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Recycled timber work

188K views 425 replies 44 participants last post by  Boxguy 
#1 ·
The basics

There are quite a few LJs asking about the pros and cons of working with recycled timber.
I use recycled timber regularly and thought my experiences may be of benefit to others.

Lets look at the availability and what's actually available from the bottom of the pile and then up to attractive sort after timber.

From the bottom

Packing crates, pallets and general shipping products.

Lets look at pallets,
They are generally made from a very diverse range of materials.

Commercial Pallets

The commercial reusable ones are usually hardwood and are not generally thrown away or discarded, so beware if it has a brand painted or has what looks like substantial construction and also very heavy it generally is not something you should touch without ensuring you have permission.

If you are able to get them they are usually always embedded with small stones on at least one side, masses of nails and possibly nail plates on the end grain.

Don't under any circumstances use your top end wood working gear on them, simply break them apart and reuse as is, they will last for years.

If you do need to work them accept the fact you will encounter foreign objects, stone, metal and just about anything else, hence the comment regarding top end wood working gear.

Ruin a tungsten blade, HSS Blade or the likes and the cost effectiveness of recycling is in one hit not sustainable.

This also includes magnetic loop testing beforehand, miss one object and its all over red rover.

Packing Crates and soft wood pallets

These are found just about everywhere and the businesses that have goods delivered in them are in most cases pleased to get rid of them at no cost to them.

Again just ask first, common courtesy and also check the conditions they expect you to comply to, meaning take everything, take whatever you want, and it usually comes with a don't make a mess doing so, this is also an etiquette requirement if collecting stuff, ensure the location is tidier when you leave that before you arrived and you will never have any problems and can return regularly to eye ball what is available.

Recognition

Usually of softwood construction, with composite materials like OSB, plywood, Plastic and Particle board being used in their construction is common.

Foreign Objects

Expect bolts and nuts, captive nuts , staples, screws, coach bolts, washers, Gang nail plate and heaps of machine inserted nails.

Now these nails/staples are a real concern, so read carefully,...they can recognised by a serrated section on the shank when you pull one out, or what looks like a small barb attached to the shank, look closely at them they are usually held together in strips by non ferrous wire! so here is the problem may arise, firstly the mag loop may not pick up the remaining metal in the timber, but it could be still embedded in the hole.
Jewellery Font Metal Hair accessory Pattern


So plan to expect the unexpected

The timbers themselves

most of the timber is rough saw full of knots, weak points, twists, bark and all sorts of variances in thickness.

Considering its original role was a one task job its understandable.

However it can be reused with a little TLC.

You can also get some nice varieties of timber mixed in the pallets, as they are include for use as off cuts or sub standard structural timber discards.

The ply wood and OSB are usually D standard, meaning the gaps knots and the likes will be visible along with variances in thickness, but again you may find some small gems.

So after checking all this at the site you still decide its something you can use so it lets go a step further.

Getting the gear home.

Loading requirements and the law.

Don't assume just because its free you are exempt from any traffic laws, you are not, make sure you are not overloaded, the gear is secure and meets all requirement for transit.
Getting busted when moving recycled timber is not funny and again puts it into the not sustainable category yet again, it may have been "free" but you do not want to have a traffic fine in the process.

At home

You are now up for quite a bit of extra work, but that will do for now.
 

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#319 ·
AKs ToolMakers Chest Widening the overall frame

Its been 2 years since I did any work on this toolmakers chest for a friend, it ran aground due to me not having enough skills to built it so it would actually work.

The problem I introduced was the lack of space at the front when the drawer fronts and handles were fitted, the front door would not fit.

We discussed the problem and looked at getting recessed handles and all that sort of variations to overcome the problem.

One line of thought was to add material at the back and move everything reawards, only problem was that it would leave heaps of routed areas exposed at the sides right at the face.

Well nothing really happened until this weekend I saw the unfinished project sitting amoung the various items I make and just stash away.

So I decided it was time to stop avoiding the issue and extend the frame re do the dovetails and generally "get onto it"

First up I milled up some more Kauri pine the do the job.
Then biscuit jointed them all on, only this time I decided to go with adding the extensions to the front.
This made the depth of the Chest 325mm.

Wood Flooring Floor Wood stain Table


Here is the base and part of one side

Wood Floor Flooring Hardwood Gas


Here is a full shot of the side.

Wood Rectangle Wood stain Hardwood Gas


Once they were dry I sanded off the overlap and set up my Gifkins Dovetail Jig and cut the additional dovetails and pins.

Fitted everything up dry assembled and cut the front door to suit.
Dismantled the assembly and routed runners for the front door glued in one side of the dovetails and reassembled it all again

Plant Wood Wood stain Table Hardwood


How noticable is the add in.
LH side

Wood Floor Flooring Hardwood Road surface

RH Side

Wood Rectangle Wood stain Floor Flooring


Happy with the progress I decided to stop for a while and continue another day.

Wood Hardwood Wood stain Plank Lumber


How did I manage to re route the dovetails with the Gifkins Jig with the timber now at 325mm?
Have a look at my tool tip if you own a Gifkins dovetail Jig, it is possible.
 

Attachments

#320 ·
AKs ToolMakers Chest Widening the overall frame

Its been 2 years since I did any work on this toolmakers chest for a friend, it ran aground due to me not having enough skills to built it so it would actually work.

The problem I introduced was the lack of space at the front when the drawer fronts and handles were fitted, the front door would not fit.

We discussed the problem and looked at getting recessed handles and all that sort of variations to overcome the problem.

One line of thought was to add material at the back and move everything reawards, only problem was that it would leave heaps of routed areas exposed at the sides right at the face.

