

#232 ·
Shoe Rack Cabinet Starting the framework

Today I made the face frame and rear bracing then realised that I had a few errors to deal with.
1. I had grossly underestimated the amount of timber I needed to do the job,and
2. The face frame I made I didnt like so I pulled it off again.
3. No stock of fine thread screws.
4. Made some smoke, and
5. Broke something.

So I spent a lot of time doing stuff but didnt really produce much progress.

Here is the frame work.

Wood Pet supply Shelving Wood stain Hardwood


I am not sure what you think but as the day went by and I started to design the tilt out drawer I realised that the face frame was way too wide and with the added width of more raised panel fronts it was going to look mismatched from the rest of the build, so I removed it and reduced it in width by 50 %

So another stick of Swamp gum from the rack was prepared.

Plant Table Wood Gas Roof


I decided to cut it into 2 pieces to make it more managable

Saw Miter saw Abrasive saw Foundry Plant


Without boring everybody with the individual processes involved this is what I ended up with.

Wood Table Floor Flooring Wood stain


Now the face frame and corresponding Raised panels will have frame work this size.

Wood Rectangle Flooring Wood stain Plank


I used pocket hole fastening for the frame and upon checking my Kreg screw stock I only had coarse threads for softwood so I did a test run to see if using the incorrect screws blew anything apart.

Wood Fixture Household hardware Door Hardwood


This is my poor mans version of the proper kreg Clamp, I didnt have the loot to buy a real clamp so I had my metal working friend weld a 8mm bolt on the end.

The incorrect screws seemed to work so I set to work with them

Wood Drawer Wood stain Hardwood Table


Milling work was not with out incident either as I was sawing away I stared producing smoke, so I stopped and checked the blade, it seemed sharp enough so I decided to take it off and clean it.

Dishware Wood Gas Circle Font


With a good clean it seemed to be free of all the resin and gunk build up on the sides.

Automotive tire Wood Grey Flooring Gas


As I had the other new blade out already so I decided to fit it and get on with what I was supposed to be doing.

The new blade worked like a charm so I continued.

The frame work continued but as I was removing my sash clamp I dropped it and it fell and I broke its foot off

Wood Composite material Flooring Building material Rectangle


Cast junk! I wonder will Mr JB weld fix it.

OMG what else is going wrong today!! enough so I packed up everything for the day.
 

Attachments

#233 ·
Shoe Rack Cabinet Starting the framework

Today I made the face frame and rear bracing then realised that I had a few errors to deal with.
1. I had grossly underestimated the amount of timber I needed to do the job,and
2. The face frame I made I didnt like so I pulled it off again.
3. No stock of fine thread screws.
4. Made some smoke, and
5. Broke something.

So I spent a lot of time doing stuff but didnt really produce much progress.

Here is the frame work.

Wood Pet supply Shelving Wood stain Hardwood


I am not sure what you think but as the day went by and I started to design the tilt out drawer I realised that the face frame was way too wide and with the added width of more raised panel fronts it was going to look mismatched from the rest of the build, so I removed it and reduced it in width by 50 %

So another stick of Swamp gum from the rack was prepared.

Plant Table Wood Gas Roof


I decided to cut it into 2 pieces to make it more managable

Saw Miter saw Abrasive saw Foundry Plant


Without boring everybody with the individual processes involved this is what I ended up with.

Wood Table Floor Flooring Wood stain


Now the face frame and corresponding Raised panels will have frame work this size.

Wood Rectangle Flooring Wood stain Plank


I used pocket hole fastening for the frame and upon checking my Kreg screw stock I only had coarse threads for softwood so I did a test run to see if using the incorrect screws blew anything apart.

Wood Fixture Household hardware Door Hardwood


This is my poor mans version of the proper kreg Clamp, I didnt have the loot to buy a real clamp so I had my metal working friend weld a 8mm bolt on the end.

The incorrect screws seemed to work so I set to work with them

Wood Drawer Wood stain Hardwood Table


Milling work was not with out incident either as I was sawing away I stared producing smoke, so I stopped and checked the blade, it seemed sharp enough so I decided to take it off and clean it.

Dishware Wood Gas Circle Font


With a good clean it seemed to be free of all the resin and gunk build up on the sides.

Automotive tire Wood Grey Flooring Gas


As I had the other new blade out already so I decided to fit it and get on with what I was supposed to be doing.

The new blade worked like a charm so I continued.

The frame work continued but as I was removing my sash clamp I dropped it and it fell and I broke its foot off

Wood Composite material Flooring Building material Rectangle


Cast junk! I wonder will Mr JB weld fix it.

OMG what else is going wrong today!! enough so I packed up everything for the day.
It's a pity that you had some rotten luck, because that is turning out beautiful!

I like the ingenuity shown on your clamp too :)
 

Attachments

#238 ·
Shoe Rack Cabinet Framework continues and door work starts

Ok I continued on and completed the frame work then went hinge hunting and commenced the top tilting door and bottom swinging doors.
After spending half a day running around trying to find Face frame inset door hinges that I wanted I gave up as a time waster, maybe they do not exist who knows.

Anyway finished the front frame work.

The top section will be the tilt out section and below the mid rail two hinged doors will be fitted

Wood Rectangle Outdoor furniture Pet supply Hardwood


A digression and "tool Tip" you cannot use coarse screws in hardwood when the dimensions are critical.
With the reduction of the width of the face frame I did another test with the coarse screws, and what do you know produced a fail, what a surprise!!

Wood Wood stain Hardwood Plank Rectangle


So yet another shopping trip, this time I bought the correct screws returned home and tried again, and what do you know they worked!!

Wood Font Tool Gas Wood stain


With all the running around not a lot was achieved yesterday so I continued on today

The doors
The front tilting drawer and the two lower doors kept me amused all of today

I made all the frames and started on the Raised panels had two which split or a knot fell out so I had to visit the timber stack and make even more stock with the Red Ironbark, this was not factored into the material required so its up again.

Wood Plant Gas Hardwood Plank


The Rejects.

Wood Wood stain Hardwood Lumber Automotive exterior


Anyway working away I managed to get two door finished when yet another panel blew out.

So I am going to glue it up overnight and take to it with the sander to see if I can repair and recover it otherwise it yet another panel to be made tomorrow. (See note below)

The doors dry assembled and sitting in their respective positions.

Plant Wood Wood stain Rectangle Natural material


One of the Raised Panel blow outs on the R/H side door.

Table Rectangle Wood Chair Flooring


After doing a few checks on Red Ironbark there is a general opinion normal glues will not work well on it so maybe its yet another Raised panel to be made.
There is also a general recommendation not to use Red ironbark for furniture due to its hardness but a there is a comment it will polish up well, they got that right.

Furniture Wood Rectangle Wood stain Flooring


That was enough for today so i packed up.

Lessons learned:

I am begining to understand why some woodworkers have more than one router, the amount of time swapping bits setting them up and profiling whatever seemed to be a very time consuming and fiddly activity.

Three routers set up would be the go, two for frame profiling bits, and the third for Raised Panel work.

Add having a back cutting combination Panel cutter bit would be a plus as well.
 

Attachments

#239 ·
Shoe Rack Cabinet Framework continues and door work starts

Ok I continued on and completed the frame work then went hinge hunting and commenced the top tilting door and bottom swinging doors.
After spending half a day running around trying to find Face frame inset door hinges that I wanted I gave up as a time waster, maybe they do not exist who knows.

Anyway finished the front frame work.

The top section will be the tilt out section and below the mid rail two hinged doors will be fitted

Wood Rectangle Outdoor furniture Pet supply Hardwood


A digression and "tool Tip" you cannot use coarse screws in hardwood when the dimensions are critical.
With the reduction of the width of the face frame I did another test with the coarse screws, and what do you know produced a fail, what a surprise!!

Wood Wood stain Hardwood Plank Rectangle


So yet another shopping trip, this time I bought the correct screws returned home and tried again, and what do you know they worked!!

Wood Font Tool Gas Wood stain


With all the running around not a lot was achieved yesterday so I continued on today

The doors
The front tilting drawer and the two lower doors kept me amused all of today

I made all the frames and started on the Raised panels had two which split or a knot fell out so I had to visit the timber stack and make even more stock with the Red Ironbark, this was not factored into the material required so its up again.

