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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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#85 ·
Making tapered legs

Whilst waiting for glue to dry I decided to make some tapered legs, well 1 tapered leg to be exact.

Step 1.
Select your timber.
I used a piece of pallet base again, cut off the rubbish and skimmed it with the table saw for uniform thickness then cut two identical lengths.

Step 2.
Set the table saw to 45 deg and cut each leg at 45 deg.

Step 3.
If all is OK use some glue on the cuts and its into the miter clamp jig.
Wood Gas Composite material Hardwood Machine


Step 4.

Once the glue has set its then time for the ripping to start.
I have a taper jig so I used that to set the cut.

Wood Gas Composite material Hardwood Metal


Wood Hardwood Wood stain Rectangle Plank


Wood Tool Gas Tints and shades Composite material


Step 5.
Examine the finished item

Wood Road surface Asphalt Floor Flooring


Table Wood Rectangle Automotive exterior Wood stain


Wood Floor Rectangle Flooring Hardwood


Wood Rectangle Floor Flooring Wood stain


Its then ready for use in your project. Simple as that!
 

Attachments

#86 ·
Making tapered legs

Whilst waiting for glue to dry I decided to make some tapered legs, well 1 tapered leg to be exact.

Step 1.
Select your timber.
I used a piece of pallet base again, cut off the rubbish and skimmed it with the table saw for uniform thickness then cut two identical lengths.

Step 2.
Set the table saw to 45 deg and cut each leg at 45 deg.

Step 3.
If all is OK use some glue on the cuts and its into the miter clamp jig.
Wood Gas Composite material Hardwood Machine


Step 4.

Once the glue has set its then time for the ripping to start.
I have a taper jig so I used that to set the cut.

Wood Gas Composite material Hardwood Metal


Wood Hardwood Wood stain Rectangle Plank


Wood Tool Gas Tints and shades Composite material


Step 5.
Examine the finished item

Wood Road surface Asphalt Floor Flooring


Table Wood Rectangle Automotive exterior Wood stain


Wood Floor Rectangle Flooring Hardwood


Wood Rectangle Floor Flooring Wood stain


Its then ready for use in your project. Simple as that!
Nice, favorited…
Is this for the table project or just a tip/trick.?
 

Attachments

#89 ·
PTLT The finishing coats commences. and some retro work completed

I did some more work on the Pallet Timber Low Table top.
This work covers using Black Japan as a finish.

While I was at it I also added some filler strips into the base where there was a mismatch between the legs and rails.

It was fairly straightforward measure a piece of timber and rip a length 3.5mm off for the fillers.

Apply some glue fit into place and clamp up

Sports equipment Gas Composite material Bicycle part Auto part


Gas Automotive exterior Auto part Metal Wood


I should have done this much earlier but I thought it would be OK so left it , however it was causing all sorts of cosmetic problems so in they went.

Black Japan:

As the table had a Japanese style I decided to stain and finish it with Black Japan.

There was an article in the Woodsmith magazine so I thought i woud give it a go.
The product I used was :

Feast Watson Stain and varnish
pre mixed.

For the first initial coat I used a brush and then decided to use a roller for the second coat to try and get some uniformity.

As you can see its a very difficult product to apply sucessfully with a brush

Wood Rectangle Gas Composite material Hardwood


The top was no better the first coat was very streaky
Brown Plant Wood Wood stain Grass


This is the underside, the plan is to slit the top equally along the widest section later.
Plant Wood Rectangle Wood stain Hardwood
 

Attachments

#90 ·
PTLT fitting hinges to the top

I wanted to conceal the opening joint as much as possible so I chose a pair of Blum Concealed Hinge Blind corner 95 deg hinges.

First up I split the table top in tha area I wanted the hinges.

Then following the installation template that was supplied I counterbored the round sunken sections and fitted them up.

Wood Bumper Gas Road surface Tints and shades


The instalation was fairly straight forward, however when I went to test the pivot the top would not swing up properly.
It appears, (and there is nothing documented on the packaging) that the hinges are only for material about 19mm in thickness, not twice that as is for my application.

I dismantled everything, cut a small 45 deg slope on each half and tried again.

Still not enough clearance

Wood Bumper Automotive exterior Tints and shades Automotive wheel system


Motor vehicle Automotive tire Tire Hood Tread


So using the table saw set at 15 deg I repeat the process depening the depth of the cut.
That produced a working joint but has given me a massive groove in the table top. Not a look that I wanted !

Wood Road surface Tints and shades Asphalt Water


Hood Automotive tire Wood Automotive lighting Road surface


I will have to leave it as I was most disapointed with the result and I am considering a complete rework of the top and a possible hinge design change.
Not a good result this far into the project, oh well such is life.

In closing the top now has its second coat of Black Japan although I have sanded it back,

To be continued. !!
 

Attachments

#91 ·
PTLT fitting hinges to the top

I wanted to conceal the opening joint as much as possible so I chose a pair of Blum Concealed Hinge Blind corner 95 deg hinges.

First up I split the table top in tha area I wanted the hinges.

Then following the installation template that was supplied I counterbored the round sunken sections and fitted them up.

Wood Bumper Gas Road surface Tints and shades


The instalation was fairly straight forward, however when I went to test the pivot the top would not swing up properly.
It appears, (and there is nothing documented on the packaging) that the hinges are only for material about 19mm in thickness, not twice that as is for my application.

I dismantled everything, cut a small 45 deg slope on each half and tried again.

Still not enough clearance

Wood Bumper Automotive exterior Tints and shades Automotive wheel system


Motor vehicle Automotive tire Tire Hood Tread


So using the table saw set at 15 deg I repeat the process depening the depth of the cut.
That produced a working joint but has given me a massive groove in the table top. Not a look that I wanted !

Wood Road surface Tints and shades Asphalt Water


Hood Automotive tire Wood Automotive lighting Road surface


I will have to leave it as I was most disapointed with the result and I am considering a complete rework of the top and a possible hinge design change.
Not a good result this far into the project, oh well such is life.

In closing the top now has its second coat of Black Japan although I have sanded it back,

To be continued. !!
Ouch! Not a fun development that far in! I think I would try removing the hinges, ripping the chamfered edges square again and reassembling with some mortised leaf hinges.

Good luck!
 

Attachments

#92 ·
PTLT I was ready to post as finished !!

I took photos of the "finished" Pallet Timber Low Table today and was going to post it as a finished project, but after seeing it in the bright sunlight I had second thoughts.

The finish was not as expected, even after four coats sanding in between the finish was less than acceptable.
That was after taking into consideration all the spots I had missed!

Plant Rectangle Outdoor furniture Wood Street furniture


The overall finish is poor even after I took just about every measure possible to prevent airborne particles.

Table Rectangle Wood Automotive exterior Composite material


The gap on the hinged top is ugly to say the least.
It certainly is not opening to 95 degrees at the moment.
I was reluctant to increase the gap even more without accurate knowledge of how to do so.

I will buy another set of these hinges and replicate the pivot and then incrementally remove material to allow 95 degs of movement in an effort to determine a satisfactory gap.
At present the hinged top stay the way it is for now.
The fixed section of the top is held in place by pocket hole screws fitted from underneath.

Hood Automotive lighting Automotive tire Motor vehicle Bumper


The inner section of the lid requires lining as its also ugly in this situation.
The lining is a seude material mounted on 3mm MDF and interference fit installation so it can be removed for maintenance and/or changed later if required

Wood Rectangle Plant Wood stain Gas


The finish I used was Feast Watsons Varnish and stain Black Japan, prompted from a Woodsmith article in issue 107

Wood Gas Automotive lighting Hardwood Wood stain


The current finish, if you could call it that,

Netbook Wood Table Rectangle Shade


Well I am going to put it away for now and revisit it later, after I conduct some hinge tests first.

Then re visit and repaint for the fifth time if only to see if I can get a nice shine! otherewise its on the footpath!!
 

Attachments

#93 ·
PTLT I was ready to post as finished !!

I took photos of the "finished" Pallet Timber Low Table today and was going to post it as a finished project, but after seeing it in the bright sunlight I had second thoughts.

The finish was not as expected, even after four coats sanding in between the finish was less than acceptable.
That was after taking into consideration all the spots I had missed!

Plant Rectangle Outdoor furniture Wood Street furniture


The overall finish is poor even after I took just about every measure possible to prevent airborne particles.

Table Rectangle Wood Automotive exterior Composite material


The gap on the hinged top is ugly to say the least.
It certainly is not opening to 95 degrees at the moment.
I was reluctant to increase the gap even more without accurate knowledge of how to do so.

I will buy another set of these hinges and replicate the pivot and then incrementally remove material to allow 95 degs of movement in an effort to determine a satisfactory gap.
At present the hinged top stay the way it is for now.
The fixed section of the top is held in place by pocket hole screws fitted from underneath.

Hood Automotive lighting Automotive tire Motor vehicle Bumper


The inner section of the lid requires lining as its also ugly in this situation.
The lining is a seude material mounted on 3mm MDF and interference fit installation so it can be removed for maintenance and/or changed later if required

Wood Rectangle Plant Wood stain Gas


The finish I used was Feast Watsons Varnish and stain Black Japan, prompted from a Woodsmith article in issue 107

Wood Gas Automotive lighting Hardwood Wood stain


The current finish, if you could call it that,

Netbook Wood Table Rectangle Shade


Well I am going to put it away for now and revisit it later, after I conduct some hinge tests first.

Then re visit and repaint for the fifth time if only to see if I can get a nice shine! otherewise its on the footpath!!
Despite your problems with the hinge and paint, it is still a very nice project that came very well. A great design and a useful table with storage. I don't think any of us are ever totally satisfied with our own work. All these little problems to be solved are the building blocks to improving our skill level and are therefore more positive than negative.
 

Attachments

#94 ·
PTLT Hinge rework

I purchased a second set of Concealed Hinge Blind Corner 95 Degree to do hinge rework on.
Firstly the hinges are only designed for 19mm timber in their present form.
This deduced from a graphic on the template and my prototype evaluation.
However you can use them on timber larger if you wish.