Well nothing really happened until this weekend I saw the unfinished project sitting amoung the various items I make and just stash away.

So I decided it was time to stop avoiding the issue and extend the frame re do the dovetails and generally "get onto it"

First up I milled up some more Kauri pine the do the job.
Then biscuit jointed them all on, only this time I decided to go with adding the extensions to the front.
This made the depth of the Chest 325mm.

Wood Flooring Floor Wood stain Table


Here is the base and part of one side

Wood Floor Flooring Hardwood Gas


Here is a full shot of the side.

Wood Rectangle Wood stain Hardwood Gas


Once they were dry I sanded off the overlap and set up my Gifkins Dovetail Jig and cut the additional dovetails and pins.

Fitted everything up dry assembled and cut the front door to suit.
Dismantled the assembly and routed runners for the front door glued in one side of the dovetails and reassembled it all again

Plant Wood Wood stain Table Hardwood


How noticable is the add in.
LH side

Wood Floor Flooring Hardwood Road surface

RH Side

Wood Rectangle Wood stain Floor Flooring


Happy with the progress I decided to stop for a while and continue another day.

Wood Hardwood Wood stain Plank Lumber


How did I manage to re route the dovetails with the Gifkins Jig with the timber now at 325mm?
Have a look at my tool tip if you own a Gifkins dovetail Jig, it is possible.
Wow, Rob, this looks to be some fine craftsmanship. Hope it continues t go well. Lots of problems to solve when you are extending the capacity of a tool. Keep tool boxing and keep posting.
 

Attachments

#328 ·
AKs ToolMakers Chest drawer fronts and start of the top case compartment

I left off working on the front extension in August, the extension of the front is to accomodate the drawer handles.
So its now October and I am motivated to get this project finished. (started 2015!)

I selected some of the timber with the dark grain effect in it for the drawer fronts.

By cutting the pieces required as a sort of book match I was able to have the grain run continously from the bottom drawer to the top drawer.

I still do not know what the timber is, but it looks nice!

Wood Shelf Shelving Wood stain Hardwood


Next I needed a thin kerf blade to cut the three upper half width drawers fronts in half as I wantd to maintain a close fit with everything.
I guess I could have used my bandsaw but instead I opted to fit a thin blade to the table saw and cut them all together with the sled.
Once thet was done I used a small round over bit to profile edge them all.

I then commenced attaching them

How I did this was:
Simply applied glue to the jointing surfaces and fitted the front, waited until the glue would hold the front under its own weight, then fitted window spacers to maintain the gap and then clamped it up in the open position.

I must have lost the picture

It was very fiddly and took almost all day to ensure everything fitted OK
The final result. (Dreadful picture I will see if I have another, looks like an elephant sat on the end!!)

Wood Rectangle Wood stain Floor Outdoor furniture


another view

Wood Outdoor furniture Rectangle Street furniture Outdoor bench


Put a couple of screws in the back in case it fell off!

Wood Flooring Floor Hardwood Wood stain


All that remains now is to determine what sort of handles I want to use, then fit them along with all the other hardware locks hinges etc, finish the top compartment and decide on a surface finish then but as of now ts practically finished.

Wood Rectangle Table Hardwood Wood stain
 

Attachments

#329 ·
AKs ToolMakers Chest drawer fronts and start of the top case compartment

I left off working on the front extension in August, the extension of the front is to accomodate the drawer handles.
So its now October and I am motivated to get this project finished. (started 2015!)

I selected some of the timber with the dark grain effect in it for the drawer fronts.

By cutting the pieces required as a sort of book match I was able to have the grain run continously from the bottom drawer to the top drawer.

I still do not know what the timber is, but it looks nice!

Wood Shelf Shelving Wood stain Hardwood


Next I needed a thin kerf blade to cut the three upper half width drawers fronts in half as I wantd to maintain a close fit with everything.
I guess I could have used my bandsaw but instead I opted to fit a thin blade to the table saw and cut them all together with the sled.
Once thet was done I used a small round over bit to profile edge them all.

I then commenced attaching them

How I did this was:
Simply applied glue to the jointing surfaces and fitted the front, waited until the glue would hold the front under its own weight, then fitted window spacers to maintain the gap and then clamped it up in the open position.

I must have lost the picture

It was very fiddly and took almost all day to ensure everything fitted OK
The final result. (Dreadful picture I will see if I have another, looks like an elephant sat on the end!!)

Wood Rectangle Wood stain Floor Outdoor furniture


another view

Wood Outdoor furniture Rectangle Street furniture Outdoor bench


Put a couple of screws in the back in case it fell off!

Wood Flooring Floor Hardwood Wood stain


All that remains now is to determine what sort of handles I want to use, then fit them along with all the other hardware locks hinges etc, finish the top compartment and decide on a surface finish then but as of now ts practically finished.

Wood Rectangle Table Hardwood Wood stain
Rob, You are a way better woodworker than I sir…beautiful!!
 

Attachments

#335 ·
My Model Contribution

I have been watching all the great toy model constructions posted, Roadsters, Trucks, Cranes, Bulldozers, and Cars for really little kids, Marble machines an the list goes on.

All sorts of members contribute Ducks, Crows, Masters of the bush, Clog people, Romans in boots and members with just about every letter of the alphabet LBD HTL and as the name list again just goes on and on.
Then there is all the wheely good Jigs that go along to get everything rolling along to support it all.

Now, I was feeling a little left out, so to link up I thought I had get a wiggle on and contribute my model effort.

I did make some little peoples Wooden Concept Cars some time ago, like 2013.

Wood Automotive tire Trunk Funeral Hardwood


Its a tow truck just in case you wondered!

Any way its now almost 2018 and I have improved my wood working skills just a little, so model making is back on the list.