Wood Plant Gas Hardwood Plank


The Rejects.

Wood Wood stain Hardwood Lumber Automotive exterior


Anyway working away I managed to get two door finished when yet another panel blew out.

So I am going to glue it up overnight and take to it with the sander to see if I can repair and recover it otherwise it yet another panel to be made tomorrow. (See note below)

The doors dry assembled and sitting in their respective positions.

Plant Wood Wood stain Rectangle Natural material


One of the Raised Panel blow outs on the R/H side door.

Table Rectangle Wood Chair Flooring


After doing a few checks on Red Ironbark there is a general opinion normal glues will not work well on it so maybe its yet another Raised panel to be made.
There is also a general recommendation not to use Red ironbark for furniture due to its hardness but a there is a comment it will polish up well, they got that right.

Furniture Wood Rectangle Wood stain Flooring


That was enough for today so i packed up.

Lessons learned:

I am begining to understand why some woodworkers have more than one router, the amount of time swapping bits setting them up and profiling whatever seemed to be a very time consuming and fiddly activity.

Three routers set up would be the go, two for frame profiling bits, and the third for Raised Panel work.

Add having a back cutting combination Panel cutter bit would be a plus as well.
... "tool Tip" you cannot use coarse screws in hardwood when the dimensions are critical….

- robscastle
rc, May I impart my own "tool Tip"... for pocket holes, you need to screw down and not screw up.

PS. Put the "re-glue" on the bottom inside corner… should have enough disguise to not be obvious.

PPS. You're lucky to have a Kreg supplier within driving distance. If not in a rush, Screw-it is an economical alternative… we (well me) just can't seem to steer clear of controversial topics…
 

Attachments

#249 ·
Shoe Rack Cabinet door work complete - minus the hinges

Well I repaired all the panels changed a couple of frame pieces with router goofs in them and glued everything together.

Spent all day perfecting repairs and reworking little annoying bits of chip out and the likes.

Plant Wood Flooring Floor Wood stain


I have taken a few pictures of the actual framework in a hope that I can find a solution to my hinge dielema.

The problem only effects the two lower swinging doors.

Wood Flooring Wood stain Floor Hardwood


The dimensions of the Face frame are.
1 At the Front about 35mm
2. At the back 25mm
3. The door width and hence the face frame is 20 mm.

Brown Wood Wood stain Plank Flooring


another view

Furniture Shelf Wood Drawer Wood stain


The hinges:

The hinge problem was my mistake. when I dreamed up the design I found some hinge pictures in the net and built the frame to suit, silly move.

Although I found Blum hinges they are not available in Australia, very odd but I need to modify the build by adding blocks at the sides behind the face frame to simulate a frameless cabinet.

Hello Robert

Unfortunately we are unable to supply this item.

As Blum do not stock in the Australian market

Kind Regards,

National Category Specialist Team

The top is next.

So another post made the supreme sacrifice.

Plant Wood Floor Hardwood Gas


Wood Gas Grass Flooring Composite material
 

Attachments

#250 ·
Shoe Rack Cabinet door work complete - minus the hinges

Well I repaired all the panels changed a couple of frame pieces with router goofs in them and glued everything together.

Spent all day perfecting repairs and reworking little annoying bits of chip out and the likes.

Plant Wood Flooring Floor Wood stain


I have taken a few pictures of the actual framework in a hope that I can find a solution to my hinge dielema.

The problem only effects the two lower swinging doors.

Wood Flooring Wood stain Floor Hardwood


The dimensions of the Face frame are.
1 At the Front about 35mm
2. At the back 25mm
3. The door width and hence the face frame is 20 mm.

Brown Wood Wood stain Plank Flooring


another view

Furniture Shelf Wood Drawer Wood stain


The hinges:

The hinge problem was my mistake. when I dreamed up the design I found some hinge pictures in the net and built the frame to suit, silly move.

Although I found Blum hinges they are not available in Australia, very odd but I need to modify the build by adding blocks at the sides behind the face frame to simulate a frameless cabinet.

Hello Robert

Unfortunately we are unable to supply this item.

As Blum do not stock in the Australian market

Kind Regards,

National Category Specialist Team

The top is next.

So another post made the supreme sacrifice.

Plant Wood Floor Hardwood Gas


Wood Gas Grass Flooring Composite material
Hello Robert,look in IKEA for small hinges
They have small 20 mm hinges like Blum or on ebay from China
Wish you luck
 

Attachments

#260 ·
Shoe Rack Cabinet top

Well some "funny' things have happened since the last blog.
I think I left off after wrestling yet another Red Ironbark post onto my table saw and cutting it up for material for the Shoe Cabinet top.

Well today I set to work thicknessing the planks and for some reason they self destructed after working them, most pecular I must say, so from five planks only two were usable.

Have a look at this:

The planks:

I had never experienced this so took some pictures for reference
Here are the five planks 1 to 5 and the outerside pieces 1 and 5 oriented so the outer edges can be seen

Table Furniture Wood Rectangle Chair


Now here we have the same configuration with 1 and 5 reversed to show the internal splitting which occured,

Brown Table Wood Shelf Flooring


Finding it all a bit unbelieavable I went and checked the two ends I had cut off before the resawing.

Wood Floor Flooring Composite material Stairs


There is some slight radial splitting but nothing that would indicate the post was unsuitable for use.

This was a bit of a surprise and a set back as I wanted to make the Cabinet top from it and polish it up as a feature.

It was not to be so, I was not really wanting to tackle yet another post so I walked away for a while and went and checked out LBD blog about Arlo. found some really interesting info so i hijacked his blog and posted the background to Alices Restaurant.

Anyway back to the problematic Shoe Cabinet I checked my stash of timber and "discovered" I still had some Camphor laurel we milled back in 2011.

It all looked to be good and as shoes sometimes pong a bit I thought it would be a good choice.

Wood Office ruler Wood stain Natural material Plank


The timber looked to be in good condition so I hauled it out dusted it off and set about attempting to match up all the nice features, and set to work Jointing everything and then reverse glue jointed them all applied glue.

Table Wood Floor Flooring Wood stain


Clamped them up and left them overnight to set.

Wood Hardwood Wood stain Plywood Flooring


I cleaned up the glue residue and sanded them.

Wood Table Motor vehicle Plant Gas


After that I cut them to size.

Wood Rectangle Wood stain Floor Flooring


It certainly was not Red Ironbark by any means and as I was pondering how to finish the edges I decided to saw up a couple of the split Red Ironbark planks and use them for edge banding, however I wanted to use them at their existing thickness so with a bit of additional work I managed to profile the material to suit.

Note: If you have a need to do this its a bit tricky to maintain accuracy and pre sawing is required to support using undersized bits but it can be done.

I didnt take any pictures as I was getting tested compentency wise doing this.

Here is the finished result.

I polished the edging before fitting it.

Table Furniture Wood Natural material Wood stain
 

Attachments

#261 ·
Shoe Rack Cabinet top

Well some "funny' things have happened since the last blog.
I think I left off after wrestling yet another Red Ironbark post onto my table saw and cutting it up for material for the Shoe Cabinet top.

Well today I set to work thicknessing the planks and for some reason they self destructed after working them, most pecular I must say, so from five planks only two were usable.

Have a look at this:

The planks:

I had never experienced this so took some pictures for reference
Here are the five planks 1 to 5 and the outerside pieces 1 and 5 oriented so the outer edges can be seen

Table Furniture Wood Rectangle Chair


Now here we have the same configuration with 1 and 5 reversed to show the internal splitting which occured,

Brown Table Wood Shelf Flooring


Finding it all a bit unbelieavable I went and checked the two ends I had cut off before the resawing.

Wood Floor Flooring Composite material Stairs


There is some slight radial splitting but nothing that would indicate the post was unsuitable for use.

This was a bit of a surprise and a set back as I wanted to make the Cabinet top from it and polish it up as a feature.

It was not to be so, I was not really wanting to tackle yet another post so I walked away for a while and went and checked out LBD blog about Arlo. found some really interesting info so i hijacked his blog and posted the background to Alices Restaurant.

Anyway back to the problematic Shoe Cabinet I checked my stash of timber and "discovered" I still had some Camphor laurel we milled back in 2011.