Here is how I used them on 38mm timber

Wood Tool Wood stain Flooring Hardwood


Simply a matter of recessing them

Wood Floor Wood stain Hardwood Flooring


This is only a prototype to enable me to complete my PTLT top with no opening gap when closed

It appears that the hinges should have the mounting plate as the fixed section and the 35 mm hinge section as the pivoting door/top

Font Material property Parallel Engineering Pattern


I think unless somebody else knows otherwise its purely a cosmetic result

Here is the hinge pivoted in both aspects

Handheld power drill Wood Drill Tool Wood stain


Wood Wood stain Hardwood Flooring Plank


I also found the template for the instalation left a lot to be desired, in particular no defined center lines were marked on the template, and info there was misleading.
Hinge drilling the center line for the 35mm hole does not extent to the edge of the template

Font Material property Parallel Engineering Pattern


The 21.5mm line on the mounting plate is not centralised on the 32mm line and the the large arrow at the top near the 5mm hole (B) is 3mm too low.
The second large arrow below the 21.5mm offset line is 5mm too high for the bottom hole!

If you use the 21.5mm off set arrow thinking its the center it miss aligns the 5mm Mounting plate holes

Ruler Office ruler Wood Rectangle Wood stain


The 21.5mm off set arrow is actually 3mm above the 16mm center line!

Ruler Rectangle Office ruler Measuring instrument Font


Ruler Rectangle Office ruler Font Measuring instrument


This is where the true centerline is.

Ruler Rectangle Office ruler Measuring instrument Font


A call to the distributor of the product was made and the sales rep I spoke to took it all on board and agreed it could be laid out clearer by extending center lines to the edge of the template in both cases.

He indicated it would be corrected at the next print run. (Stand By)
Meanwhile if you use the hinges draw your own center lines on first before starting work!!

Just goes to show some times its worth the explantion.

Any way back to the PTLT top

Here is the prototype next to the table

Wood Rectangle Wood stain Tints and shades Hardwood


And in its open position

Wood Wood stain Flooring Rectangle Hardwood


We now have the correct 95 degrees opening this time.

Conclusion:

Looks like the existing table top will be removed, a new one redesigned from the prototype and refitted and re Varnished and stained…soon.
 

Attachments

#95 ·
PTLT Hinge rework

I purchased a second set of Concealed Hinge Blind Corner 95 Degree to do hinge rework on.
Firstly the hinges are only designed for 19mm timber in their present form.
This deduced from a graphic on the template and my prototype evaluation.
However you can use them on timber larger if you wish.

Here is how I used them on 38mm timber

Wood Tool Wood stain Flooring Hardwood


Simply a matter of recessing them

Wood Floor Wood stain Hardwood Flooring


This is only a prototype to enable me to complete my PTLT top with no opening gap when closed

It appears that the hinges should have the mounting plate as the fixed section and the 35 mm hinge section as the pivoting door/top

Font Material property Parallel Engineering Pattern


I think unless somebody else knows otherwise its purely a cosmetic result

Here is the hinge pivoted in both aspects

Handheld power drill Wood Drill Tool Wood stain


Wood Wood stain Hardwood Flooring Plank


I also found the template for the instalation left a lot to be desired, in particular no defined center lines were marked on the template, and info there was misleading.
Hinge drilling the center line for the 35mm hole does not extent to the edge of the template

Font Material property Parallel Engineering Pattern


The 21.5mm line on the mounting plate is not centralised on the 32mm line and the the large arrow at the top near the 5mm hole (B) is 3mm too low.
The second large arrow below the 21.5mm offset line is 5mm too high for the bottom hole!

If you use the 21.5mm off set arrow thinking its the center it miss aligns the 5mm Mounting plate holes

Ruler Office ruler Wood Rectangle Wood stain


The 21.5mm off set arrow is actually 3mm above the 16mm center line!

Ruler Rectangle Office ruler Measuring instrument Font


Ruler Rectangle Office ruler Font Measuring instrument


This is where the true centerline is.

Ruler Rectangle Office ruler Measuring instrument Font


A call to the distributor of the product was made and the sales rep I spoke to took it all on board and agreed it could be laid out clearer by extending center lines to the edge of the template in both cases.

He indicated it would be corrected at the next print run. (Stand By)
Meanwhile if you use the hinges draw your own center lines on first before starting work!!

Just goes to show some times its worth the explantion.

Any way back to the PTLT top

Here is the prototype next to the table

Wood Rectangle Wood stain Tints and shades Hardwood


And in its open position

Wood Wood stain Flooring Rectangle Hardwood


We now have the correct 95 degrees opening this time.

Conclusion:

Looks like the existing table top will be removed, a new one redesigned from the prototype and refitted and re Varnished and stained…soon.
Moving right along…
 

Attachments

#98 ·
PTLT fixed section and hinge rework

I decided to get on with the rework on the Pallet Timber Low Table, this weekend so after dismantling everything and cutting off the ugly vee grove at the hinge joints I found I would have to re manufacture the fixed section of the table top due to so much material being removed.

I replicated the fixed section as close as possile to the dimensions of the larger tilt up section.

Here it is about to get the edges profiled.

Wood Rectangle Wood stain Flooring Floor


Due to the material being removed from the edge of original table top section, it meant I had to not only mortice them down to the correct height but re sink the holes in their new locations.

I made a jig to do this recessing as it was now recessed 19mm and I didnt want to screw uo again!

Handwriting Font Wood Road surface Writing


Jig Description:
The jig has two parts,

Part 1 of 2 The large section is a morticing template and,
Part 2 of 2 A small reversable insert, designed to insert into the morticing template simply to locate the center of the circle and the reverse position to locate the two screws, due to the work required is below the surface of the timber in the recess.

Pt 1 The morticing component
Saw Wood Table Handheld power drill Drill


Pt 2 The drilling Guide
Here it is set up for the ciircle simply align with the pencil line and drill
Wood Handwriting Gas Rectangle Hardwood


and for the cross section reversed and re inserted.
Wood Hardwood Wood stain Plank Wooden block


Here are both the sections morticed,
Wood Rectangle Wood stain Hardwood Plank


All worked well
Wood Automotive tire Gas Flooring Tints and shades

I soon had them assembled for a test run before commencing the stain and varnish again.
Wood Wood stain Hardwood Composite material Rectangle


No more ugly gap
Wood Rectangle Tints and shades Shade Hardwood

Might be a bit hard to see with the extereme contrast.

And opened!
Hood Wood Automotive exterior Rectangle Bumper


Sucess at last !
 

Attachments

#99 ·
PTLT fixed section and hinge rework

I decided to get on with the rework on the Pallet Timber Low Table, this weekend so after dismantling everything and cutting off the ugly vee grove at the hinge joints I found I would have to re manufacture the fixed section of the table top due to so much material being removed.

I replicated the fixed section as close as possile to the dimensions of the larger tilt up section.

Here it is about to get the edges profiled.

Wood Rectangle Wood stain Flooring Floor


Due to the material being removed from the edge of original table top section, it meant I had to not only mortice them down to the correct height but re sink the holes in their new locations.

I made a jig to do this recessing as it was now recessed 19mm and I didnt want to screw uo again!

Handwriting Font Wood Road surface Writing


Jig Description:
The jig has two parts,

Part 1 of 2 The large section is a morticing template and,
Part 2 of 2 A small reversable insert, designed to insert into the morticing template simply to locate the center of the circle and the reverse position to locate the two screws, due to the work required is below the surface of the timber in the recess.

Pt 1 The morticing component
Saw Wood Table Handheld power drill Drill


Pt 2 The drilling Guide
Here it is set up for the ciircle simply align with the pencil line and drill
Wood Handwriting Gas Rectangle Hardwood


and for the cross section reversed and re inserted.
Wood Hardwood Wood stain Plank Wooden block


Here are both the sections morticed,
Wood Rectangle Wood stain Hardwood Plank


All worked well
Wood Automotive tire Gas Flooring Tints and shades

I soon had them assembled for a test run before commencing the stain and varnish again.
Wood Wood stain Hardwood Composite material Rectangle


No more ugly gap
Wood Rectangle Tints and shades Shade Hardwood

Might be a bit hard to see with the extereme contrast.

And opened!
Hood Wood Automotive exterior Rectangle Bumper


Sucess at last !
You aced it Robert! Looks great and a creative use of those Euro hinges too.
 

Attachments

#102 ·
The Poor Man's Joint...inhale and remember you are still alive

Picture this:
Here you are as poor as,

No jointing tools available,
No morticer.
No Tennoning Jig.
No pocket hole gear.
No Biscuit jointer.
No finger or dovetail jigs, just a trusy table saw and a few clamps.

You need to make a reasonably large cross section joint and all you have is a collection of recycled timber pallets.

Now back to reality.

Being Sunday and a nice day I was outside tidying up.

I started to think while looking at some of my recycle clutter would it be possible to laminate some of it into bigger size lumber.

So I did I made this table leg

Rectangle Wood Gas Tints and shades Font


Rectangle Wood Composite material Tints and shades Automotive tire


Laminated together 1Ă—45 degree joint and 1Ă—90 deg joint inherently weak and totally reliant on strong glue.

So thinking some more I tried again, this time overlapping the ajoining joint profiles and sides.

Activity No 2

Lamination 1

Rectangle Wood Wood stain Hardwood Tints and shades


Lamination 2

Brown Wood Rectangle Wood stain Hardwood


Finally Lamination 3

Wood Rectangle Wood stain Hardwood Varnish


All stacked up and looking something like this as an exploded view.

Wood Rectangle Wood stain Material property Hardwood


Glue up

I glued them all up and let them set

Glue up Shot 1

Thigh Gas Human leg Knee Electric blue


Glue up Shot 2

Wheel Tire Automotive tire Gas Auto part


Glue up Shot 3

Wood Automotive tire Gas Tints and shades Hardwood


Once the glue had dryed I sanded the edges and did a bit of t@rd polishing on it simply to make it a bit more photogenic, and because as well I liked the end grain effect.

Wood Rectangle Flooring Plank Wood stain


Another view

Rectangle Wood Plank Flooring Wood stain


Was the joint accurate? I think it was, however you be the judge.