My contribution begins with looking at my recycle stack from my Smiths Potato Crate repair work.

Wood Flooring Wood stain Hardwood Gas


This stuff is butt ugly and tough as old boots but finishes fantasticly so I am going to recycle it into a model.

I will start by cleaning, Mag testing it and then begin its new Role, as I ponder what I can make.

BTW this blog is real, ...its not just a recognition (AKA Suck up) of all the LJs model toy making skills, its just I left it a little late in the day to make a start so stay tuned!
 

Attachments

#336 ·
My Model Contribution

I have been watching all the great toy model constructions posted, Roadsters, Trucks, Cranes, Bulldozers, and Cars for really little kids, Marble machines an the list goes on.

All sorts of members contribute Ducks, Crows, Masters of the bush, Clog people, Romans in boots and members with just about every letter of the alphabet LBD HTL and as the name list again just goes on and on.
Then there is all the wheely good Jigs that go along to get everything rolling along to support it all.

Now, I was feeling a little left out, so to link up I thought I had get a wiggle on and contribute my model effort.

I did make some little peoples Wooden Concept Cars some time ago, like 2013.

Wood Automotive tire Trunk Funeral Hardwood


Its a tow truck just in case you wondered!

Any way its now almost 2018 and I have improved my wood working skills just a little, so model making is back on the list.

My contribution begins with looking at my recycle stack from my Smiths Potato Crate repair work.

Wood Flooring Wood stain Hardwood Gas


This stuff is butt ugly and tough as old boots but finishes fantasticly so I am going to recycle it into a model.

I will start by cleaning, Mag testing it and then begin its new Role, as I ponder what I can make.

BTW this blog is real, ...its not just a recognition (AKA Suck up) of all the LJs model toy making skills, its just I left it a little late in the day to make a start so stay tuned!
Rob, sounds like a plan. I am waiting for the result. Keep making sawdust.
 

Attachments

#352 ·
Model Raw materials prep

I started work early this morning trying to beat the heat.

I ran my metal detector loop over the timber to ensure it had no metalic FO in it.
Next was a good wire brushing to remove crud build up.
Satisfied all was good to go I fed them into the thicknesser and followed up by edging them with the table saw.
I then ripped the damaged pieces with splits in them and ended up with a material stock list looking like this

Wood Wood stain Outdoor furniture Hardwood Grass


Unfortunately there was only about six pieces of any practical use.

Natural material Wood Outdoor furniture Wood stain Hardwood


Wondering just what I could make with them it suddenly dawned on me I could make a model Potato crate!
I certainly had enough small pieces to do that.
A bit off the track of a toy model with wheels doors and any dynamic parts, but I decided to give it a go.

Here is what a full size Potato Crate looks like.

Wood Road surface Gas Hardwood Wood stain


Its roughly a standard pallet 1160Ă—1160 with four sides added and held together with 50mm angle.

Without having the ability to scale it I decided to make the base 150mm x 150mm and the side panels the same.

So I set up the table saw with the fence on the left side of the blade and fed all the smaller pieces through to make the actual boards, the base bearers I did much the same with but there was less of them and different dimensions obviously.

I had enough materials to make four model crates.
Ripping material that small required two push sticks and very careful operation of the saw as pinkies were very close to a manicuring.

Then it was a safer and simpler task of cutting them to length on the drop saw.

As luck would have it I still had the original pictures from when I first quoted to do the job back in 2013.
The boards are actually staggered end wise and alternated on the frame work

Wood Asphalt Road surface Composite material Automotive tire


So I recut the boards so to match the shorter ones.

I then bagged up all the parts so I could keep track of what was doing

Water bottle Bottle Table Wood Toy airplane


I then started on the crate bases.

I had planned on just brad nailing everyting together but my test run proved this to be not a good idea as although the brads were small they still split my test sample.

Wood Rectangle Wood stain Hardwood Cross


Pre drilling them all was out of the question as I could hardly see the drill bit let alone do any accurate repetition drilling, there are 8 x slats on the base and 28 x on the sides 3x bearers and 4x 45deg vertical posts.

So I resorted to just glueing them all together.

This is what I ended up with before the heat beat me.



They were a reasonable result and looked to be representative scale models



Not forgetting the odd bit of sanding to remove saw blade burn marks.

So I religated my model making to that of a simple model Box not a toy car as planned, a bit disapointing I guess but at least Big Al will be pleased!!

Its time for a re hydrate!
 

Attachments

#353 ·
Model Raw materials prep

I started work early this morning trying to beat the heat.

I ran my metal detector loop over the timber to ensure it had no metalic FO in it.
Next was a good wire brushing to remove crud build up.
Satisfied all was good to go I fed them into the thicknesser and followed up by edging them with the table saw.
I then ripped the damaged pieces with splits in them and ended up with a material stock list looking like this

Wood Wood stain Outdoor furniture Hardwood Grass


Unfortunately there was only about six pieces of any practical use.

Natural material Wood Outdoor furniture Wood stain Hardwood


Wondering just what I could make with them it suddenly dawned on me I could make a model Potato crate!
I certainly had enough small pieces to do that.
A bit off the track of a toy model with wheels doors and any dynamic parts, but I decided to give it a go.

Here is what a full size Potato Crate looks like.

Wood Road surface Gas Hardwood Wood stain


Its roughly a standard pallet 1160Ă—1160 with four sides added and held together with 50mm angle.

Without having the ability to scale it I decided to make the base 150mm x 150mm and the side panels the same.

So I set up the table saw with the fence on the left side of the blade and fed all the smaller pieces through to make the actual boards, the base bearers I did much the same with but there was less of them and different dimensions obviously.