It all looked to be good and as shoes sometimes pong a bit I thought it would be a good choice.

Wood Office ruler Wood stain Natural material Plank


The timber looked to be in good condition so I hauled it out dusted it off and set about attempting to match up all the nice features, and set to work Jointing everything and then reverse glue jointed them all applied glue.

Table Wood Floor Flooring Wood stain


Clamped them up and left them overnight to set.

Wood Hardwood Wood stain Plywood Flooring


I cleaned up the glue residue and sanded them.

Wood Table Motor vehicle Plant Gas


After that I cut them to size.

Wood Rectangle Wood stain Floor Flooring


It certainly was not Red Ironbark by any means and as I was pondering how to finish the edges I decided to saw up a couple of the split Red Ironbark planks and use them for edge banding, however I wanted to use them at their existing thickness so with a bit of additional work I managed to profile the material to suit.

Note: If you have a need to do this its a bit tricky to maintain accuracy and pre sawing is required to support using undersized bits but it can be done.

I didnt take any pictures as I was getting tested compentency wise doing this.

Here is the finished result.

I polished the edging before fitting it.

Table Furniture Wood Natural material Wood stain
Rob, this looks better with each post. I am ready for the next round. Odd splitting of the wood, but wood will do its own thing from time to time. Could be that the original tree was struck by lightening.
 

Attachments

#264 ·
Shoe Rack Cabinet Door hinges fitted and The tilt drawer started

OK after getting some good advice I decided to stop waiting for a miracle and get on with the hinge work.

The hinges are Euro style inset for frameless cabinets type with blocks to simulate a frameless cabinet.
Not something I wanted to do but needed to get on with it so this is what I did.

The hinge arrangement.

Wood Flooring Wood stain Hardwood Varnish


There are small blocks attached to the cabinet sides building the profile out flush with the face frame.
Not the best looking solution but I needed to get some progress going.

Here are the doors in the closed position

Wood Rectangle Floor Wood stain Flooring


Some shots of the doors open.

The left hand side door.

Wood Rectangle Wood stain Hardwood Flooring


The right hand side door.

Drawer Shelf Wood Cabinetry Shelving


The production of the blocks was not without its issues, trying to make them as less obtrusive as possible led to quit a few in the bin.
Then add the chinese screws supplied with the hinges generated another problem, the tips broke off in the wood, I didnt realise what was happening at first until I took a closer look at the screws

Have a look at thiis.

Road surface Natural material Asphalt Beach Shell


Another view

Automotive tire Road surface Asphalt Grey Gas


The result.

Wood Wood stain Hardwood Plywood Gas


I thought ar first they were copper screws so I clamped one in the pliers and ground the head and then checked with a magnet sure enough the were ferrous.
Obviously not hardened like "normal" screws so I sent them all on a council arranged holiday somewhere!

Forgot, something I fitted the floor first!!

Overcoming that I moved onto the top tilt out drawer.

I used some plywood for the frame and set about glueing it all together.

Here it is in the clamps.

General description:
The "tits" just visible above the sash clamps on the R/H side are the stops, which may require tuning upon fitup.

Looking at the picture The tilt frame is in the closed position and oriented correctly, the left hand side and the highest part of the "bat wing" is the front and the panel section Front will go on here.

Wood Floor Flooring Hardwood Plywood


Fiddling about while the glue dries.

I tried to determine where the partitions should go.

Ignore the clamps they are just there to try to position the dividers.

Wood Road surface Flooring Gas Composite material


another view.

Wood Garden tool Gas Tool Plywood


Well thats it for today pack up time.

Oh BTW speaking of miracles I PMed Patron so if your a buddy you will be interested to learn he is OK ,still getting older, has a sick brother and the winter has slowed his shop work, but he was happy for my welfare check up.
 

Attachments

#265 ·
Shoe Rack Cabinet Door hinges fitted and The tilt drawer started

OK after getting some good advice I decided to stop waiting for a miracle and get on with the hinge work.

The hinges are Euro style inset for frameless cabinets type with blocks to simulate a frameless cabinet.
Not something I wanted to do but needed to get on with it so this is what I did.

The hinge arrangement.

Wood Flooring Wood stain Hardwood Varnish


There are small blocks attached to the cabinet sides building the profile out flush with the face frame.
Not the best looking solution but I needed to get some progress going.

Here are the doors in the closed position

Wood Rectangle Floor Wood stain Flooring


Some shots of the doors open.

The left hand side door.

Wood Rectangle Wood stain Hardwood Flooring


The right hand side door.

Drawer Shelf Wood Cabinetry Shelving


The production of the blocks was not without its issues, trying to make them as less obtrusive as possible led to quit a few in the bin.
Then add the chinese screws supplied with the hinges generated another problem, the tips broke off in the wood, I didnt realise what was happening at first until I took a closer look at the screws

Have a look at thiis.

Road surface Natural material Asphalt Beach Shell


Another view

Automotive tire Road surface Asphalt Grey Gas


The result.

Wood Wood stain Hardwood Plywood Gas


I thought ar first they were copper screws so I clamped one in the pliers and ground the head and then checked with a magnet sure enough the were ferrous.
Obviously not hardened like "normal" screws so I sent them all on a council arranged holiday somewhere!

Forgot, something I fitted the floor first!!

Overcoming that I moved onto the top tilt out drawer.

I used some plywood for the frame and set about glueing it all together.

Here it is in the clamps.

General description:
The "tits" just visible above the sash clamps on the R/H side are the stops, which may require tuning upon fitup.

Looking at the picture The tilt frame is in the closed position and oriented correctly, the left hand side and the highest part of the "bat wing" is the front and the panel section Front will go on here.

Wood Floor Flooring Hardwood Plywood


Fiddling about while the glue dries.

I tried to determine where the partitions should go.

Ignore the clamps they are just there to try to position the dividers.

Wood Road surface Flooring Gas Composite material


another view.

Wood Garden tool Gas Tool Plywood


Well thats it for today pack up time.

Oh BTW speaking of miracles I PMed Patron so if your a buddy you will be interested to learn he is OK ,still getting older, has a sick brother and the winter has slowed his shop work, but he was happy for my welfare check up.
looking good there robert
we do what we have to
to get things right
sometimes it works
sometimes it leads to further improvements
all part of the craft

thanks for the check-up

rain here today
so procrastination is in the works
it's either that or more cleaning (groan)
 

Attachments

#270 ·
Shoe rack cabinet Tilting Door done Back is on and In Location

I completed the Tilting Drawer today, rounded over the edges sanded and sealed it

Wood Automotive design Chair Tints and shades Natural material


Fitted a drop handle, along with the other two doors.

Brown Rectangle Wood Wood stain Hardwood


Took everything into the house and assembled it there.

Once that was all OK on went the back.

Wood Floor Fixture Flooring Hardwood


Then the top

Cabinetry Wood Drawer Fixture Wood stain


To get the the top to fit correctly it required a bit of surgery I had to cut a couple of pieces out to allow for the existing house profiles.

1 The brickwork.

Brown Wood Rectangle Floor Flooring


and,

2. And at the back to match the existing panel profile.

Brown Wood Floor Wood stain Flooring


Nothing to serious I can always make up another top if we win the lottery and move!

So thats it all done.

Rectangle Wood Chair Water Flooring
 

Attachments

#271 ·
Shoe rack cabinet Tilting Door done Back is on and In Location

I completed the Tilting Drawer today, rounded over the edges sanded and sealed it

Wood Automotive design Chair Tints and shades Natural material


Fitted a drop handle, along with the other two doors.

Brown Rectangle Wood Wood stain Hardwood


Took everything into the house and assembled it there.

Once that was all OK on went the back.

Wood Floor Fixture Flooring Hardwood


Then the top

Cabinetry Wood Drawer Fixture Wood stain


To get the the top to fit correctly it required a bit of surgery I had to cut a couple of pieces out to allow for the existing house profiles.

1 The brickwork.

Brown Wood Rectangle Floor Flooring


and,

2. And at the back to match the existing panel profile.

Brown Wood Floor Wood stain Flooring


Nothing to serious I can always make up another top if we win the lottery and move!

So thats it all done.