External Check

Wood Rectangle Triangle Hardwood Electric blue


another view

Wood Rectangle Gas Hardwood Flooring


Internal check

Wood Rectangle Wood stain Hardwood Flooring


I guess you do not even need to make a 45 deg joint but I did it for symmerty.

Conclusion:

A strong joint nice looking end grains lots of surface area, accurate results and simple to make.
 

Attachments

#103 ·
The Poor Man's Joint...inhale and remember you are still alive

Picture this:
Here you are as poor as,

No jointing tools available,
No morticer.
No Tennoning Jig.
No pocket hole gear.
No Biscuit jointer.
No finger or dovetail jigs, just a trusy table saw and a few clamps.

You need to make a reasonably large cross section joint and all you have is a collection of recycled timber pallets.

Now back to reality.

Being Sunday and a nice day I was outside tidying up.

I started to think while looking at some of my recycle clutter would it be possible to laminate some of it into bigger size lumber.

So I did I made this table leg

Rectangle Wood Gas Tints and shades Font


Rectangle Wood Composite material Tints and shades Automotive tire


Laminated together 1Ă—45 degree joint and 1Ă—90 deg joint inherently weak and totally reliant on strong glue.

So thinking some more I tried again, this time overlapping the ajoining joint profiles and sides.

Activity No 2

Lamination 1

Rectangle Wood Wood stain Hardwood Tints and shades


Lamination 2

Brown Wood Rectangle Wood stain Hardwood


Finally Lamination 3

Wood Rectangle Wood stain Hardwood Varnish


All stacked up and looking something like this as an exploded view.

Wood Rectangle Wood stain Material property Hardwood


Glue up

I glued them all up and let them set

Glue up Shot 1

Thigh Gas Human leg Knee Electric blue


Glue up Shot 2

Wheel Tire Automotive tire Gas Auto part


Glue up Shot 3

Wood Automotive tire Gas Tints and shades Hardwood


Once the glue had dryed I sanded the edges and did a bit of t@rd polishing on it simply to make it a bit more photogenic, and because as well I liked the end grain effect.

Wood Rectangle Flooring Plank Wood stain


Another view

Rectangle Wood Plank Flooring Wood stain


Was the joint accurate? I think it was, however you be the judge.

External Check

Wood Rectangle Triangle Hardwood Electric blue


another view

Wood Rectangle Gas Hardwood Flooring


Internal check

Wood Rectangle Wood stain Hardwood Flooring


I guess you do not even need to make a 45 deg joint but I did it for symmerty.

Conclusion:

A strong joint nice looking end grains lots of surface area, accurate results and simple to make.
Looks like you got coming & going… The 45* miter joint should NOT have been done…

Just rotating the other Two would result in a very good Half-Lap type of joint… Much stronger than what you did. LOL

Just my 2 cents…
 

Attachments

#111 ·
A Gate for No 1 Son

My Number one son, Adam and his family sold their home over Christmas New Year, and moved into a rental property pending finding a new abode.

They have a family dog so the yard had to be dog proofed.

The owners were OK with us making a gate and closing off under the house so we set to work.

Wood Fence Plant Road surface Grass


We saw a tile shop and out front was a stack of very good packing timber, they were happy for us to take as much as we wanted so a load went into the ute.

Outdoor bench Wood Plant Grass Outdoor furniture


Plant Wood Outdoor bench Table Grass


It looked to be a pine genus of Indian origin, had all the appropriate stamp for bugs and preservation so I set about de nailing it all.

It took about 2 hours to achieve the desired result

Plant Wood Outdoor furniture Table Outdoor table


We ended up with this stockpile as a result

Wood Grass Groundcover Hardwood Wood stain


Outdoor bench Wood Grass Outdoor furniture Wood stain


I then ripped about five lengths in half with portable hand power saw to make the pallings, leaving the ends intact for later docking.
With a drop saw cut the frame rails and stiles to length half lap jointed it all together and added a diagonal cross brace for the frame.

Correction: The correct terminology for the joints I used is a T halvng joint not a Half Lap joint.

Product Rectangle Line Parallel Font


Wood Fence Wood stain Hardwood Plank


All the pailings were cut to length then mitered on the corners as preparation for fixing.
Then with the assistance of a Paslode nail gun fixed the pailings to the frame, and added a catch to the original location at the bottom.

We then made a matching under floor closure for the opening on the left.

As you can see there was a drain opening right in the walkway so some left overs were cut to plug the opening also.

This was the finished result:-

The new gate
Wood Fence Wood stain Picket fence Home fencing


The under floor cover

Plant Road surface Wood Automotive tire Rectangle


The drain cover

Wood Automotive tire Road surface Lifebuoy Gas


Tools and Materials

Tools used
Drop saw (which is actually a compound sliding miter saw)
Portable power saw
Paslode Nail Gun

Materials

All recycled or reused hardware
Material cost Nil.
Hardware cost Nil.
Life expectancy hoped to be at least 12 months.

We kept the original gate for replacement later if the landlord desires

With the fun part now over it was to start hauling furniture and Chattels!!

Enjoy
 

Attachments

#112 ·
A Gate for No 1 Son

My Number one son, Adam and his family sold their home over Christmas New Year, and moved into a rental property pending finding a new abode.

They have a family dog so the yard had to be dog proofed.

The owners were OK with us making a gate and closing off under the house so we set to work.

Wood Fence Plant Road surface Grass


We saw a tile shop and out front was a stack of very good packing timber, they were happy for us to take as much as we wanted so a load went into the ute.

Outdoor bench Wood Plant Grass Outdoor furniture


Plant Wood Outdoor bench Table Grass


It looked to be a pine genus of Indian origin, had all the appropriate stamp for bugs and preservation so I set about de nailing it all.

It took about 2 hours to achieve the desired result

Plant Wood Outdoor furniture Table Outdoor table


We ended up with this stockpile as a result

Wood Grass Groundcover Hardwood Wood stain


Outdoor bench Wood Grass Outdoor furniture Wood stain


I then ripped about five lengths in half with portable hand power saw to make the pallings, leaving the ends intact for later docking.
With a drop saw cut the frame rails and stiles to length half lap jointed it all together and added a diagonal cross brace for the frame.

Correction: The correct terminology for the joints I used is a T halvng joint not a Half Lap joint.

Product Rectangle Line Parallel Font


Wood Fence Wood stain Hardwood Plank


All the pailings were cut to length then mitered on the corners as preparation for fixing.
Then with the assistance of a Paslode nail gun fixed the pailings to the frame, and added a catch to the original location at the bottom.

We then made a matching under floor closure for the opening on the left.

As you can see there was a drain opening right in the walkway so some left overs were cut to plug the opening also.

This was the finished result:-

The new gate
Wood Fence Wood stain Picket fence Home fencing


The under floor cover

Plant Road surface Wood Automotive tire Rectangle


The drain cover

Wood Automotive tire Road surface Lifebuoy Gas


Tools and Materials

Tools used
Drop saw (which is actually a compound sliding miter saw)
Portable power saw
Paslode Nail Gun

Materials

All recycled or reused hardware
Material cost Nil.
Hardware cost Nil.
Life expectancy hoped to be at least 12 months.

We kept the original gate for replacement later if the landlord desires

With the fun part now over it was to start hauling furniture and Chattels!!

Enjoy
A COOL rags to riches event!

Very NICE!

... and you had some wood left over for other things! :)
 

Attachments

#116 ·
1800 x700 Work bench

I have an ongoing problem with too many wood working Project Creations too much WW materials and not enough room.
There is very little I can do to improve the situation but dump "stuff" or work out a better storage system.
Dumping is not an option as I may as well give away my beloved woodworking activities, so this is what I did.

I had lots of recycled timber so I chose to convert them it into a work bench, thinking I could solve both problems at once so its really a storage bench for the time being.

I used 90mm x 45mm pine pieces as the frame and a recycled laminated desk top for the top surface and recycled melamine coated particle board for the lower shelf.

I built a bench similar to this one some time ago and copied its dimensions but has issues with the center saging.
Read as overloaded with stuff!.

This posed a problem for me second time around as I did not want 6 legs, meaning I had 4 x on each corner and 2 x in the middle front and back as I saw them as limiting my ability to utilise the 1800mm open length.

I eventually went with 5 x legs one centerally located as a compromise.

This is how I did it

Wood Wood stain Composite material Hardwood Gas


I built a basic frame using the recycled timber I has stashed away, cut up all the respective parts and then joinedthem all together with decking screws and Titebond glue.

I put a cross beam in the middle of the top and used a modified bridle joint to fit leg No 5.

This leg would support the top and prevent sagging no problems but not the bottom shelf so I decided to add a stopped housing jointoff this leg for the bottom shelf support.

Wood Cross Hardwood Composite material Tints and shades


The whole center leg is removable as I was concerned as to getting it in the doorway once completed.

Removable meaning there is a single screw holding the bridle joint to the top cross member and screws on the outside of the two horizontal sections supporting the lower shelf supports only, its a interference fit at the stopped joint at the center.

Opps No 1 If you wondered what the work below the stopped housing joint is well its a classic measure twice cut once situation. It looked terrible so I filled it with off cuts.

The End legs were fairly straight forward,

Table Wood Wood stain Plank Rectangle


The bottom shelf I made from two sections of melamine Particle board, as these were again recycled I was restricted in the width I wanted, by the time I squared them they wereonly 680mm deep (rats, needed 720mm ideal)

Opps No 2 I cut both pieces together to length on the table saw and cut the recesses for the center leg and the two respective end legs, by measuring from one end only, silly move!

Hood Wood Rectangle Road surface Flooring


Upon fit up only one fitted perfectly. How could this be I wondered and set about trying to find the error.

Wood Rectangle Wood stain Plank Shade


After running the tape back and forth I found the culprit, it was the center leg! it was offsest at the bridle joint!

The perils of working with recycled materials.

Wood Rectangle Table Wood stain Hardwood


Now this now was most annoying as I had no more materials to be able to fix it, so I had to now add bits to the rebate gap on the slelving ends.