I had enough materials to make four model crates.
Ripping material that small required two push sticks and very careful operation of the saw as pinkies were very close to a manicuring.

Then it was a safer and simpler task of cutting them to length on the drop saw.

As luck would have it I still had the original pictures from when I first quoted to do the job back in 2013.
The boards are actually staggered end wise and alternated on the frame work

Wood Asphalt Road surface Composite material Automotive tire


So I recut the boards so to match the shorter ones.

I then bagged up all the parts so I could keep track of what was doing

Water bottle Bottle Table Wood Toy airplane


I then started on the crate bases.

I had planned on just brad nailing everyting together but my test run proved this to be not a good idea as although the brads were small they still split my test sample.

Wood Rectangle Wood stain Hardwood Cross


Pre drilling them all was out of the question as I could hardly see the drill bit let alone do any accurate repetition drilling, there are 8 x slats on the base and 28 x on the sides 3x bearers and 4x 45deg vertical posts.

So I resorted to just glueing them all together.

This is what I ended up with before the heat beat me.

Wood Rectangle Flooring Floor Wood stain


They were a reasonable result and looked to be representative scale models

Wood Rectangle Flooring Floor Wood stain


Not forgetting the odd bit of sanding to remove saw blade burn marks.

So I religated my model making to that of a simple model Box not a toy car as planned, a bit disapointing I guess but at least Big Al will be pleased!!

Its time for a re hydrate!
Now Spud, all ya gotta do is grow some miniature potatoes before the 5th of Feb.
 

Attachments

#361 ·
Model potato Crate Making the sides

Hello again,

well here I am busy working away and get stopped to put up Christmas lights.

So a late start and no doubt an early finish due to heat. O boy the joys of getting old.

Anyway back to it
To make the four sides, it involves a bit of planning as two opposite sides are the same, a uniform spacing all round, however the other two have a bottom board which overlaps the pallet base.

I made a simple jig to set them out in and I used some window spacers to maintain the final spacing.

Here is the jig.

An explanation: I cut the window spacers in half and used two sizes to allow uniform vertical spacing.
To produce the alternate horizontal offsetting I used the off cuts from the short boards turned on their ends pushed them all up tight and glued in the 45 deg corner post.

Wood Rectangle Wood stain Flooring Floor


Another view.
Notice the end post is in line with the top and bottom board.

Rectangle Wood Wood stain Hardwood Shelving


Now the two opposite sides,
Notice the top board (its actually upside down) is overlapping the 45 deg post end.

Wood Wood stain Hardwood Rectangle Natural material


So continuing on I have to make 8 of each style and only one Jig, so I am going to be a while, its no point in boring you with any more ho hum stuff so thats it for a while, I will however keep swaping them out every couple of hours, to get them finished I am not just goofing off ! ... pickling the brain, ...just yet!

Oh almost forgot Clamping. (echo O boy the joys of getting old.)

I used a battery and some camping mat as the post kept turning with a conventional clamp.

Wood Gas Hardwood Wood stain Office ruler
 

Attachments

#362 ·
Model potato Crate Making the sides

Hello again,

well here I am busy working away and get stopped to put up Christmas lights.

So a late start and no doubt an early finish due to heat. O boy the joys of getting old.

Anyway back to it
To make the four sides, it involves a bit of planning as two opposite sides are the same, a uniform spacing all round, however the other two have a bottom board which overlaps the pallet base.

I made a simple jig to set them out in and I used some window spacers to maintain the final spacing.

Here is the jig.

An explanation: I cut the window spacers in half and used two sizes to allow uniform vertical spacing.
To produce the alternate horizontal offsetting I used the off cuts from the short boards turned on their ends pushed them all up tight and glued in the 45 deg corner post.

Wood Rectangle Wood stain Flooring Floor


Another view.
Notice the end post is in line with the top and bottom board.

Rectangle Wood Wood stain Hardwood Shelving


Now the two opposite sides,
Notice the top board (its actually upside down) is overlapping the 45 deg post end.

Wood Wood stain Hardwood Rectangle Natural material


So continuing on I have to make 8 of each style and only one Jig, so I am going to be a while, its no point in boring you with any more ho hum stuff so thats it for a while, I will however keep swaping them out every couple of hours, to get them finished I am not just goofing off ! ... pickling the brain, ...just yet!

Oh almost forgot Clamping. (echo O boy the joys of getting old.)

I used a battery and some camping mat as the post kept turning with a conventional clamp.

Wood Gas Hardwood Wood stain Office ruler
You're going all out on this model experiment Rob…
 

Attachments

#364 ·
The model Potato Crate gets assembled

Some "interesting" progress for a change.
After making 2 sets of sides I realised I could speed progress up some what by implementing an alternative assembly method while waiting for the jig lots glue to dry.

As I had made enough of of the opposing sides I decided to use assembly method No 2 in an attempt to speed things up.

So Method 1. Was to assemble the four prefabricated sides to the base all in one go, with only one jig I was getting bored watching glue dry. As I had four matching sides done I had this brainstorm for another method.

You might call it a duck moment!

So Method 2. Using two matching prefabricated sides and four individual boards I could semi assemble the sides.

Something like this

Wood Wood stain Hardwood Gas Musical instrument


A bit fiddlly needed more attention to squaring up but a suppliment to the alternative assembly method 1,

Wood Chair Hardwood Flooring Wood stain


That worked OK for two of the crates. So I did them.

Then once the glue was dry it was a simple matter of adding the remaining individual boards.

Wood Wood stain Hardwood Gas Tire


Apply glue and simply add more boards.

Wood Tool Wood stain Hardwood Saw


In no time at all I had reduced the assembly process by 50% duration,

I was pleased with that as I got into trouble wandering around in the garden pulling "weeds" my wife tells me they were chilli plants she was nurtruring, so I quicky put them back and scampered.