Rectangle Wood Chair Water Flooring
well done robert

from a bunch of old 4Ă—4's to a finished piece of furniture
it came out real nice

now it's the wife's turn

she needs you to go shopping
and carry all her new shoes home
 

Attachments

#276 ·
Mushroom seat Mk II Pt 1

Back in 2011 and from the looks of it, it was before I joined LJs that I made a mushroom seat from some pine recycled pallet wood.

At the time I used polyeurathene glue and Kreg pocket holes along with biscuit joints.

I am not sure how I made the "splay" joints at the time, ... I think I just sanded them until i got a reasonable fit!.

Leaf Plant Grass Gas Groundcover


The inside detail

Tints and shades Wood Circle Triangle Concrete


It spent most of its life in the garden as my go seat when I was doing "stuff"
Last week I was replacing the disc pads on my Ute and had it under the body holding tools for me.

I left to do some cleaning and upon my return found the hydraulic trolley jack had leaked down putting all the body weight on the little seat.

The mushroom seat is now no more, ... 7 years of loyal use has ended!

Plant Chair Wood Grass Tree


Natural material Wood Grass Groundcover Grass family


As it was a vey usefull piece of kit so I decided to make another one today.

I had a heap of Red Ironbark available (nothing will crush that) so I decide to use it.

Wood Plant Grass Natural material Groundcover


I replicated the original design with a few mods and this time I used used Matthias Wandel's Polygon chart to calculate the required "splay"

Basic design
300mm high
10 deg angle
8 segments

So looking at MW's chart that gave me 4.11 deg and 22.14 deg to work with.
Now trying to achieve those sub divisions was impossible for me so I set 4 deg angle and 22(and a bit) of blade tilt.

I worked out how to set everything up and cut the first angles.

Wood Wood stain Hardwood Lumber Roof


This is the simple jig setup.

Wood Floor Automotive exterior Wood stain Bumper


Once I had everything cut I dry fitted it up on the bench, to see how much of a gap mismatch there was.

Wood Table Wood stain Hardwood Flooring


It looked reasonably OK so I set it all up on the table saw for more accuracy.

Wood Table Wood stain Hardwood Plank


Now the dilemma starts, ... how on earth could I glue up something like this accurately? ... after muddling around trying all sorts of bizare methods I decide to just frame it up in two halves then progress from there.
(Again Matthias has it covered, check the link for his method)

Here is 1 half side.

Wood Composite material Gas Creative arts Automotive design


and the other end.

Ruler Office ruler Wood Composite material Gas


Then it was the the second half 's turn

Wheel Vehicle Wood Automotive exterior Triangle


and another view.

Wood Gas Hardwood Composite material Wood stain


Thats all I managed to achieve today, so tomorrow, I will have to figure out the internal bracing to ensure its rigid and continue on.
 

Attachments

#277 ·
Mushroom seat Mk II Pt 1

Back in 2011 and from the looks of it, it was before I joined LJs that I made a mushroom seat from some pine recycled pallet wood.

At the time I used polyeurathene glue and Kreg pocket holes along with biscuit joints.

I am not sure how I made the "splay" joints at the time, ... I think I just sanded them until i got a reasonable fit!.

Leaf Plant Grass Gas Groundcover


The inside detail

Tints and shades Wood Circle Triangle Concrete


It spent most of its life in the garden as my go seat when I was doing "stuff"
Last week I was replacing the disc pads on my Ute and had it under the body holding tools for me.

I left to do some cleaning and upon my return found the hydraulic trolley jack had leaked down putting all the body weight on the little seat.

The mushroom seat is now no more, ... 7 years of loyal use has ended!

Plant Chair Wood Grass Tree


Natural material Wood Grass Groundcover Grass family


As it was a vey usefull piece of kit so I decided to make another one today.

I had a heap of Red Ironbark available (nothing will crush that) so I decide to use it.

Wood Plant Grass Natural material Groundcover


I replicated the original design with a few mods and this time I used used Matthias Wandel's Polygon chart to calculate the required "splay"

Basic design
300mm high
10 deg angle
8 segments

So looking at MW's chart that gave me 4.11 deg and 22.14 deg to work with.
Now trying to achieve those sub divisions was impossible for me so I set 4 deg angle and 22(and a bit) of blade tilt.

I worked out how to set everything up and cut the first angles.

Wood Wood stain Hardwood Lumber Roof


This is the simple jig setup.

Wood Floor Automotive exterior Wood stain Bumper


Once I had everything cut I dry fitted it up on the bench, to see how much of a gap mismatch there was.

Wood Table Wood stain Hardwood Flooring


It looked reasonably OK so I set it all up on the table saw for more accuracy.

Wood Table Wood stain Hardwood Plank


Now the dilemma starts, ... how on earth could I glue up something like this accurately? ... after muddling around trying all sorts of bizare methods I decide to just frame it up in two halves then progress from there.
(Again Matthias has it covered, check the link for his method)

Here is 1 half side.

Wood Composite material Gas Creative arts Automotive design


and the other end.

Ruler Office ruler Wood Composite material Gas


Then it was the the second half 's turn

Wheel Vehicle Wood Automotive exterior Triangle


and another view.

Wood Gas Hardwood Composite material Wood stain


Thats all I managed to achieve today, so tomorrow, I will have to figure out the internal bracing to ensure its rigid and continue on.
sweet success rob

great up-grade and replacement

'course now maybe a bottom 'shelf'
drawn down thru the hopper
set up a bit from the bottom
and maybe a couple access cut-outs
on the sides to store tools or stuff

here in the states at our age
maybe a recliner modification
with a shade umbrella
and pop-up drink holder
wi-fi port and blue tooth range extender

or just get a golf cart

iron on
 

Attachments

#281 ·
Mushroom Seat Mk II Pt 2 unassembled finished

Today I managed to get quite a bit more done:
1. Made the seat top
2. Glued the two halves of the base together
3. Sanded everything
4. Polished everything

First up I joined two more pieces together to make the seat.

Post Note: Parallel clamps courtesy of Degoose's fire sale!

Green Wood Wood stain Natural material Hardwood


While they were drying I wrestled the base into a position to glue the two halves together.
First up I tried to screw them but that idea was a fail as all it did was misalign the sections.
So it was out with my Big Al's band clamps and a couple of pieces of Rep band to passify it whilst glueing

Automotive tire Wood Bumper Automotive exterior Motor vehicle


That was the end of any work for a few hours, and i managed to get it all done by 1100, then a bit of quiet time for remembrance day, ... then in the afternoon added the final screws and began sanding.

Started at 60 Grit and worked my way up to 800 Grit.

Wood Interior design Floor Flooring Outdoor furniture


Wood Rectangle Wood stain Hardwood Gas


here is the progress at 120 Grit.

Lectern Wood Table Plant Pedestal


Then quite a few hours later at 800 Grit.

Wood Plant Table Hardwood Wood stain


Next was the final polishing of the individual parts.

Plant Table Wood Tree Rectangle


All that is left to do is to now is to attach the top of the seat and finish everything.

But now Its time to pack up for the day and go inside.

I will do that tomorrow and then if all goes well post it as a finished project.
 

Attachments

#282 ·
Mushroom Seat Mk II Pt 2 unassembled finished

Today I managed to get quite a bit more done:
1. Made the seat top
2. Glued the two halves of the base together
3. Sanded everything
4. Polished everything

First up I joined two more pieces together to make the seat.

Post Note: Parallel clamps courtesy of Degoose's fire sale!

Green Wood Wood stain Natural material Hardwood


While they were drying I wrestled the base into a position to glue the two halves together.
First up I tried to screw them but that idea was a fail as all it did was misalign the sections.
So it was out with my Big Al's band clamps and a couple of pieces of Rep band to passify it whilst glueing

Automotive tire Wood Bumper Automotive exterior Motor vehicle


That was the end of any work for a few hours, and i managed to get it all done by 1100, then a bit of quiet time for remembrance day, ... then in the afternoon added the final screws and began sanding.

Started at 60 Grit and worked my way up to 800 Grit.

Wood Interior design Floor Flooring Outdoor furniture


Wood Rectangle Wood stain Hardwood Gas


here is the progress at 120 Grit.

Lectern Wood Table Plant Pedestal


Then quite a few hours later at 800 Grit.

Wood Plant Table Hardwood Wood stain


Next was the final polishing of the individual parts.