Road surface Rectangle Asphalt Grey Floor


With this fixed I added the top,

Opps No 3 Now I find one leg was proud about 1mm, Oh no! what else could go wrong! as I had glued the legs on earlier removal was not an option.

So after some severe talking to myself I decided to use my trusty Japanese Pull saw to fix the problem.

The Fix
I sat a section of wood as a datum point and sawed off the offending protrusion !

This got me out of jail quite well Thank god for Pull saws,an easy fix!

Wood Wood stain Table Hardwood Plank


With all completed it was time to install the bench…... where is No4 Son when you need him! (Gone Back Home)

Aurora and I got it in no problems and as I fitted the table top in situ the removable leg issue was a non event

Wood Wood stain Hardwood Loom Plank


Well I still dont have any where near the amount of free space I thought it would create, I simply piled more junk on it.
So it looks like an ebay sell off of my treasured creations is the order !!

Enjoy!
 

Attachments

#117 ·
1800 x700 Work bench

I have an ongoing problem with too many wood working Project Creations too much WW materials and not enough room.
There is very little I can do to improve the situation but dump "stuff" or work out a better storage system.
Dumping is not an option as I may as well give away my beloved woodworking activities, so this is what I did.

I had lots of recycled timber so I chose to convert them it into a work bench, thinking I could solve both problems at once so its really a storage bench for the time being.

I used 90mm x 45mm pine pieces as the frame and a recycled laminated desk top for the top surface and recycled melamine coated particle board for the lower shelf.

I built a bench similar to this one some time ago and copied its dimensions but has issues with the center saging.
Read as overloaded with stuff!.

This posed a problem for me second time around as I did not want 6 legs, meaning I had 4 x on each corner and 2 x in the middle front and back as I saw them as limiting my ability to utilise the 1800mm open length.

I eventually went with 5 x legs one centerally located as a compromise.

This is how I did it

Wood Wood stain Composite material Hardwood Gas


I built a basic frame using the recycled timber I has stashed away, cut up all the respective parts and then joinedthem all together with decking screws and Titebond glue.

I put a cross beam in the middle of the top and used a modified bridle joint to fit leg No 5.

This leg would support the top and prevent sagging no problems but not the bottom shelf so I decided to add a stopped housing jointoff this leg for the bottom shelf support.

Wood Cross Hardwood Composite material Tints and shades


The whole center leg is removable as I was concerned as to getting it in the doorway once completed.

Removable meaning there is a single screw holding the bridle joint to the top cross member and screws on the outside of the two horizontal sections supporting the lower shelf supports only, its a interference fit at the stopped joint at the center.

Opps No 1 If you wondered what the work below the stopped housing joint is well its a classic measure twice cut once situation. It looked terrible so I filled it with off cuts.

The End legs were fairly straight forward,

Table Wood Wood stain Plank Rectangle


The bottom shelf I made from two sections of melamine Particle board, as these were again recycled I was restricted in the width I wanted, by the time I squared them they wereonly 680mm deep (rats, needed 720mm ideal)

Opps No 2 I cut both pieces together to length on the table saw and cut the recesses for the center leg and the two respective end legs, by measuring from one end only, silly move!

Hood Wood Rectangle Road surface Flooring


Upon fit up only one fitted perfectly. How could this be I wondered and set about trying to find the error.

Wood Rectangle Wood stain Plank Shade


After running the tape back and forth I found the culprit, it was the center leg! it was offsest at the bridle joint!

The perils of working with recycled materials.

Wood Rectangle Table Wood stain Hardwood


Now this now was most annoying as I had no more materials to be able to fix it, so I had to now add bits to the rebate gap on the slelving ends.

Road surface Rectangle Asphalt Grey Floor


With this fixed I added the top,

Opps No 3 Now I find one leg was proud about 1mm, Oh no! what else could go wrong! as I had glued the legs on earlier removal was not an option.

So after some severe talking to myself I decided to use my trusty Japanese Pull saw to fix the problem.

The Fix
I sat a section of wood as a datum point and sawed off the offending protrusion !

This got me out of jail quite well Thank god for Pull saws,an easy fix!

Wood Wood stain Table Hardwood Plank


With all completed it was time to install the bench…... where is No4 Son when you need him! (Gone Back Home)

Aurora and I got it in no problems and as I fitted the table top in situ the removable leg issue was a non event

Wood Wood stain Hardwood Loom Plank


Well I still dont have any where near the amount of free space I thought it would create, I simply piled more junk on it.
So it looks like an ebay sell off of my treasured creations is the order !!

Enjoy!
You have been busy….
 

Attachments

#120 ·
AKs ToolMakers Chest the begining Pt 1

A friend of mine asked me to make him a tool makers Chest.

He sent me a few photos and in the intrim I accepted the task.

A few months later about Dec 2014 he delivered a bundle of timber for the task.
We spoke about it and I said that I would be able to do nothing with it until 2015, he was OK with that.

A few days later I ran the metal detector over each piece checked everything visually and removed some foreign objects, marked it all up as mag tested and packed it away for the New Year.

The pack was a mixture of all sorts and sizes of what looked to be early Huon or Kauri Pine, quite old and used for school desks and cupboards, tomy knowledge and very hard to get these days.

Wood Table Outdoor bench Outdoor furniture Wood stain


Along with some common garden variety pine
Wood Musical instrument Outdoor bench Wood stain Hardwood


It had paint and varnish on most of the pieces
Wood Road surface Rectangle Composite material Gas


I wondered what I had gotten myself in for.
 

Attachments

#121 ·
AKs ToolMakers Chest the begining Pt 1

A friend of mine asked me to make him a tool makers Chest.

He sent me a few photos and in the intrim I accepted the task.

A few months later about Dec 2014 he delivered a bundle of timber for the task.
We spoke about it and I said that I would be able to do nothing with it until 2015, he was OK with that.

A few days later I ran the metal detector over each piece checked everything visually and removed some foreign objects, marked it all up as mag tested and packed it away for the New Year.

The pack was a mixture of all sorts and sizes of what looked to be early Huon or Kauri Pine, quite old and used for school desks and cupboards, tomy knowledge and very hard to get these days.

Wood Table Outdoor bench Outdoor furniture Wood stain


Along with some common garden variety pine
Wood Musical instrument Outdoor bench Wood stain Hardwood


It had paint and varnish on most of the pieces
Wood Road surface Rectangle Composite material Gas


I wondered what I had gotten myself in for.
It's always good to have a challenge Rob. That is when good things happen (and maybe a few problems arise too). A great growing opportunity.
 

Attachments

#123 ·
AKs ToolMakers Chest Thicknessing Pt 2

Today I busted open the pack, consulted my drawings for the concept, selected some timber of a suitable size for the chest frame and ran the lengths through the thicknesser to clean them up and get some consistant thicknesses

The timber came up a treat, I am not sure now that it is in fact pine, as I have never seen the dark streaks before
Plant Wood Outdoor furniture Gas Hardwood


The smaller sections most certainly are pine, and again cleaned up OK
Wood Handwriting Shipping box Gas Hardwood


I intend to use the long piece for the top and sides the piece with the holes in it for the base, otherwise that piece would be either wasted or repaired or resawn for drawers.

Well its time for a coffee and tomorrow out with the sander.
 

Attachments

#124 ·
AKs ToolMakers Chest Thicknessing Pt 2

Today I busted open the pack, consulted my drawings for the concept, selected some timber of a suitable size for the chest frame and ran the lengths through the thicknesser to clean them up and get some consistant thicknesses

The timber came up a treat, I am not sure now that it is in fact pine, as I have never seen the dark streaks before
Plant Wood Outdoor furniture Gas Hardwood


The smaller sections most certainly are pine, and again cleaned up OK
Wood Handwriting Shipping box Gas Hardwood


I intend to use the long piece for the top and sides the piece with the holes in it for the base, otherwise that piece would be either wasted or repaired or resawn for drawers.

Well its time for a coffee and tomorrow out with the sander.
You sure wouldn't find pine that looks like that anywhere around here.
 

Attachments

#126 ·
AKs ToolMakers Chest Drawer Making Pt 3

Today saw a full day designing and making the drawers for the toolMakers Chest.

From the offcuts supplied I ripped and thicknessed lots of timber to make the frames for the nine drawers.

3 x full width and 6 x half width.

This was the plan rip stock joint it and thicknesss it rebate the frames for the drawer bases and dovetail joint them all together.

Table Wood Rectangle Wood stain Hardwood


Wood Rectangle Wood stain Flooring Plank


The plan worked but not completely, it did not work fully for a couple of reasons, firstly I should not have rebated the timber for the drawer bases before doing the joints.

Wood Rectangle Wood stain Hardwood Plank


The reason being its almost impossible to preposition each piece exactly in the middle of the Gifkins Dovetail Jig jig and,

Attempting to dovetail timber less than 40mm does not produce a nice looking joint,I think finger joints would be more applicable.

In hindsight I would consider the need for at least three pins or three tails to make a suitable joint, and as a dovetail bit is about 15mm diameter this puts a suitable joint in timber at 35mm +.

My Gifkins dovetail jig is not designed to be used with timber 40 mm width or below.

This is a picture of the rear of the Jig where I had to pack out the area between the locks to enable the clamp to hold correctly.

Wood Gas Engineering Machine Electric blue


Looking at the front the clamp arrangment is also a bit dodgy
Table Wood Gas Flooring Machine


So I am of the belief that if you are jointing anything smaller than 40 mm that one should not consider Dovetailing as a means of jointing.

Tasks, tomorrow its a rebuild of the six small drawers, for no other reason other than that I was not completely happy with the results and cutting the rebates first up was a fail, as there was too much missalignment at assembly.

Here is all my days work.

The three full width drawers at 40mm height.

They will survive.

Wood Rectangle Wood stain Composite material Hardwood


And a couple of shots of the six smaller drawers destined for rework.

Wood Rectangle Wood stain Flooring Plank


Property Rectangle Wood Wood stain Floor


Just goes to show after many years of wood working you can always learn something new when making projects if you try to build from concept drawings.
 

Attachments

#127 ·
AKs ToolMakers Chest Drawer Making Pt 3

Today saw a full day designing and making the drawers for the toolMakers Chest.