Wood Saw Hardwood Flooring Wood stain


Much sooner than expected I had two crates almost fully assembled.

Rectangle Wood Basket Hardwood Wood stain


I say "almost fully assembled" as there now needs to be four metal angles on the corners for authenticity.
So I am off looking for some pressed steel 1/4" or 6 mm angle to do the job.
 

Attachments

#365 ·
The model Potato Crate gets assembled

Some "interesting" progress for a change.
After making 2 sets of sides I realised I could speed progress up some what by implementing an alternative assembly method while waiting for the jig lots glue to dry.

As I had made enough of of the opposing sides I decided to use assembly method No 2 in an attempt to speed things up.

So Method 1. Was to assemble the four prefabricated sides to the base all in one go, with only one jig I was getting bored watching glue dry. As I had four matching sides done I had this brainstorm for another method.

You might call it a duck moment!

So Method 2. Using two matching prefabricated sides and four individual boards I could semi assemble the sides.

Something like this

Wood Wood stain Hardwood Gas Musical instrument


A bit fiddlly needed more attention to squaring up but a suppliment to the alternative assembly method 1,

Wood Chair Hardwood Flooring Wood stain


That worked OK for two of the crates. So I did them.

Then once the glue was dry it was a simple matter of adding the remaining individual boards.

Wood Wood stain Hardwood Gas Tire


Apply glue and simply add more boards.

Wood Tool Wood stain Hardwood Saw


In no time at all I had reduced the assembly process by 50% duration,

I was pleased with that as I got into trouble wandering around in the garden pulling "weeds" my wife tells me they were chilli plants she was nurtruring, so I quicky put them back and scampered.

Wood Saw Hardwood Flooring Wood stain


Much sooner than expected I had two crates almost fully assembled.

Rectangle Wood Basket Hardwood Wood stain


I say "almost fully assembled" as there now needs to be four metal angles on the corners for authenticity.
So I am off looking for some pressed steel 1/4" or 6 mm angle to do the job.
rc, I have lost perspective of the magnitude of this Eifel Tower!

Have you considered CA? If it's the magnitude of the 8th. wonder of the world, perhaps a 4 minute epoxy (I'm deducting 1 minute for Qld. weather) could stimulate an extension to your life!
 

Attachments

#379 ·
The Model Potato Crate Surface finishing

Almost done, once all the glue was set it was time to commence surface finishing

I started off on the disc Sander getting all the board edges level and then commenced sanding all the saw blade burn marks out.
I used my 1/2 sheet orbital sander and a ROS started with 80 grit and finished with 400 grit.

Plant Wood Gas Vehicle Grass


I burned up heaps of sheets sanding this tough as timber I think each crate devoured a single sheet of each grade but it was worth it all.

Sanding:-
This was the result I obtained.
The left crate has been sanded, and its mate on the right awaiting its turn

Wood Rectangle Flooring Wood stain Plank


The grits I used were, 80 120 240 320 an finished with 400.

Once I had finished the sanding I set up my polishing gear to finish the project.

I used a white compound and a sisal pad mounted on a spindle to polish each crate.

Plant Tire Automotive tire Wood Motor vehicle


Working away I produced the following results.

Polishing:-

Plant Wood Gas Vehicle Grass


And this is the final finished job, some of the saw marks you see were left for the rustic effect.

Wood Outdoor furniture Wood stain Flooring Hardwood


The stack of dead sanding consumables are on the right!

That completes the actual woodworking aspects, all that remains now is to fit the angle bracing on the corners.

I went looking for suitable angle today on both the net and local harware suppliers but returned empty handed, I hope this doesn't turn into a activity like the Euro hinge hunt saga.

Well thats it for the blog, once I find the angle I will fit it all, and will then post the Model Crates as a project.

BTW I got a good result with the friction polishing, however I thought I could improve on it, so I decided to use some furniture polish to see if I could get a better sheen, ...dont try this at home … the furniture polish produced a less sheen effect which was actually worse! ... and I had to re-polish a section again to match the rest of the crate.

Thanks for following and commenting.
 

Attachments

#380 ·
The Model Potato Crate Surface finishing

Almost done, once all the glue was set it was time to commence surface finishing

I started off on the disc Sander getting all the board edges level and then commenced sanding all the saw blade burn marks out.
I used my 1/2 sheet orbital sander and a ROS started with 80 grit and finished with 400 grit.

Plant Wood Gas Vehicle Grass


I burned up heaps of sheets sanding this tough as timber I think each crate devoured a single sheet of each grade but it was worth it all.

Sanding:-
This was the result I obtained.
The left crate has been sanded, and its mate on the right awaiting its turn

Wood Rectangle Flooring Wood stain Plank


The grits I used were, 80 120 240 320 an finished with 400.

Once I had finished the sanding I set up my polishing gear to finish the project.

I used a white compound and a sisal pad mounted on a spindle to polish each crate.

Plant Tire Automotive tire Wood Motor vehicle


Working away I produced the following results.

Polishing:-

Plant Wood Gas Vehicle Grass


And this is the final finished job, some of the saw marks you see were left for the rustic effect.

Wood Outdoor furniture Wood stain Flooring Hardwood


The stack of dead sanding consumables are on the right!

That completes the actual woodworking aspects, all that remains now is to fit the angle bracing on the corners.

I went looking for suitable angle today on both the net and local harware suppliers but returned empty handed, I hope this doesn't turn into a activity like the Euro hinge hunt saga.

Well thats it for the blog, once I find the angle I will fit it all, and will then post the Model Crates as a project.