Plant Table Wood Tree Rectangle


All that is left to do is to now is to attach the top of the seat and finish everything.

But now Its time to pack up for the day and go inside.

I will do that tomorrow and then if all goes well post it as a finished project.
Rob, that a 1000% improvement on the painted (original) one. That timber look absolutely shmicko.

I'm guessing it'll be a neutral finish to exploit the timber grain.

However, 800 grit for something outside (if it's a replacement?
)... do you have surplus sandpaper(
?)... or are you mushrooming us (??)?... kept in the dark and fed bull-********************.
 

Attachments

#289 ·
My First Slab part 1

I brought a huge slab of wood back from my friend Grant's place in Kyogle

I have no real idea what the species is so would be keen to hear your opinion on it.

Note :-
From the suppliers belief its flooded gum or Sydney rose gum is another name

Here it is upon arrival.

Table Wood Floor Flooring Wood stain


Tire Plant Vehicle Wood Motor vehicle


Today I spent a bit of time on it and sanded to top face to 40Grit

Wood Grass Table Outdoor furniture Trunk


Plant Wood Table Chair Grass


Not being real sure just what I was going to build with it at this stage I decided to Turbo plane the edges to remove any bark and damaged parts.

Wood Grass Trunk Gas Wood stain


Plant Wood Outdoor furniture Grass Chair


So that's my effort for today, the actual edge design is a TBA and what I intend to do with it as a finished product will be the subject of a continuing blog later.
Although I said in the Title this was my first Slab I need to validate that by saying "my first wood slab"

Now my thoughts on the species, Its obviously an Australian Gum of some sort and looking at the result may be a Red gum.

The reason i say this is because the remaining bark that I removed was a cream colour, which is evident in the third picture on the small arm.

Eucalyptus camaldulensis, commonly known as the river red gum, is a tree that is endemic to Australia. It has smooth white or cream-coloured bark.
 

Attachments

#290 ·
My First Slab part 1

I brought a huge slab of wood back from my friend Grant's place in Kyogle

I have no real idea what the species is so would be keen to hear your opinion on it.

Note :-
From the suppliers belief its flooded gum or Sydney rose gum is another name

Here it is upon arrival.

Table Wood Floor Flooring Wood stain


Tire Plant Vehicle Wood Motor vehicle


Today I spent a bit of time on it and sanded to top face to 40Grit

Wood Grass Table Outdoor furniture Trunk


Plant Wood Table Chair Grass


Not being real sure just what I was going to build with it at this stage I decided to Turbo plane the edges to remove any bark and damaged parts.

Wood Grass Trunk Gas Wood stain


Plant Wood Outdoor furniture Grass Chair


So that's my effort for today, the actual edge design is a TBA and what I intend to do with it as a finished product will be the subject of a continuing blog later.
Although I said in the Title this was my first Slab I need to validate that by saying "my first wood slab"

Now my thoughts on the species, Its obviously an Australian Gum of some sort and looking at the result may be a Red gum.

The reason i say this is because the remaining bark that I removed was a cream colour, which is evident in the third picture on the small arm.

Eucalyptus camaldulensis, commonly known as the river red gum, is a tree that is endemic to Australia. It has smooth white or cream-coloured bark.
Prime candidate for a Nakashima imitation, IMO.
 

Attachments

#308 ·
My First Slab Question time for me

I guess its pitched to those who have made slab tables.
Mark A. DeCou, Manitario etc

I can assure you I am an expert at finishing slabs most of the time.

However wooden ones are a learning curve for me, so its a few da
questions if you please.

1. Do you really need to fit dutch mans or butterfly's in the cracks?
2. Which is the preferred side to be up, in relation the the live edge the wide side or the narrower side?
3. When using epoxy to fill voids what brands did you use?
4. Also in relation to the epoxy who adds tints and other bits, like fishes duck beagles or cows etc.

I have a few loose screws so I was thinking of adding them along with the key to my motorbike but I was concerned about any corrosive actions that may take place later as a a result of reacting with the epoxy.

The Plan:-

Tomorrow I am getting the slab out and continuing on the second side trimming the ends, drinking beer and generally acting like I know what I am doing.

Other associated trivia:-

5. I wonder how that pregnant cow at Anthony's place is going I haven't heard any birth results yet
6. I hope that pump is filling the drinking troughs OK too.

7. Wait for it ...Hey forgot to tell you nearly screwed up big time, when I was there I almost put diesel in his petrol lawn Mower! Good thing he shouted at me from a far!


Research list:-


https://www.woodmagazine.com/how-to-work-with-natural-edge-slabs
 
#327 ·
My First Slab Day 2

well after getting lots of good advice I hauled the slab out and began to surface it to determine which side I would use.

Side 2 In the Raw. (SIDE BLOODY 2 Mate)

Wood Grass Outdoor furniture Trunk Table


Then it was time to get the turboplaner going

Bottle Camera lens Wood Gas Cameras & optics


the finish after a complete workover

Plant Wood Grass Gas Groundcover


Wood Plant Trunk Natural material Grass


next I ferret out my slab guide but it didn't take much grey matter t work out it was not suitable, so I had to make another one.

Wood Table Tripod Wood stain Hardwood


looks a bit like Danny DeVito and Arnold Schwarzenegger standing side by side !

Suit trousers Hat Tie Sleeve Helmet


Wood Composite material Hardwood Wood stain Gas


I did some basic high spot work to get a reasonable level but that's it for today .
Tomorrow I hope to have both sided finished for display.

I did determine the top will be side 1 at this stage.

Stand by for more fun! (well sorta)
 

Attachments

#328 ·
My First Slab Day 2

well after getting lots of good advice I hauled the slab out and began to surface it to determine which side I would use.

Side 2 In the Raw. (SIDE BLOODY 2 Mate)

Wood Grass Outdoor furniture Trunk Table


Then it was time to get the turboplaner going

Bottle Camera lens Wood Gas Cameras & optics


the finish after a complete workover

Plant Wood Grass Gas Groundcover


Wood Plant Trunk Natural material Grass


next I ferret out my slab guide but it didn't take much grey matter t work out it was not suitable, so I had to make another one.

Wood Table Tripod Wood stain Hardwood


looks a bit like Danny DeVito and Arnold Schwarzenegger standing side by side !

Suit trousers Hat Tie Sleeve Helmet


Wood Composite material Hardwood Wood stain Gas


I did some basic high spot work to get a reasonable level but that's it for today .
Tomorrow I hope to have both sided finished for display.

I did determine the top will be side 1 at this stage.

Stand by for more fun! (well sorta)
How did the turboplane go Rob.
I have one but it scares the daylights out of me.

Also how did your set up the router skies?
 

Attachments

#337 ·
Day 3 lots of exciting stuff to share

Well its Day 3 and I got stuck into the slab big time.
A series of preparatory activities were required before I was able to do any actual work.
I thought they may be of interest so I have included them.

No1 Was the leveling of the work surface.
No2 Mounting the router in the sled
No 3 fitting guide rails and aligning the slab on the table.

How I did it (apologies to Anieia McGuinnesss)



No 1 Leveling of the work surface.
As my drive way is not level and slopes out the gate and to one side I needed a level accurate surface to work on this includes later when I do the epoxy pour.
I used four blocks of wood under the table legs to make sure it was level.

Wood Road surface Asphalt Flooring Gas


The actual establishing a level took some time and I achieved it by boring forstner bit holes in the blocks and checking the levels, then boring each block out to achieve my desired result, all a bit fiddly but I eventually got there.

Table Wood Rectangle Road surface Asphalt


next it was

No2 Mounting the router in the sled.
I mounted the router in the middle of the sled but in reality I should have off set it for a more practical application. Mainly reaching out to the edges would have been better even if it ment reversing the sled.
Inside the sled you may see my router base template, I used it to mark out the mounting holes.
I marked out five points and predrilled and countersunk the four to fit the screws.
The center opening I used a hole saw to allow the router bit to fit through.
I have a planner bit which works well so I resurrected it from my router bits box and fitted it to the unmounted router then fitted the unit to the sled, good to go.

Musical instrument Wood Keyboard Automotive tire Wood stain


Next was:-

No 3 fitting the guide rails and aligning the slab on the table.