From the offcuts supplied I ripped and thicknessed lots of timber to make the frames for the nine drawers.

3 x full width and 6 x half width.

This was the plan rip stock joint it and thicknesss it rebate the frames for the drawer bases and dovetail joint them all together.

Table Wood Rectangle Wood stain Hardwood


Wood Rectangle Wood stain Flooring Plank


The plan worked but not completely, it did not work fully for a couple of reasons, firstly I should not have rebated the timber for the drawer bases before doing the joints.

Wood Rectangle Wood stain Hardwood Plank


The reason being its almost impossible to preposition each piece exactly in the middle of the Gifkins Dovetail Jig jig and,

Attempting to dovetail timber less than 40mm does not produce a nice looking joint,I think finger joints would be more applicable.

In hindsight I would consider the need for at least three pins or three tails to make a suitable joint, and as a dovetail bit is about 15mm diameter this puts a suitable joint in timber at 35mm +.

My Gifkins dovetail jig is not designed to be used with timber 40 mm width or below.

This is a picture of the rear of the Jig where I had to pack out the area between the locks to enable the clamp to hold correctly.

Wood Gas Engineering Machine Electric blue


Looking at the front the clamp arrangment is also a bit dodgy
Table Wood Gas Flooring Machine


So I am of the belief that if you are jointing anything smaller than 40 mm that one should not consider Dovetailing as a means of jointing.

Tasks, tomorrow its a rebuild of the six small drawers, for no other reason other than that I was not completely happy with the results and cutting the rebates first up was a fail, as there was too much missalignment at assembly.

Here is all my days work.

The three full width drawers at 40mm height.

They will survive.

Wood Rectangle Wood stain Composite material Hardwood


And a couple of shots of the six smaller drawers destined for rework.

Wood Rectangle Wood stain Flooring Plank


Property Rectangle Wood Wood stain Floor


Just goes to show after many years of wood working you can always learn something new when making projects if you try to build from concept drawings.
It certainly looks ok, though I would rather use my scroll saw for dovetails Rob. Stock thickness is not an issue nor are the dovetail sizes, and while it isn't quite as fast as using a dovetail jig it is still pretty quick and easy if the work process is efficient.
 

Attachments

#130 ·
AKs ToolMakers Chest Tweeking the joints Pt 4

We left off the Chest yesterday after making the 6Ă—30mm Drawers and me being unhappy with the results.

Well today I revisited the joints and the mess I had made of them. Rather than scrap the lot and do finger joints I opted to attempt a workable repair.

This took quite a lot of self encouragement as I didnt think it was at all achieavable however I was wrong.

How I did it:-
1 I examined all the six drawers and the missmatched sections and marked the sections of material needing removal to effect a level fitup.
2. I used a sacrificial off cut first up to perfect the procedure and to re set the Gifkins jig and recut the piece to fit the missmatched pins at the new setting.
3. Fitted it up and found that I could again remove more material to better correct the missmatch.
4. I did this and produced an acceptable result abeit the joints were now much looser.
5. Then set to work on the individual pieces needing rework.

Here are the inital raw results

The A sides.

Wood Rectangle Wood stain Plank Hardwood


The B sides.

Brown Rectangle Wood Wood stain Plank


The C sides.

Wood Rectangle Plant Wood stain Tree


and finally the D sides.

Rectangle Wood Wood stain Plank Flooring


I was happy with the preliminary work and continued on finishing all the drawers..

Brown Wood Rectangle Wood stain Plank


A reasonable raw result was obtained.

Wood Rectangle Flooring Hardwood Wood stain


So it was off for a lunch break pleased with the results.
 

Attachments

#131 ·
AKs ToolMakers Chest Tweeking the joints Pt 4

We left off the Chest yesterday after making the 6Ă—30mm Drawers and me being unhappy with the results.

Well today I revisited the joints and the mess I had made of them. Rather than scrap the lot and do finger joints I opted to attempt a workable repair.

This took quite a lot of self encouragement as I didnt think it was at all achieavable however I was wrong.

How I did it:-
1 I examined all the six drawers and the missmatched sections and marked the sections of material needing removal to effect a level fitup.
2. I used a sacrificial off cut first up to perfect the procedure and to re set the Gifkins jig and recut the piece to fit the missmatched pins at the new setting.
3. Fitted it up and found that I could again remove more material to better correct the missmatch.
4. I did this and produced an acceptable result abeit the joints were now much looser.
5. Then set to work on the individual pieces needing rework.

Here are the inital raw results

The A sides.

Wood Rectangle Wood stain Plank Hardwood


The B sides.

Brown Rectangle Wood Wood stain Plank


The C sides.

Wood Rectangle Plant Wood stain Tree


and finally the D sides.

Rectangle Wood Wood stain Plank Flooring


I was happy with the preliminary work and continued on finishing all the drawers..

Brown Wood Rectangle Wood stain Plank


A reasonable raw result was obtained.

Wood Rectangle Flooring Hardwood Wood stain


So it was off for a lunch break pleased with the results.
Well done Robert. There is a way to tighten up those loose dovetail joints, but easiest if they were left protruding a little. here is a blog about it. It might not work on this project, but good for future reference. I always leave my dovetails a little proud of the surface for just that reason. If you try it on these drawers I suggest that instead of using a ballpeen hammer, it would be best to use a rod with a smaller rounded end that you can strike with your hammer so you don't hit the surrounding sides.
 

Attachments

#133 ·
AKs ToolMakers Chest Filling Sanding and Routing 9 Drawers

Well here I am back again with the afternoons progress.

I finished all the drawer bases using available MDF and Plywood 2x were MDF offcuts and 7 x were Plywood offcuts.

I then dry fitted everything together to ensure it was ready to glue.

I set to work glueing everything up using a paint brush to apply the Titebond III.

Once they were glued on went the band clamps and a check for squareness done.
As I didnt have enough band clamps the drawers were done in three secessions which took a lot longer than normal.

Once the glue was dry I then did an initial sand to remove all the rough edges.
Next came the Timber Mate application on all the nicks and exposed rebate holes.
Once that was done and allwas dry everyting went through the drum sander at 80 G to level to top face and the bottoms.

Setting up the shaper I then edge rounded the four inside edges and three outside edges those being B, C and D.

The A face will be used to attach drawer fronts so very little finishing was done there, including not filling of the visible rebate area.

Then 120 grit finish to remove router lines and general tidy up of corners.

The drawers are now finished construction wise for the time being.

The end results are begining to look quite nice.

The Rough finished A Side


Wood Rectangle Plank Hardwood Wood stain


The Profiled and Sanded B Side.


Wood Rectangle Packing materials Wood stain Flooring


The Profiled and Sanded C and D Side.


Rectangle Tableware Wood Outdoor furniture Hardwood


All the drawers together, looking nice but they are actually the backs of the drawers.

Wood Wood stain Rectangle Plank Flooring


All that is left to do is to now is to add the fronts, which will occur after the Chest frame is completed.

I am pleased with how the smaller drawers in particular turned out today, my initial concerns regarding them being too small to dove tail may have been misfounded, regardless of having to effect some repair procedures mid construction.

Timber Used :-
Pine and Maple for the frames
5mm Plywood and 5mm MDF for the bases
I certainly learned a lot in regard to working with dovetails and what actions are required to correct errors.
 

Attachments

#134 ·
AKs ToolMakers Chest Filling Sanding and Routing 9 Drawers

Well here I am back again with the afternoons progress.

I finished all the drawer bases using available MDF and Plywood 2x were MDF offcuts and 7 x were Plywood offcuts.

I then dry fitted everything together to ensure it was ready to glue.

I set to work glueing everything up using a paint brush to apply the Titebond III.

Once they were glued on went the band clamps and a check for squareness done.
As I didnt have enough band clamps the drawers were done in three secessions which took a lot longer than normal.

Once the glue was dry I then did an initial sand to remove all the rough edges.
Next came the Timber Mate application on all the nicks and exposed rebate holes.
Once that was done and allwas dry everyting went through the drum sander at 80 G to level to top face and the bottoms.

Setting up the shaper I then edge rounded the four inside edges and three outside edges those being B, C and D.

The A face will be used to attach drawer fronts so very little finishing was done there, including not filling of the visible rebate area.

Then 120 grit finish to remove router lines and general tidy up of corners.

The drawers are now finished construction wise for the time being.

The end results are begining to look quite nice.

The Rough finished A Side


Wood Rectangle Plank Hardwood Wood stain


The Profiled and Sanded B Side.


Wood Rectangle Packing materials Wood stain Flooring


The Profiled and Sanded C and D Side.


Rectangle Tableware Wood Outdoor furniture Hardwood


All the drawers together, looking nice but they are actually the backs of the drawers.

Wood Wood stain Rectangle Plank Flooring


All that is left to do is to now is to add the fronts, which will occur after the Chest frame is completed.

I am pleased with how the smaller drawers in particular turned out today, my initial concerns regarding them being too small to dove tail may have been misfounded, regardless of having to effect some repair procedures mid construction.

Timber Used :-
Pine and Maple for the frames
5mm Plywood and 5mm MDF for the bases
I certainly learned a lot in regard to working with dovetails and what actions are required to correct errors.
COOL drawers!

You are making GOOD progress…

... now, to install them… :) LOL
 

Attachments

#137 ·
AKs ToolMakers Chest Carcass Assembly

Today saw some good results along with some not so good ones.

Trying to work professional results using amateur skills I guess produces a result some where in between, anyway I had a great day learning how to overcome self inflicted errors.

I had spent some previous hours attempting to determine how to mount the drawers in the chest, there was no "minature slides" around so I gave up on the slide idea.

I chose to use plywood support separators for the drawers mainly to keep the overall height down and set to work cutting stopped dados in the sides to accept them.
The first challenge I discovered was that I did not have a 7mm router bit so I used a 6.3 mm 1/4 " one and a steel rule to enlarge the rebate to fit the 6 to whatever mm plywood I had, every spot I gauged it up gave different results ranging from 6mm to 6.5mm.
This took ages to do, mainly because of the time taken up with setting up, checking correct positions, clamping and then rechecking everything before each cut was ready to go.