BTW I got a good result with the friction polishing, however I thought I could improve on it, so I decided to use some furniture polish to see if I could get a better sheen, ...dont try this at home … the furniture polish produced a less sheen effect which was actually worse! ... and I had to re-polish a section again to match the rest of the crate.

Thanks for following and commenting.
Rob, nice project…now if you had just put splines in the corners it would look like this.

Rectangle Wood Hardwood Varnish Wood stain
 

Attachments

#382 ·
Pallet Table 2012 to 2018

Back in Jul 2012 I made a pine Pallet table and stained it Cedar.

I am not sure why I never posted it, possibly because using recycled pallet timber for "fine' furniture is not really the done thing, and it was actually not completed or finished.

Regardless here is a short story about it.



Apart from the shop bought turned legs all the rest is recycled pallet wood.



The top is a typical breadboard end construction.



I dont remember what method I used to edge join the sections, but it looks like I used polyurethane glue in the construction.



The underside has a central brace fitted.



The frame I simply profiled with a router bit.



Then for finishing, In Jul 2012 I profiled the table top edge and stained it Cedar.

It then remained unfinished and unused until this week.
I think at one stage I put it on ebay for sale, but it attracted no interest, and got stored away.

Now in 2018, into my wood disposal items it was placed.

Brown Rectangle Plant Wood Flooring


Its interesting to see that there is no real movement in the timber after all this time.

So maybe pallet timber has a place in furniture after all.
 

Attachments

#383 ·
Pallet Table 2012 to 2018

Back in Jul 2012 I made a pine Pallet table and stained it Cedar.

I am not sure why I never posted it, possibly because using recycled pallet timber for "fine' furniture is not really the done thing, and it was actually not completed or finished.

Regardless here is a short story about it.

Wood Composite material Gas Hardwood Plank


Apart from the shop bought turned legs all the rest is recycled pallet wood.

Wood Rectangle Table Varnish Plank


The top is a typical breadboard end construction.

Wood Gas Hardwood Wood stain Flooring


I dont remember what method I used to edge join the sections, but it looks like I used polyurethane glue in the construction.

Wood Wood stain Hardwood Plank Flooring


The underside has a central brace fitted.

Wood Rectangle Wood stain Hardwood Plank


The frame I simply profiled with a router bit.

Wood Rectangle Outdoor furniture Table Plant


Then for finishing, In Jul 2012 I profiled the table top edge and stained it Cedar.

It then remained unfinished and unused until this week.
I think at one stage I put it on ebay for sale, but it attracted no interest, and got stored away.

Now in 2018, into my wood disposal items it was placed.

Brown Rectangle Plant Wood Flooring


Its interesting to see that there is no real movement in the timber after all this time.

So maybe pallet timber has a place in furniture after all.
Don't sell yourself too short rc... You migh not have had any eBay offers but it's a neat piece of furniture anyway. Only Pierre Cardin is qualified to question the timber's origin/species and most people can't even spell his name.

You should salvage it from the disposal stack, give it a good shellacking (or two) and promote it to a worthwhile house item.

Its interesting to see that there is no real movement in the timber after all this time.
- robscastle
Put it on a set of wheels and feed it prunes… then stand back and watch it move…
and when it stops drag it back into your house!
 

Attachments

#386 ·
Finishing the Potato Crate models

Well after a delay due to not knowing how to proceed with the metal retaining angles I had to put the job on hold.

After searching high and low for suitable material I by chance found some material close to what I wanted in my local ALDI store.

I brought it home and set about finding somebody that could cut the metal to the size I needed.
I had no such luck in finding anybody so the project got shelved for some time.

Well its now May and I have decided that I could cut the angle on my combination saw.

So I set up some jigs and got my Einhell Drop saw out, dusted it off and checked the manual, sure enough the saw with its current blade was supposed to be able to cut metal plastic and also wood.

Automotive tire Motor vehicle Font Gas Automotive wheel system


So I thought I would see what it could do.

Sure enough it would cut steel if you were careful.

Rectangle Wood Flooring Floor Wood stain


This is a shot of the angle before and after "ripping" it to the size I wanted.

Rectangle Wood Plant Natural material Wood stain


I then drilled holes in the angle and screwed them onto the crate.

Wood Wood stain Hardwood Gas Flooring


Job complete, at last. ...

In closing does the subject of cuting steel on the saw interest you ? and want to know the pros and cons of doing so?

I could do a blog on the process, its quite interesting and can be done if you have a universal type saw and, like me, never considered doing it before.
 

Attachments

#387 ·
Finishing the Potato Crate models

Well after a delay due to not knowing how to proceed with the metal retaining angles I had to put the job on hold.

After searching high and low for suitable material I by chance found some material close to what I wanted in my local ALDI store.

I brought it home and set about finding somebody that could cut the metal to the size I needed.
I had no such luck in finding anybody so the project got shelved for some time.

Well its now May and I have decided that I could cut the angle on my combination saw.

So I set up some jigs and got my Einhell Drop saw out, dusted it off and checked the manual, sure enough the saw with its current blade was supposed to be able to cut metal plastic and also wood.

Automotive tire Motor vehicle Font Gas Automotive wheel system


So I thought I would see what it could do.

Sure enough it would cut steel if you were careful.

Rectangle Wood Flooring Floor Wood stain


This is a shot of the angle before and after "ripping" it to the size I wanted.

Rectangle Wood Plant Natural material Wood stain


I then drilled holes in the angle and screwed them onto the crate.

Wood Wood stain Hardwood Gas Flooring


Job complete, at last. ...

In closing does the subject of cuting steel on the saw interest you ? and want to know the pros and cons of doing so?

I could do a blog on the process, its quite interesting and can be done if you have a universal type saw and, like me, never considered doing it before.
That looks pretty good to my eye Rob.
 