After a few experiments on best fit and use of the slab I chose the flattest surfave and set it on the table.
I use a few wedges to align and stabilise the slab for best fit.
I then fitted the sled guide rails around the slab.
I used some dressed pine for this and cut sections to suit the profiles.
they are fixed with screws from underneath.

Wood Natural material Table Plank Hardwood


Now the actual work

I set the planner depth using the shallowest spot and then moved it about to see how much material would be removed on high spots. Then adjusted it for about 4mm depth of removal of material worst case.
The first run left a few untouched areas on the slab so I readjusted and replaned.
I did about 3 runs until I had a neat almost featherless result.
I estimate about 10 to 12 mm of material was removed worst case.

Furniture Table Wood Natural material Plant


Then I rolled out the dewalt ROS and began sanding.
It didn't take too long to realise that the smaller Dewalt it couldn't cut the vegemite.

So out with the Metabo, This is similar to the one I donated to Mike acg and somebody took it upon themselves to pinch, (hint hint)

Automotive tire Flooring Floor Bumper Wood


I started with 40 G worked myself up to 80G the a final touch up with 150g things went very smoothly here for now, may possibly require more later.

The result.

Wood Outdoor furniture Plant Font Plywood


Table Wood Hardwood Grass Wood stain


OK looking good so far however I had to stop mid way sadly my woodworking buddy Wally died while I was away in Sydney and his funeral was today.

Wlodzimierz Sznajder

I need to digress here as he is worth a special mention
I met "Wally" (not sure why he was called Wally however he lived nearby in the home he bought for his wife and family many years ago. Had a working wood shop under his house of which to me was a treasure trove of tools and timber. I never met his wife as she had passed on before I came on the scene. Wally used to walk past on his way going to the shops and stop for a chat on world events for hours a most fascinating man.

Bottle Tartan Gesture Wine Plaid


Wally lived to age 99 and his son Mark advised at the Eulogy he got up, did his morning routine, cleaned his teeth and departed.

Within my blogs there are many references to him, the tools that I either bought or he gave me, and lots of the timber I have came from him also and he was the subject of many of my blogs. however no more after today..

Back to the slab.

some closing shots.
Its the duck side if you wondered

Table Wood Natural material Plant Trunk


Wood Table Wood stain Hardwood Plank


I tried to show the grain effect by wetting it down but its so hot here at the moment it dried faster than it took me to get the phone out of my pocket.

Wood Natural material Table Wood stain Hardwood


looking good for taping filling and then epoxying. At a time later

stand by!!
 

Attachments

#338 ·
Day 3 lots of exciting stuff to share

Well its Day 3 and I got stuck into the slab big time.
A series of preparatory activities were required before I was able to do any actual work.
I thought they may be of interest so I have included them.

No1 Was the leveling of the work surface.
No2 Mounting the router in the sled
No 3 fitting guide rails and aligning the slab on the table.

How I did it (apologies to Anieia McGuinnesss)



No 1 Leveling of the work surface.
As my drive way is not level and slopes out the gate and to one side I needed a level accurate surface to work on this includes later when I do the epoxy pour.
I used four blocks of wood under the table legs to make sure it was level.

Wood Road surface Asphalt Flooring Gas


The actual establishing a level took some time and I achieved it by boring forstner bit holes in the blocks and checking the levels, then boring each block out to achieve my desired result, all a bit fiddly but I eventually got there.

Table Wood Rectangle Road surface Asphalt


next it was

No2 Mounting the router in the sled.
I mounted the router in the middle of the sled but in reality I should have off set it for a more practical application. Mainly reaching out to the edges would have been better even if it ment reversing the sled.
Inside the sled you may see my router base template, I used it to mark out the mounting holes.
I marked out five points and predrilled and countersunk the four to fit the screws.
The center opening I used a hole saw to allow the router bit to fit through.
I have a planner bit which works well so I resurrected it from my router bits box and fitted it to the unmounted router then fitted the unit to the sled, good to go.

Musical instrument Wood Keyboard Automotive tire Wood stain


Next was:-

No 3 fitting the guide rails and aligning the slab on the table.

After a few experiments on best fit and use of the slab I chose the flattest surfave and set it on the table.
I use a few wedges to align and stabilise the slab for best fit.
I then fitted the sled guide rails around the slab.
I used some dressed pine for this and cut sections to suit the profiles.
they are fixed with screws from underneath.

Wood Natural material Table Plank Hardwood


Now the actual work

I set the planner depth using the shallowest spot and then moved it about to see how much material would be removed on high spots. Then adjusted it for about 4mm depth of removal of material worst case.
The first run left a few untouched areas on the slab so I readjusted and replaned.
I did about 3 runs until I had a neat almost featherless result.
I estimate about 10 to 12 mm of material was removed worst case.

Furniture Table Wood Natural material Plant


Then I rolled out the dewalt ROS and began sanding.
It didn't take too long to realise that the smaller Dewalt it couldn't cut the vegemite.

So out with the Metabo, This is similar to the one I donated to Mike acg and somebody took it upon themselves to pinch, (hint hint)

Automotive tire Flooring Floor Bumper Wood


I started with 40 G worked myself up to 80G the a final touch up with 150g things went very smoothly here for now, may possibly require more later.

The result.

Wood Outdoor furniture Plant Font Plywood


Table Wood Hardwood Grass Wood stain


OK looking good so far however I had to stop mid way sadly my woodworking buddy Wally died while I was away in Sydney and his funeral was today.

Wlodzimierz Sznajder

I need to digress here as he is worth a special mention
I met "Wally" (not sure why he was called Wally however he lived nearby in the home he bought for his wife and family many years ago. Had a working wood shop under his house of which to me was a treasure trove of tools and timber. I never met his wife as she had passed on before I came on the scene. Wally used to walk past on his way going to the shops and stop for a chat on world events for hours a most fascinating man.

Bottle Tartan Gesture Wine Plaid


Wally lived to age 99 and his son Mark advised at the Eulogy he got up, did his morning routine, cleaned his teeth and departed.

Within my blogs there are many references to him, the tools that I either bought or he gave me, and lots of the timber I have came from him also and he was the subject of many of my blogs. however no more after today..

Back to the slab.

some closing shots.
Its the duck side if you wondered

Table Wood Natural material Plant Trunk


Wood Table Wood stain Hardwood Plank


I tried to show the grain effect by wetting it down but its so hot here at the moment it dried faster than it took me to get the phone out of my pocket.

Wood Natural material Table Wood stain Hardwood


looking good for taping filling and then epoxying. At a time later

stand by!!
Looks good Rob.
Thank you for showing the table and skies setup.
Will you fill the cracks with epoxy or acrylic??
 

Attachments

#355 ·
Grants Slab day 6

Well I guess all the dedicated followers are patiently waiting to see what fantastic results I got with Glow in the dark Epoxy resin filler and all that sort of stuff.

Well these are the bare cold facts.

1.First up why did I call it furniture? well I did it because I really intended to make some legs for it and call it a table.however a few factors were recognised as reality.

2. I have no idea what I am going to do with it, and it may well likely it ends up back at my mate Grant"s place as a veranda table for him and the family.
3. Understanding this fact along with almost zip experience with epoxy fillers along with the capital outlay for the products I baulked at doing it.

So with that confession off my chest what did I actually do? Well nothing really exciting I assure you.

For the last 3 days I mixed up a concoction of fine saw dust and TBIII glue and stuffed it in the openings on the Top or A side.
For the B side or AKA LBD side I used some contaminated sawdust and also fille the various splits knot holes and the likes.

Side A or the Top:

This took about 3 days of filling, a partial fill and let it dry Day 2 sand and refill as per day 1 Day 3 as smear to remove any duck holes and then sand to a reasonable finish.

So this is what it all looked like

first fill

Brown Amber Wood Flooring Floor

second fill

Same as fill 1

third fill
Wood Table Wood stain Floor Hardwood


Brown Amber Wood Flooring Floor


stuffing in the filler

I used a rubber mallet and a sheet of plastic to embed the filler.
Process:- place the plastic sheet it over the fill site and wack down,
slide the plastic sheet off and repeat as required, dont lift the sheet up as it may drag the filler out.

apart from sanding which I tried to do it with 240 g but clogged almost immediately so I resorted to 80 g and took it easy. I also used a scraper on the areas near the fill too remove the excess pfrior to sanding.