Now trying to produce repetitive dados in the frame sides made me lean towards using my shaper, so it was off with the existing fence and use a length of wood and clamps as a guide,

Here is a shot of the setup and the very first cuts, all went really well and I was able to mirror the opposite side OK and used a backer block to prevent tearout.

Table Wood Wheel Automotive exterior Workbench


Wood Rectangle Floor Wood stain Hardwood


Only problem was it was in the incorrect location! ....it was right smack in the middle of where the drawer slide was going to go. So I stopped took out my eraser and removed all the additional lines I had made and now no longer needed.

I continued on adjusting the fence and checking the setup more closely this time (well so I thought) and continued on
It wasnt untill I saw a few dados completed that the stop/start points were all over the place.

OMG how could this be? then I realised when I reset the fence I didnt realign the center point for the stop start index as well.
This really annoyed me as I knew I was going to have to try and recut the dados somehow.

Wood Rectangle Beige Flooring Floor


Now attempting to reset my make shift fence correctly and get everything lined up again was in my mind to me almost impossible and would lead to nothing but a wriggly mess. I didnt have enough timber to re do the frame either !

So I made a jig that would stay parallel on the shaper top for a start, I then used the backer I was using to reset the height of the cutter, that was a stroke of luck I tell you as I had changed bits to do round over of the ply!

A more defined center line was added as well!

Wood Rectangle Floor Wood stain Composite material


I set everything up again and set to work expecting the worst however I pulled one out of the hat and got a much better result than I ever expected.

Wood Rectangle Wood stain Hardwood Plank


I was so surprised with my ability to align everything by just my eye, it gave me increased confidence and I pressed on making the support bases for the full length drawers and dry asembled everything.

Wood Wood stain Floor Flooring Hardwood


Beavering away I then completed the six half size drawer frames and dry assembled them also,

Things were really looking up!

Wood Rectangle Natural material Wood stain Hardwood


The Opps fix:
I cut a secton of timber from scrap and glued it in the goof area and later sanded it off, could not do much more than that.

Wood Rectangle Flooring Wood stain Floor


The 7mm Dado:
How I obtained a 7mm dado with a 6.3mm bit. Possibly not something to recommend to WW learners but it was my "fix" (I cannot believe how much variation ply wood has…its almost rubbish !!)

Rectangle Wood Table Flooring Floor


As the first cut required me to use a back cutting method I chose to use the rule first up and after removal made a normal cut thus removing the run on problem from the backcutting situation.

Well the day is done, I wasted lots of time but eventually obtained some satisfactory results.

Wood Automotive exterior Hardwood Rectangle Gas


Next comes the completion of the top box and the figureing out how the disappearing front door will work.

Editing Note: In my original post I used the terminology Rabbet / Rebate, this has since been changed to more accurately refelect the correct treminology of the groove which is a Stopped Dado
 

Attachments

#138 ·
AKs ToolMakers Chest Carcass Assembly

Today saw some good results along with some not so good ones.

Trying to work professional results using amateur skills I guess produces a result some where in between, anyway I had a great day learning how to overcome self inflicted errors.

I had spent some previous hours attempting to determine how to mount the drawers in the chest, there was no "minature slides" around so I gave up on the slide idea.

I chose to use plywood support separators for the drawers mainly to keep the overall height down and set to work cutting stopped dados in the sides to accept them.
The first challenge I discovered was that I did not have a 7mm router bit so I used a 6.3 mm 1/4 " one and a steel rule to enlarge the rebate to fit the 6 to whatever mm plywood I had, every spot I gauged it up gave different results ranging from 6mm to 6.5mm.
This took ages to do, mainly because of the time taken up with setting up, checking correct positions, clamping and then rechecking everything before each cut was ready to go.

Now trying to produce repetitive dados in the frame sides made me lean towards using my shaper, so it was off with the existing fence and use a length of wood and clamps as a guide,

Here is a shot of the setup and the very first cuts, all went really well and I was able to mirror the opposite side OK and used a backer block to prevent tearout.

Table Wood Wheel Automotive exterior Workbench


Wood Rectangle Floor Wood stain Hardwood


Only problem was it was in the incorrect location! ....it was right smack in the middle of where the drawer slide was going to go. So I stopped took out my eraser and removed all the additional lines I had made and now no longer needed.

I continued on adjusting the fence and checking the setup more closely this time (well so I thought) and continued on
It wasnt untill I saw a few dados completed that the stop/start points were all over the place.

OMG how could this be? then I realised when I reset the fence I didnt realign the center point for the stop start index as well.
This really annoyed me as I knew I was going to have to try and recut the dados somehow.

Wood Rectangle Beige Flooring Floor


Now attempting to reset my make shift fence correctly and get everything lined up again was in my mind to me almost impossible and would lead to nothing but a wriggly mess. I didnt have enough timber to re do the frame either !

So I made a jig that would stay parallel on the shaper top for a start, I then used the backer I was using to reset the height of the cutter, that was a stroke of luck I tell you as I had changed bits to do round over of the ply!

A more defined center line was added as well!

Wood Rectangle Floor Wood stain Composite material


I set everything up again and set to work expecting the worst however I pulled one out of the hat and got a much better result than I ever expected.

Wood Rectangle Wood stain Hardwood Plank


I was so surprised with my ability to align everything by just my eye, it gave me increased confidence and I pressed on making the support bases for the full length drawers and dry asembled everything.

Wood Wood stain Floor Flooring Hardwood


Beavering away I then completed the six half size drawer frames and dry assembled them also,

Things were really looking up!

Wood Rectangle Natural material Wood stain Hardwood


The Opps fix:
I cut a secton of timber from scrap and glued it in the goof area and later sanded it off, could not do much more than that.

Wood Rectangle Flooring Wood stain Floor


The 7mm Dado:
How I obtained a 7mm dado with a 6.3mm bit. Possibly not something to recommend to WW learners but it was my "fix" (I cannot believe how much variation ply wood has…its almost rubbish !!)

Rectangle Wood Table Flooring Floor


As the first cut required me to use a back cutting method I chose to use the rule first up and after removal made a normal cut thus removing the run on problem from the backcutting situation.

Well the day is done, I wasted lots of time but eventually obtained some satisfactory results.

Wood Automotive exterior Hardwood Rectangle Gas


Next comes the completion of the top box and the figureing out how the disappearing front door will work.

Editing Note: In my original post I used the terminology Rabbet / Rebate, this has since been changed to more accurately refelect the correct treminology of the groove which is a Stopped Dado
That's some serious storage compartments.
 

Attachments

#140 ·
AKs ToolMakers Chest Making the Front Panel Door

The design of the front door is when its closed its vertical and upon unlocking and opening it it dissapears horizontally under the bottom drawer.

This is what the original rough out looked like.

Wood Wood stain Floor Flooring Hardwood


It was a bit bland and heavy so I decided to cut it into rails and stile to make a four panel door.

I didnt want a fancy profile and found I had a suitable shaper bit that would do the job

Here is my test prototype.

Brown Table Wood Rectangle Flooring


With a satisfactory fit production went ahead.

First up I did all the internal profiles then the end mating parts.

The long parts were no problem but the shorter internal ones needed securing to a block for accurate profiling.

Wood Floor Flooring Composite material Gas


Here is the dry assembled frame.

Rectangle Wood Mesh Tints and shades Gas


Its a bit difficult to see the profile so here is a few other shots.

Grey Road surface Asphalt Wood Rectangle


Here it is dry assembled in its raw form.

Outdoor bench Rectangle Wood Wood stain Outdoor furniture


All went well and finished the frame without a hitch.

Upon close inspection I found there was a few "whiskers in the joint.

Brown Wood Road surface Beige Floor


These were easly removed with a careful application of a box cutter knife.

Wood Wood stain Plank Hardwood Natural material


The panels are next and I intend to mill down the featured board to do them so they match the drawer fronts.

Wood Hardwood Rectangle Wood stain Plank


I am now off looking for latches, plunger spring locks for the sides and suitable drawer pulls for the drawers.

Product Font Automotive tire Rectangle Screenshot
 

Attachments

#141 ·
AKs ToolMakers Chest Making the Front Panel Door

The design of the front door is when its closed its vertical and upon unlocking and opening it it dissapears horizontally under the bottom drawer.

This is what the original rough out looked like.

Wood Wood stain Floor Flooring Hardwood


It was a bit bland and heavy so I decided to cut it into rails and stile to make a four panel door.

I didnt want a fancy profile and found I had a suitable shaper bit that would do the job

Here is my test prototype.

Brown Table Wood Rectangle Flooring


With a satisfactory fit production went ahead.

First up I did all the internal profiles then the end mating parts.

The long parts were no problem but the shorter internal ones needed securing to a block for accurate profiling.

Wood Floor Flooring Composite material Gas


Here is the dry assembled frame.

Rectangle Wood Mesh Tints and shades Gas


Its a bit difficult to see the profile so here is a few other shots.

Grey Road surface Asphalt Wood Rectangle


Here it is dry assembled in its raw form.

Outdoor bench Rectangle Wood Wood stain Outdoor furniture


All went well and finished the frame without a hitch.

Upon close inspection I found there was a few "whiskers in the joint.

Brown Wood Road surface Beige Floor


These were easly removed with a careful application of a box cutter knife.

Wood Wood stain Plank Hardwood Natural material


The panels are next and I intend to mill down the featured board to do them so they match the drawer fronts.

Wood Hardwood Rectangle Wood stain Plank


I am now off looking for latches, plunger spring locks for the sides and suitable drawer pulls for the drawers.

Product Font Automotive tire Rectangle Screenshot
Coming along nicely mate…
 

Attachments

#145 ·
AKs ToolMakers Chest Door Panel Production and Final Assembly

The door panels were cut from the unusual featured timber supplied

After selecting a section that I could get grain flow continuity across the panels I set to work profiling them.

The rebate at the back was no real concern however the length of the front profile was

I dont have a lot of small panel bits, in fact I have only one full size one which is scale wise way too big for a panel with the overall size about 320mm x 560mm.
Its designed for front doors or kitchen cupboard doors at least twice the size I am worling with.