Attachments

#394 ·
MushroomSeat Mk III secretly underway.

After having my wife bless my work at the finish post I have secretly started No 3 in a hope I dont get busted and loose yet another Work seat/step stool.

After seven years I could not remember how I made the original one so it was all re discovery work.

I had no worries about making the base sections from recycled pine this time as the previous one lasted 7 years outside so that will do me.

I used the same incorrect process to cut them as per the Mk II seat and did the biscuit cut outs today then hid them all away from prying eyes.

This time I will again use No 20 biscuits and pocket holes, hoping it will make the assembly more managable.
I will also go see if there is a better method the join them all together.
The outside faces will receive some sort of router work on them, not sure how I will do that but its gotta be improvement from the original otherwise learning has not taken place.

I know one fact documenting the process saves a lot of time for the additional builds.

I had to remake the biscuit Jig as I had no recollection as to how I did the cut outs before.

The jig for the biscuit cuts:

Note :This Jig is unecessary if you know how to use your Biscuit Cutter correctly.

Picture No 1 showing an off cut from the tapering work as a angle guide.

Wood Composite material Automotive tire Gas Tradesman


Its handed, so once a side was done I needed to dismantle it and do the other edge, nothing too complicated I just used a square and some edge off cuts to setup the correct position so the biscuits cuts perfectly matched each ajoining section.

Here is a section set up on the jig.

Picture 2 Showing the joining section set up at 90 degrees or parallel to the biscuit jointer face.

Wood Flooring Floor Wood stain Hardwood


Then another shot showing the indexing block.

Picture No 3 showing the indexing block and a section of masonite to raise the cutter blade to exactly mid way of the edge. The indexing block ensures the section is flat on the surface and holds every in place.

Wood Audio equipment Floor Flooring Office chair


And finally the results to date.

Wood Flooring Floor Hardwood Wood stain


To be continued in a few days as I have a few non woodworking tasks to do.
 

Attachments

#395 ·
MushroomSeat Mk III secretly underway.

After having my wife bless my work at the finish post I have secretly started No 3 in a hope I dont get busted and loose yet another Work seat/step stool.

After seven years I could not remember how I made the original one so it was all re discovery work.

I had no worries about making the base sections from recycled pine this time as the previous one lasted 7 years outside so that will do me.

I used the same incorrect process to cut them as per the Mk II seat and did the biscuit cut outs today then hid them all away from prying eyes.

This time I will again use No 20 biscuits and pocket holes, hoping it will make the assembly more managable.
I will also go see if there is a better method the join them all together.
The outside faces will receive some sort of router work on them, not sure how I will do that but its gotta be improvement from the original otherwise learning has not taken place.

I know one fact documenting the process saves a lot of time for the additional builds.

I had to remake the biscuit Jig as I had no recollection as to how I did the cut outs before.

The jig for the biscuit cuts:

Note :This Jig is unecessary if you know how to use your Biscuit Cutter correctly.

Picture No 1 showing an off cut from the tapering work as a angle guide.

Wood Composite material Automotive tire Gas Tradesman


Its handed, so once a side was done I needed to dismantle it and do the other edge, nothing too complicated I just used a square and some edge off cuts to setup the correct position so the biscuits cuts perfectly matched each ajoining section.

Here is a section set up on the jig.

Picture 2 Showing the joining section set up at 90 degrees or parallel to the biscuit jointer face.

Wood Flooring Floor Wood stain Hardwood


Then another shot showing the indexing block.

Picture No 3 showing the indexing block and a section of masonite to raise the cutter blade to exactly mid way of the edge. The indexing block ensures the section is flat on the surface and holds every in place.

Wood Audio equipment Floor Flooring Office chair


And finally the results to date.

Wood Flooring Floor Hardwood Wood stain


To be continued in a few days as I have a few non woodworking tasks to do.
Clever and innovative Rob….
 

Attachments

#403 ·
Mushroom seat Mk III continunes or Pt2

OK, so has anybody got any of these pieces of kit still ?

Its a 3D router carver I have had it for years, (and it cost a fortune over time) and now its used it less than my Hollow Chisel Mortiser!
So it got dragged out dusted off today then set to work.
Remember I said I was going to route a few features on the Mushroom Seat Mk III?

Well I got stuck into it today.

Now as usual I made life hard for myself as this work should have been done before cutting tapering edges, however it's what it is.

I made a jig from bits of off cuts and set everything up ready to go.



I used the Cascade template as it would fit my tapered sections OK.

Its a bit of fiddling about so rather than some long winded quacking and boring you with lots of reading here is a four photo sequence covering everything

Carve 1.



Carve 2.



Carve 3.



Carve 4.



Then on with the rest.



Now please don't be telling me I should have used a CNC and just watched the action, I already know its "Old School" and I should put it on ebay!

Anyway I was reasonably happy with the results, but thought I could do better so after ferreting around I found my Gold and Copper leaf gear and set about gilding the carving.

This is now the result.



you ask why? ... Well a man has got to have a "flasher" seat than the wife!!

Added some glue and biscuits and glued it all up then it was the strap ons again.



Checked the joints.

Top.



Bottom.



No pocket screws used this time Mike, and doesn't look much like a Mushroom Seat any more now, but what the heck …anyway thats enough for today.
 

Attachments

#404 ·
Mushroom seat Mk III continunes or Pt2

OK, so has anybody got any of these pieces of kit still ?

Its a 3D router carver I have had it for years, (and it cost a fortune over time) and now its used it less than my Hollow Chisel Mortiser!
So it got dragged out dusted off today then set to work.
Remember I said I was going to route a few features on the Mushroom Seat Mk III?

Well I got stuck into it today.