Pausing at 1100 for the mandatory break, ... go to my home page if you need more detail.

Side B or the LBD side

As this was gunna be down under side I didn't use any fine sawdust but just some contaminated stuff, I mixed it up as previous and just rubbed the bulk of it in by hand but then switched to my veneer hammer. Again this produced a suitable result.

Wood Table Floor Flooring Wood stain


Its all drying now so its coffee time and parcel delivery receipt

Material property Font Rectangle Packing materials Packaging and labeling
 

Attachments

#356 ·
Grants Slab day 6

Well I guess all the dedicated followers are patiently waiting to see what fantastic results I got with Glow in the dark Epoxy resin filler and all that sort of stuff.

Well these are the bare cold facts.

1.First up why did I call it furniture? well I did it because I really intended to make some legs for it and call it a table.however a few factors were recognised as reality.

2. I have no idea what I am going to do with it, and it may well likely it ends up back at my mate Grant"s place as a veranda table for him and the family.
3. Understanding this fact along with almost zip experience with epoxy fillers along with the capital outlay for the products I baulked at doing it.

So with that confession off my chest what did I actually do? Well nothing really exciting I assure you.

For the last 3 days I mixed up a concoction of fine saw dust and TBIII glue and stuffed it in the openings on the Top or A side.
For the B side or AKA LBD side I used some contaminated sawdust and also fille the various splits knot holes and the likes.

Side A or the Top:

This took about 3 days of filling, a partial fill and let it dry Day 2 sand and refill as per day 1 Day 3 as smear to remove any duck holes and then sand to a reasonable finish.

So this is what it all looked like

first fill

Brown Amber Wood Flooring Floor

second fill

Same as fill 1

third fill
Wood Table Wood stain Floor Hardwood


Brown Amber Wood Flooring Floor


stuffing in the filler

I used a rubber mallet and a sheet of plastic to embed the filler.
Process:- place the plastic sheet it over the fill site and wack down,
slide the plastic sheet off and repeat as required, dont lift the sheet up as it may drag the filler out.

apart from sanding which I tried to do it with 240 g but clogged almost immediately so I resorted to 80 g and took it easy. I also used a scraper on the areas near the fill too remove the excess pfrior to sanding.

Pausing at 1100 for the mandatory break, ... go to my home page if you need more detail.

Side B or the LBD side

As this was gunna be down under side I didn't use any fine sawdust but just some contaminated stuff, I mixed it up as previous and just rubbed the bulk of it in by hand but then switched to my veneer hammer. Again this produced a suitable result.

Wood Table Floor Flooring Wood stain


Its all drying now so its coffee time and parcel delivery receipt

Material property Font Rectangle Packing materials Packaging and labeling
I have been keeping an eye out for your posts.Keep having fun and stay safe.
 

Attachments

#360 ·
Sewing station repair

It seem sewing stations are the flavour at the moment.
I had a lady ask me to repair her sewing station.

Wood Gas Rectangle Tints and shades Composite material


The construction of the station is very well done, however the choice of veneered particle board is not.

The station is worth about $600 to $900 from what I see on Horn furniture website.

https://www.horn.com.au/sewing/horn-furniture.aspx

So I emailed them to see if spare parts were available, as the whole floor had been damaged beyond repair.

While waiting to get a reply back I had a good look to determine if I could retrofit a floor.

Black Wood Grass Rectangle Road surface


Wood Wood stain Hardwood Gas Luggage and bags


It was possible sew I decided to fabricate a new one.

Wood Road surface Floor Composite material Wood stain


I cut and attached full supports instead of the original wedgies to permit fixing to.

Wood Bumper Gas Motor vehicle Automotive exterior


Finished the externals with Orange Oil wood cleaner and them applied some Howards wax.

It was all ready to be returned when I fell off the back of my Ute.

Wood Flooring Shelving Cabinetry Hardwood
 

Attachments

#361 ·
Sewing station repair

It seem sewing stations are the flavour at the moment.
I had a lady ask me to repair her sewing station.

Wood Gas Rectangle Tints and shades Composite material


The construction of the station is very well done, however the choice of veneered particle board is not.

The station is worth about $600 to $900 from what I see on Horn furniture website.

https://www.horn.com.au/sewing/horn-furniture.aspx

So I emailed them to see if spare parts were available, as the whole floor had been damaged beyond repair.

While waiting to get a reply back I had a good look to determine if I could retrofit a floor.

Black Wood Grass Rectangle Road surface


Wood Wood stain Hardwood Gas Luggage and bags


It was possible sew I decided to fabricate a new one.

Wood Road surface Floor Composite material Wood stain


I cut and attached full supports instead of the original wedgies to permit fixing to.

Wood Bumper Gas Motor vehicle Automotive exterior


Finished the externals with Orange Oil wood cleaner and them applied some Howards wax.

It was all ready to be returned when I fell off the back of my Ute.

Wood Flooring Shelving Cabinetry Hardwood
.... It was all ready to be returned when I fell off the back of my Ute.
- robscastle
Hang onto it for a few more days and you can sew your fern back together…. or stitch up the joker that tried to kill your plastic owl.

We're back into stage 4, however, when/if we emerge, my old animal nighty is getting a tad tattered
Interior design Wood Art Linens Picture frame

and I might need help with a sewing table to tackle the replacement.
Baby & toddler clothing Sleeve T-shirt Creative arts Pattern
 

Attachments

#372 ·
Bench Seat Day 1 In the begining.

No 2 Son sent a picture of his friends Bench seat his Dad had made him.

Wood Wood stain Hardwood Plank Rectangle


No2 Son asked if i could make one for him too.
So not being able to pass up a challenge I said yes.

So under the cover of my timber stash I went

Plant Outdoor furniture Outdoor table Wood Grass


I first thought this piece would do the trick nicely.

However sadly enough no, too much rubbish, mortices, foreign objects and natural defects to get a usable length.

Wood Grass Gas Sawhorse Machine


So I de buried treasure it

Wood Natural material Table Grass Wood stain


Ended up with a few pieces about 500mm long which were use-able

Furniture Plant Outdoor bench Outdoor furniture Wood


Eventually I decided to use it for legs.

Brown Wood Rectangle Road surface Brick


then dragged out a second piece

Outdoor bench Street furniture Plant Wood Outdoor furniture


Ripped it into three lengths about 45mm x 140 mm x 1800

Plant Wood Outdoor furniture Outdoor bench Wood stain


That was enough for today.

Yep you guessed it, Red IronBark again, so it should look fantastic when finished.

Opps been hit with the sideways pictures issue standby!( should be Fixed now!)
 

Attachments

#373 ·
Bench Seat Day 1 In the begining.

No 2 Son sent a picture of his friends Bench seat his Dad had made him.

Wood Wood stain Hardwood Plank Rectangle


No2 Son asked if i could make one for him too.
So not being able to pass up a challenge I said yes.

So under the cover of my timber stash I went

Plant Outdoor furniture Outdoor table Wood Grass


I first thought this piece would do the trick nicely.

However sadly enough no, too much rubbish, mortices, foreign objects and natural defects to get a usable length.

Wood Grass Gas Sawhorse Machine


So I de buried treasure it

Wood Natural material Table Grass Wood stain


Ended up with a few pieces about 500mm long which were use-able

Furniture Plant Outdoor bench Outdoor furniture Wood


Eventually I decided to use it for legs.

Brown Wood Rectangle Road surface Brick


then dragged out a second piece

Outdoor bench Street furniture Plant Wood Outdoor furniture


Ripped it into three lengths about 45mm x 140 mm x 1800

Plant Wood Outdoor furniture Outdoor bench Wood stain


That was enough for today.

Yep you guessed it, Red IronBark again, so it should look fantastic when finished.

Opps been hit with the sideways pictures issue standby!( should be Fixed now!)
... So I de buried treasure it

Wood Natural material Table Grass Wood stain


- robscastle
Did you keep them? With the proliferation of synthetics, they'll be worth a fortune in 500 years!

My #1 son tried that on me years ago… I told him to get his friend's dad to make him one too!
 