So to over come this problem I recessed the router bit on an sacrificial table and set the bearing back 10mm.

The reason for doing this was to reduce both the depth and length of the profile.

Once I was ready to try it out a cut on the test pieces I had.

Wood Toy Flooring Hardwood Wood stain


This is the result, it looked OK fit up wise and cosmetically so off I set to work.

Brown Rectangle Wood Textile Beige


Starting with the end grain then with the grain they machined up without a fault

Product Rectangle Wood Flooring Floor


Dry assembly then conducted and fine detailing of the parts, removal of whiskers and other stragglers along with a initial sanding.

Brown Rectangle Wood Wood stain Hardwood


I marked a series of index lines to assist in the final assembly and dismantled everything for glue prep

Table Wood Rectangle Automotive exterior Gas


If you did not know how small it was it could pass for a full size standard Panel Door

Wood Rectangle Automotive exterior Gas Tints and shades


A slight imperfection requiring attention. Looks like snipe!!, anyway a visit to the drumsander tomorrow should remove it.

Wood Hardwood Wood stain Gas Siding


A diagonal check for parallism and the matching index lines then and it was set aside to dry.

Once dry a preliminary sanding was conducted then it was pack up for the day.

Wood Rectangle Wood stain Hardwood Natural material
 

Attachments

#146 ·
AKs ToolMakers Chest Door Panel Production and Final Assembly

The door panels were cut from the unusual featured timber supplied

After selecting a section that I could get grain flow continuity across the panels I set to work profiling them.

The rebate at the back was no real concern however the length of the front profile was

I dont have a lot of small panel bits, in fact I have only one full size one which is scale wise way too big for a panel with the overall size about 320mm x 560mm.
Its designed for front doors or kitchen cupboard doors at least twice the size I am worling with.

So to over come this problem I recessed the router bit on an sacrificial table and set the bearing back 10mm.

The reason for doing this was to reduce both the depth and length of the profile.

Once I was ready to try it out a cut on the test pieces I had.

Wood Toy Flooring Hardwood Wood stain


This is the result, it looked OK fit up wise and cosmetically so off I set to work.

Brown Rectangle Wood Textile Beige


Starting with the end grain then with the grain they machined up without a fault

Product Rectangle Wood Flooring Floor


Dry assembly then conducted and fine detailing of the parts, removal of whiskers and other stragglers along with a initial sanding.

Brown Rectangle Wood Wood stain Hardwood


I marked a series of index lines to assist in the final assembly and dismantled everything for glue prep

Table Wood Rectangle Automotive exterior Gas


If you did not know how small it was it could pass for a full size standard Panel Door

Wood Rectangle Automotive exterior Gas Tints and shades


A slight imperfection requiring attention. Looks like snipe!!, anyway a visit to the drumsander tomorrow should remove it.

Wood Hardwood Wood stain Gas Siding


A diagonal check for parallism and the matching index lines then and it was set aside to dry.

Once dry a preliminary sanding was conducted then it was pack up for the day.

Wood Rectangle Wood stain Hardwood Natural material
Lotsa gr8 machining there Rob
 

Attachments

#148 ·
Removing Twist or wind from timber

Usually the best method to remove twist from a piece of timber is to cut it into smaller lengths, but what if you really needed the length effected to stay the same.

As I had two pieces left over from my Tool Trolley project which were" badly" twisted this got me thinking as to how it could be done.

Piece 1 Getting examined
Side 1

Wood Rectangle Flooring Floor Outdoor bench


Side 2
Wood Fence Rectangle Outdoor bench Line


Side 3
Sky Wood Rectangle Fence Wall


Side 4
(must have lost the picture)

Piece 2 Getting Examined
Side 1
Sky Wood Fence Composite material Hardwood


Side 2
Wood Sky Fence Road surface Hardwood


Side 3
Daytime Property Sky Wood Fence


Side 4
Sky Wood Fence Road surface Composite material


So they all have what looks to be very bad twist and not worth persevering with.

I know you could mount it on a sled wedge them up and run it through the thicknesser, but what if the thicknesser was unavailable?

It may be possible to do them on the jointer freehand so I "fiddled" about trying to work out how you could hold them vertically and remain stable away from the fence.

As you usually joint timber with the bow up I worked out that you may be able to support the center section with sacrificial blocks to stablise it as the timber was jointed.

So I set up piece 2, as it appeared to have the lesser twist, in this jig.

Light Wood Flooring Rectangle Composite material


Ran it through about for times and examined the results
Light Wood Flooring Floor Rectangle


It seemed to be OK so I removed the jig and jointed the other side and checked it again.

Rectangle Wood Floor Wood stain Hardwood


From what I saw it looked like it was going to be an exercise in making wood shavings from the amount of material that had been removed.

Anyway I set up the table saw and continued.
Wood Bumper Automotive exterior Plant Gas


The edge trued up OK so I continued on the side, taking a bare min pass first up, then reset and resawed to 35mm
It worked well so I did both pieces.

Here are the results.
Wood Table Plank Wood stain Hardwood


Next was a check on Squareness.

Position 1
Wood Rectangle Automotive exterior Gas Road surface


Position 2
Rectangle Wood Road surface Line Flooring


Position 3
Wood Flooring Rectangle Floor Wood stain


All looked like they were good so as a final check I layed them out together and checked the edge profiles against each other.

Profile Position 1
Table Light Wood Rectangle Flooring


Profile Position 2
Wood Rectangle Flooring Hardwood Plank


Profile Position 3
Light Wood Flooring Floor Wood stain


Profile Position 4
Wood Floor Flooring Gas Font


I then wondered just how much material was removed in the process, so I checked the work with a rough sawn original
Handwriting Wood Rectangle Wooden block Hardwood


Results
From the two "discarded" original pieces I found that there was no more than 5mm removed to return the timber to a servicable condition, quite surprising after seeing the winding sticks, so,

Conclusion:

Was it worth the effort?

Factors: Time taken about 1 hr, material cost nil material worth effectively nil again, as it was some very soft pine doing the same with a piece of hardwood may possibly take longer and produce more wear and tear.
So consideration to the time taken, material worth and other factors it may be a possible stop gap measure/save but not much else.
 

Attachments

#149 ·
Removing Twist or wind from timber

Usually the best method to remove twist from a piece of timber is to cut it into smaller lengths, but what if you really needed the length effected to stay the same.

As I had two pieces left over from my Tool Trolley project which were" badly" twisted this got me thinking as to how it could be done.

Piece 1 Getting examined
Side 1

Wood Rectangle Flooring Floor Outdoor bench


Side 2
Wood Fence Rectangle Outdoor bench Line


Side 3
Sky Wood Rectangle Fence Wall


Side 4
(must have lost the picture)

Piece 2 Getting Examined
Side 1
Sky Wood Fence Composite material Hardwood


Side 2
Wood Sky Fence Road surface Hardwood


Side 3
Daytime Property Sky Wood Fence


Side 4
Sky Wood Fence Road surface Composite material


So they all have what looks to be very bad twist and not worth persevering with.

I know you could mount it on a sled wedge them up and run it through the thicknesser, but what if the thicknesser was unavailable?

It may be possible to do them on the jointer freehand so I "fiddled" about trying to work out how you could hold them vertically and remain stable away from the fence.

As you usually joint timber with the bow up I worked out that you may be able to support the center section with sacrificial blocks to stablise it as the timber was jointed.

So I set up piece 2, as it appeared to have the lesser twist, in this jig.

Light Wood Flooring Rectangle Composite material


Ran it through about for times and examined the results
Light Wood Flooring Floor Rectangle


It seemed to be OK so I removed the jig and jointed the other side and checked it again.

Rectangle Wood Floor Wood stain Hardwood


From what I saw it looked like it was going to be an exercise in making wood shavings from the amount of material that had been removed.

Anyway I set up the table saw and continued.
Wood Bumper Automotive exterior Plant Gas


The edge trued up OK so I continued on the side, taking a bare min pass first up, then reset and resawed to 35mm
It worked well so I did both pieces.

Here are the results.
Wood Table Plank Wood stain Hardwood


Next was a check on Squareness.

Position 1
Wood Rectangle Automotive exterior Gas Road surface


Position 2
Rectangle Wood Road surface Line Flooring


Position 3
Wood Flooring Rectangle Floor Wood stain


All looked like they were good so as a final check I layed them out together and checked the edge profiles against each other.

Profile Position 1
Table Light Wood Rectangle Flooring


Profile Position 2
Wood Rectangle Flooring Hardwood Plank


Profile Position 3
Light Wood Flooring Floor Wood stain


Profile Position 4
Wood Floor Flooring Gas Font


I then wondered just how much material was removed in the process, so I checked the work with a rough sawn original
Handwriting Wood Rectangle Wooden block Hardwood


Results
From the two "discarded" original pieces I found that there was no more than 5mm removed to return the timber to a servicable condition, quite surprising after seeing the winding sticks, so,

Conclusion:

Was it worth the effort?

Factors: Time taken about 1 hr, material cost nil material worth effectively nil again, as it was some very soft pine doing the same with a piece of hardwood may possibly take longer and produce more wear and tear.
So consideration to the time taken, material worth and other factors it may be a possible stop gap measure/save but not much else.
You got some good practice in on some cheap wood…
Next time, the wood might make it Worth it… :)

You did good!
 

Attachments

#151 ·
Smiths Industrial Bin raid

I am repairing more Potato Crates for Smiths Crisps, and while I was working away I spotted a large Industrial bin with some timber poking out.
Upon inspection I found what looked to be a machine shipping crate of some sort, the dimensions were huge and what I considered to be "usefull"

So I made some enquiries as to the possibility of being able to recover it.
The reply was if I could use it and get it out it was mine, so I set to work attempting to haul it out, but it was way too heavy for me to manage, so I approached the guy who drives the fork moving the Potato Crates for me to repair for possible help.

As I got up to him he smiles at me and says "what do you want? so I told him what I was trying to do and he patiently listened as I explained and then said,
Yeah I was watching you and wondered how long it would take before you would think to use a fork!

Sure enough with very little effort he had the timber out of the bin and on the Ute for me in no time.