Now as usual I made life hard for myself as this work should have been done before cutting tapering edges, however it's what it is.

I made a jig from bits of off cuts and set everything up ready to go.

Ruler Wood Tool Font Rectangle


I used the Cascade template as it would fit my tapered sections OK.

Its a bit of fiddling about so rather than some long winded quacking and boring you with lots of reading here is a four photo sequence covering everything

Carve 1.

Handwriting Wood Font Hardwood Wood stain


Carve 2.

Wood Font Office ruler Rectangle Ruler


Carve 3.

Wood Rectangle Wood stain Hardwood Plywood


Carve 4.

Wood Rectangle Goggles Beige Hardwood


Then on with the rest.

Table Wood Wood stain Hardwood Rectangle


Now please don't be telling me I should have used a CNC and just watched the action, I already know its "Old School" and I should put it on ebay!

Anyway I was reasonably happy with the results, but thought I could do better so after ferreting around I found my Gold and Copper leaf gear and set about gilding the carving.

This is now the result.

Table Wood Rectangle Wood stain Flooring


you ask why? ... Well a man has got to have a "flasher" seat than the wife!!

Added some glue and biscuits and glued it all up then it was the strap ons again.

Plant Wood Outdoor furniture Gas Wood stain


Checked the joints.

Top.

Wood Gas Hand tool Tool Automotive tire


Bottom.

Wood Art Hardwood Wood stain Plywood


No pocket screws used this time Mike, and doesn't look much like a Mushroom Seat any more now, but what the heck …anyway thats enough for today.
..... you ask why? ...
- robscastle
WHY?....

Actually (or is it Shirley), WHY is in response to you asking me why I ask why…

That is neat… bugger the CNC… like the way you built it up… must admit you had me questioning your sanity when I saw picture #1…

Now that I've seen it all… I still question your sanity… nevertheless,

Table Wood Wood stain Hardwood Rectangle


I like!
 

Attachments

#411 ·
Mower shed repair work

In Dec 2013 and again in Aug 2014 I built two "Mower Sheds" from recycled materials.
They all faired reasonably well and considering my construction skills at the time most of the weathering was attributed to poor design on my behalf in the first place.

The first shed that had plain butt jointed roofing was rectified by covering with a rubber mat. It needs a complete rebuild, but to simply weatherproof in the short term that was the temporary fix.

Wood Flooring Wood stain Floor Building


The second shed had a plywood roof but it developed rot in the wooden ridge capping of which I thought was odd, however checking my build photos the ridge capping was fitted in two pieces, no doubt I scaffed them but again a poor design feature.
So I removed the damaged capping and replaced it.

This time I made a continous complete length of ridge capping and increased its dimensions.

The problem:

Plant Wood Terrestrial plant Road surface Groundcover


The fix:

Table saws Wood Automotive exterior Bumper Gas


Preparation:
Set the table saw to 22.5 degrees and make four cuts in the timber
Gas Audio equipment Machine Technology Electronic instrument

I cut drip edges underneath and sloped the ends at 10 deg
Profiling:
1. Ripped four cuts in the timber, take care as a projectile hazard may exist doing Right tilt cutting with a table saw.

Wood Flooring Wood stain Creative arts Hardwood


2. There is a bit of timber wastage but thats life
Wood Flooring Wood stain Creative arts Hardwood


3. Here is the final edge capping in the raw.
Wood Table Flooring Floor Wood stain


Fitup:
I used construction adhesive along the roof ridge joints and the screwed the capping on.
At this stage it had been sanded and sealed.
Plant Wood Table Shade Wood stain


Finishing:
over the next 2 days I will undercoat it and then apply the final finishing coats, and the job is complete.

Both could do replacement with larger similar footprint single shed but its in the future at the moment, as my son has one he will remove upon his own home renos being completed and I will recycle it.
 

Attachments

#412 ·
Mower shed repair work

In Dec 2013 and again in Aug 2014 I built two "Mower Sheds" from recycled materials.
They all faired reasonably well and considering my construction skills at the time most of the weathering was attributed to poor design on my behalf in the first place.

The first shed that had plain butt jointed roofing was rectified by covering with a rubber mat. It needs a complete rebuild, but to simply weatherproof in the short term that was the temporary fix.

Wood Flooring Wood stain Floor Building


The second shed had a plywood roof but it developed rot in the wooden ridge capping of which I thought was odd, however checking my build photos the ridge capping was fitted in two pieces, no doubt I scaffed them but again a poor design feature.
So I removed the damaged capping and replaced it.

This time I made a continous complete length of ridge capping and increased its dimensions.

The problem:

Plant Wood Terrestrial plant Road surface Groundcover


The fix:

Table saws Wood Automotive exterior Bumper Gas


Preparation:
Set the table saw to 22.5 degrees and make four cuts in the timber
Gas Audio equipment Machine Technology Electronic instrument

I cut drip edges underneath and sloped the ends at 10 deg
Profiling:
1. Ripped four cuts in the timber, take care as a projectile hazard may exist doing Right tilt cutting with a table saw.

Wood Flooring Wood stain Creative arts Hardwood


2. There is a bit of timber wastage but thats life
Wood Flooring Wood stain Creative arts Hardwood


3. Here is the final edge capping in the raw.
Wood Table Flooring Floor Wood stain


Fitup:
I used construction adhesive along the roof ridge joints and the screwed the capping on.
At this stage it had been sanded and sealed.
Plant Wood Table Shade Wood stain


Finishing:
over the next 2 days I will undercoat it and then apply the final finishing coats, and the job is complete.

Both could do replacement with larger similar footprint single shed but its in the future at the moment, as my son has one he will remove upon his own home renos being completed and I will recycle it.
Clever bugger
 

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