Attachments

#378 ·
Bench Seat day 2

Spent another enjoyable day outside

Jointing:-
I did all the timbers I had cut up.
Seat top sections

Wood Outdoor furniture Wood stain Grass Hardwood


The associated parts for legs and framing components

Furniture Plant Outdoor bench Outdoor furniture Wood


One of the seat sections has had a resin hole filled so I left it there

Wood Plant Grass Rectangle Plank

(see the center section left hand side top)

unfortunately as I was thicknessing everything the repair job fell out.

Wood Office ruler Table Rectangle Automotive exterior


I was a little disapointed the resin hole was full thickness and as I didn't want to epoxy the hole removing it would mean the seat would be 20mm narrower.

Wood Plant Wood stain Grass Hardwood


Then to add to my probs one section was damaged on the end and had to be reduced to 1600mm

Plant Table Rectangle Wood Ruler


That just about did it for me so I packed up for the day and went off to consult with No2 son for his requirements.

Outdoor bench Furniture Plant Street furniture Wood
 

Attachments

#379 ·
Bench Seat day 2

Spent another enjoyable day outside

Jointing:-
I did all the timbers I had cut up.
Seat top sections

Wood Outdoor furniture Wood stain Grass Hardwood


The associated parts for legs and framing components

Furniture Plant Outdoor bench Outdoor furniture Wood


One of the seat sections has had a resin hole filled so I left it there

Wood Plant Grass Rectangle Plank

(see the center section left hand side top)

unfortunately as I was thicknessing everything the repair job fell out.

Wood Office ruler Table Rectangle Automotive exterior


I was a little disapointed the resin hole was full thickness and as I didn't want to epoxy the hole removing it would mean the seat would be 20mm narrower.

Wood Plant Wood stain Grass Hardwood


Then to add to my probs one section was damaged on the end and had to be reduced to 1600mm

Plant Table Rectangle Wood Ruler


That just about did it for me so I packed up for the day and went off to consult with No2 son for his requirements.

Outdoor bench Furniture Plant Street furniture Wood
Well - there's your problem - that tape measure isn't in inches. ;+P
 

Attachments

#396 ·
Bench Seat Legs day 3

Due to it raining and disrupting stuff this is day 3 now its not a chronological day 3 but in fact a working day 3

So what have i been doing!

Well I tried woodshavers timber stretcher but it didn't work for me so I accepted the fact the length of the seat top will be about 1600 mm
I set up all the gear and commenced jointing quite a difficult task considering the mass and length is way beyond my gear, but here goes.

Its all a bit boring just ripping jointing and thicknessing

These will be the legs! (see post note below)

Plant Wood Street furniture Outdoor furniture Rectangle


two rips per piece and we are away

Outdoor bench Wood Street furniture Outdoor furniture Wood stain


Then in no time we have the stock we need.

Wood Flooring Natural material Wood stain Hardwood


Roll out the trusty jointer and get everything square well 1 x edge and 1 x face that is

Wood Automotive tire Rectangle Asphalt Bumper


piece after piece

side 1 before
Wood Asphalt Bumper Road surface Automotive exterior


side 1 after

Wood Bumper Gas Automotive exterior Machine

then edging to complete the process

Road surface Flowerpot Plant Asphalt Wood


I dint pictorial the thicknessing.

and its starting to sprinkle gain, rats … well beer time then!

Fence Plant Grass Mesh Road surface


Post addition

I just noticed I missed a very important preparation fact, you may have picked up on it or didn't realise.
Prior to doing any cutting or finishing the timber was completely cleared of and paint and buried treasure.
How I did this was using my Arbortech planner on my angle grinder.

Green Wood Outdoor furniture Grass Outdoor bench


It doesnt take long and all sides can be done in a few minutes

Plant Wood Grass Outdoor bench Flowerpot


The reason i say this is important is because paint is a meduim very close to abrasive on cutting knives

Outdoor bench Plant Wood Outdoor furniture Grass


So in conclusion
The less cutters are subjected to unnecessary abrasive mediums the more they will like you !!
 

Attachments

#397 ·
Bench Seat Legs day 3

Due to it raining and disrupting stuff this is day 3 now its not a chronological day 3 but in fact a working day 3

So what have i been doing!

Well I tried woodshavers timber stretcher but it didn't work for me so I accepted the fact the length of the seat top will be about 1600 mm
I set up all the gear and commenced jointing quite a difficult task considering the mass and length is way beyond my gear, but here goes.

Its all a bit boring just ripping jointing and thicknessing

These will be the legs! (see post note below)

Plant Wood Street furniture Outdoor furniture Rectangle


two rips per piece and we are away

Outdoor bench Wood Street furniture Outdoor furniture Wood stain


Then in no time we have the stock we need.

Wood Flooring Natural material Wood stain Hardwood


Roll out the trusty jointer and get everything square well 1 x edge and 1 x face that is

Wood Automotive tire Rectangle Asphalt Bumper


piece after piece

side 1 before
Wood Asphalt Bumper Road surface Automotive exterior


side 1 after

Wood Bumper Gas Automotive exterior Machine

then edging to complete the process

Road surface Flowerpot Plant Asphalt Wood


I dint pictorial the thicknessing.

and its starting to sprinkle gain, rats … well beer time then!

Fence Plant Grass Mesh Road surface


Post addition

I just noticed I missed a very important preparation fact, you may have picked up on it or didn't realise.
Prior to doing any cutting or finishing the timber was completely cleared of and paint and buried treasure.
How I did this was using my Arbortech planner on my angle grinder.

Green Wood Outdoor furniture Grass Outdoor bench


It doesnt take long and all sides can be done in a few minutes

Plant Wood Grass Outdoor bench Flowerpot


The reason i say this is important is because paint is a meduim very close to abrasive on cutting knives

Outdoor bench Plant Wood Outdoor furniture Grass


So in conclusion
The less cutters are subjected to unnecessary abrasive mediums the more they will like you !!
progress is progress regardless of how much or how little.
 

Attachments

#405 ·
Bench Seat preparationDay 4

After much pondering about the resin defect I decided to rip it off

Wood Tool Wood stain Table Rectangle


this served two purposes
1. removed a problem I didnt really know how to deal with effectively nor did I have any gear.

Wood Table Rectangle Wood stain Varnish


and

2. reduce the width of the seat enough for me to fit it into my thicknesser.
So a little more edge jointing and out with my biscuit jointer

Wood Flooring Floor Automotive exterior Wood stain


being such a big glue up I had to resort to working on the floor of my garage

Wood Wood stain Floor Table Hardwood


2 x panel clamps (courtesy of Lazy Larry) and 2 x sash clamps

Wood Wood stain Flooring Hardwood Musical instrument


next day it was off with the clamps and scraping off glue spots before wrestling it into my thicknesser.

Wood Outdoor bench Outdoor furniture Wood stain Plank


I did both sides and determined which side I would use as a datum

set up some rollers to manage the monster an ran both sides through

Table Outdoor bench Plant Wood Picnic table


then back to the customer for more information as to the required edge finishing

Wood Rectangle Wood stain Plank Flooring


then almost like Mexico here comes the rain again!
 

Attachments

#406 ·
Bench Seat preparationDay 4

After much pondering about the resin defect I decided to rip it off

Wood Tool Wood stain Table Rectangle


this served two purposes
1. removed a problem I didnt really know how to deal with effectively nor did I have any gear.

Wood Table Rectangle Wood stain Varnish


and

2. reduce the width of the seat enough for me to fit it into my thicknesser.
So a little more edge jointing and out with my biscuit jointer

Wood Flooring Floor Automotive exterior Wood stain


being such a big glue up I had to resort to working on the floor of my garage

Wood Wood stain Floor Table Hardwood


2 x panel clamps (courtesy of Lazy Larry) and 2 x sash clamps

Wood Wood stain Flooring Hardwood Musical instrument


next day it was off with the clamps and scraping off glue spots before wrestling it into my thicknesser.

Wood Outdoor bench Outdoor furniture Wood stain Plank


I did both sides and determined which side I would use as a datum

set up some rollers to manage the monster an ran both sides through

Table Outdoor bench Plant Wood Picnic table


then back to the customer for more information as to the required edge finishing

Wood Rectangle Wood stain Plank Flooring


then almost like Mexico here comes the rain again!
Yep Rob, It's been a wet summer down here too, over 200mm in January and December was just as wet.
We've had another 30+mm already this month.
My shed is just seeping moisture through the sandstone.
The timber looks good.
 

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