So I brought it home at the end of the day and commenced unloading it.

Tire Wheel Truck Vehicle Automotive tire


I just wriggled it along the back of the tray and when it reached its balancing point I just tipped it off.

Wood Composite material Gas Brickwork Automotive exterior


The large pieces are 80mm x 80mm the boards are about 20mm or thereabouts thichness, the OSB (of which is still very foreign here), is stamped premium grade.

It was a bit damaged by nails and staples on the edges but cut down I am sure it is still useable for something.

Wood Trunk Plant Grass Shade


It all shows Heat Treating IPPS (see Note Below) stamps and GB as the country of origin.

Make that ISPM not IPPS
Info:-
1. What is ISPM 15?
ISPM 15 is the 'International Standards for Phytosanitary Measures Publication No. 15 (2009):
Regulation of Wood Packaging Material in International Trade'.

2. Why was ISPM 15 developed?
ISPM 15 was developed to address the global spread of timber pests by regulating the movement of timber
packaging and dunnage in international trade.
ISPM 15 describes phytosanitary measures to reduce the risk of introduction and/or spread of quarantine pests associated with solid timber packaging material (includes dunnage).

I spent about 3 hours dismantling everything and de screwing staple and nail removal for it all

Wood Floor Flooring Wood stain Hardwood


The main base is yet to be started as it has heaps of planks and some of the biggest nails in it I have ever seen.

Wood Rectangle Wood stain Hardwood Grass


Recovered additional booty.
Who ever made the crate did a great engineering task but I managed to reverse engineer it for them.

Check out these screws!

Material property Nickel Jewellery Electric blue Hand tool


Now its all whats to looks to be like low grade pine (less the OSB) but I should be able to make something out of it later.

Here is a shot of one of the "nails" and some of the small bits attached to the timber that I discarded.

Wood Flooring Hardwood Gas Composite material
 

Attachments

#152 ·
Smiths Industrial Bin raid

I am repairing more Potato Crates for Smiths Crisps, and while I was working away I spotted a large Industrial bin with some timber poking out.
Upon inspection I found what looked to be a machine shipping crate of some sort, the dimensions were huge and what I considered to be "usefull"

So I made some enquiries as to the possibility of being able to recover it.
The reply was if I could use it and get it out it was mine, so I set to work attempting to haul it out, but it was way too heavy for me to manage, so I approached the guy who drives the fork moving the Potato Crates for me to repair for possible help.

As I got up to him he smiles at me and says "what do you want? so I told him what I was trying to do and he patiently listened as I explained and then said,
Yeah I was watching you and wondered how long it would take before you would think to use a fork!

Sure enough with very little effort he had the timber out of the bin and on the Ute for me in no time.

So I brought it home at the end of the day and commenced unloading it.

Tire Wheel Truck Vehicle Automotive tire


I just wriggled it along the back of the tray and when it reached its balancing point I just tipped it off.

Wood Composite material Gas Brickwork Automotive exterior


The large pieces are 80mm x 80mm the boards are about 20mm or thereabouts thichness, the OSB (of which is still very foreign here), is stamped premium grade.

It was a bit damaged by nails and staples on the edges but cut down I am sure it is still useable for something.

Wood Trunk Plant Grass Shade


It all shows Heat Treating IPPS (see Note Below) stamps and GB as the country of origin.

Make that ISPM not IPPS
Info:-
1. What is ISPM 15?
ISPM 15 is the 'International Standards for Phytosanitary Measures Publication No. 15 (2009):
Regulation of Wood Packaging Material in International Trade'.

2. Why was ISPM 15 developed?
ISPM 15 was developed to address the global spread of timber pests by regulating the movement of timber
packaging and dunnage in international trade.
ISPM 15 describes phytosanitary measures to reduce the risk of introduction and/or spread of quarantine pests associated with solid timber packaging material (includes dunnage).

I spent about 3 hours dismantling everything and de screwing staple and nail removal for it all

Wood Floor Flooring Wood stain Hardwood


The main base is yet to be started as it has heaps of planks and some of the biggest nails in it I have ever seen.

Wood Rectangle Wood stain Hardwood Grass


Recovered additional booty.
Who ever made the crate did a great engineering task but I managed to reverse engineer it for them.

Check out these screws!

Material property Nickel Jewellery Electric blue Hand tool


Now its all whats to looks to be like low grade pine (less the OSB) but I should be able to make something out of it later.

Here is a shot of one of the "nails" and some of the small bits attached to the timber that I discarded.

Wood Flooring Hardwood Gas Composite material
You sure have fun!!
 

Attachments

#159 ·
Smiths Crate has attracted quite a bit of attention

The crate I recovered has been annexed by family friends for various timber tasks

So much for me getting to play with Maloof joints just yet

The following requests have been made:
1. Two appliance benchs for the kitchen 900Ă—600mm from Aurora's friend Edna
2. A second step stool from Aurora, and
3. and our family friend Michael wanted small low non load bearing wall frame for his holiday house, along with a Duck box for their ducks to sleep and lay in.

I think I will have to do individual blogs on each of the activities due to their varying construction methods, however here is some of the prep work for the appliance tables.

Food Wood Gas Machine Ingredient


A PS Note: After doing some research on Norbord OSB products and checking out other LJs OSB posts I have a new box for my Ute made from the OSB in mind.

The OBS I have appears to be OSB2 suitable for making boxes and crates.
I wonder do any other LJs know how long I could expect the OSB to survive in the back of a Ute?

More interesting "stuff" to follow!
 

Attachments

#160 ·
Smiths Crate has attracted quite a bit of attention

The crate I recovered has been annexed by family friends for various timber tasks

So much for me getting to play with Maloof joints just yet

The following requests have been made:
1. Two appliance benchs for the kitchen 900Ă—600mm from Aurora's friend Edna
2. A second step stool from Aurora, and
3. and our family friend Michael wanted small low non load bearing wall frame for his holiday house, along with a Duck box for their ducks to sleep and lay in.

I think I will have to do individual blogs on each of the activities due to their varying construction methods, however here is some of the prep work for the appliance tables.

Food Wood Gas Machine Ingredient


A PS Note: After doing some research on Norbord OSB products and checking out other LJs OSB posts I have a new box for my Ute made from the OSB in mind.

The OBS I have appears to be OSB2 suitable for making boxes and crates.
I wonder do any other LJs know how long I could expect the OSB to survive in the back of a Ute?

More interesting "stuff" to follow!
Go Rob!
 

Attachments

#162 ·
Edna's Kitchen Work Benches Timber Planning and preparation

Aurora's friend Edna requested two kitchen work benches.

Dimensions required were:
900mm high x 900mm long x 600mm wide.
Also they had to be light enough to moved around by a lady.

So I used some of my current pallet crate stash for all the work

Wood Hardwood Beam Tints and shades Lumber


The usual jointing and thicknessing was undertaken to produce some useable timber.

Wood Wood stain Outdoor furniture Plank Outdoor bench


I used a router to cut the 20mm deep mortices to hold the frame sides and ends together
and dry assembled the carcass frame.

Wood Stool Flooring Gas Shelving


The top will be six sections of timber reverse glue jointed together.
So thats the planning preparation and basic design taken care of.
 

Attachments

#163 ·
Edna's Kitchen Work Benches Timber Planning and preparation

Aurora's friend Edna requested two kitchen work benches.

Dimensions required were:
900mm high x 900mm long x 600mm wide.
Also they had to be light enough to moved around by a lady.

So I used some of my current pallet crate stash for all the work

Wood Hardwood Beam Tints and shades Lumber


The usual jointing and thicknessing was undertaken to produce some useable timber.

Wood Wood stain Outdoor furniture Plank Outdoor bench


I used a router to cut the 20mm deep mortices to hold the frame sides and ends together
and dry assembled the carcass frame.

Wood Stool Flooring Gas Shelving


The top will be six sections of timber reverse glue jointed together.
So thats the planning preparation and basic design taken care of.
Mighty fine work so far. I'm quite sure she'll be pleased.
 

Attachments

#165 ·
Edna's Workbenches Modified design and glue up of the frame

I thought the overall look was too chunky so I decided to improve on it.

First up I rounded over the legs using a 2" roundover bit, it was smaller then the overall diameter so they ended up with rounded over as opposed to completely round

Floor Composite material Gas Flooring Auto part


This was the initial result on the test leg.

Monoplane Wood Road surface Asphalt Aircraft


Then the eight legs.

Wood Gas Tool Clock Composite material


As the results looked OK I then rounded over the side and end pieces.

Wood Building Shelving Floor Flooring


Still room for improvement so I used a cove bit on the legs and bull nosed the side and end pieces that fitted into the mortices.

I was reasonably happy with the leg coving but it was a bit wavy doing it by hand.

Added a 25mm dowel at the base for stability and then satisfied with the results glued them all up.

Wood Gas Plywood Composite material Automotive exterior


Bumper Automotive exterior Wood Bicycle part Gas


This may be of interest

https://www.lumberjocks.com/reviews/6170
 

Attachments

#166 ·
Edna's Workbenches Modified design and glue up of the frame

I thought the overall look was too chunky so I decided to improve on it.

First up I rounded over the legs using a 2" roundover bit, it was smaller then the overall diameter so they ended up with rounded over as opposed to completely round

Floor Composite material Gas Flooring Auto part


This was the initial result on the test leg.

Monoplane Wood Road surface Asphalt Aircraft


Then the eight legs.

Wood Gas Tool Clock Composite material


As the results looked OK I then rounded over the side and end pieces.

Wood Building Shelving Floor Flooring


Still room for improvement so I used a cove bit on the legs and bull nosed the side and end pieces that fitted into the mortices.

I was reasonably happy with the leg coving but it was a bit wavy doing it by hand.

Added a 25mm dowel at the base for stability and then satisfied with the results glued them all up.

Wood Gas Plywood Composite material Automotive exterior


Bumper Automotive exterior Wood Bicycle part Gas


This may be of interest

https://www.lumberjocks.com/reviews/6170
That really makes a difference!

Amazing what a little Round-Over will do!

Thank you!
 

Attachments

#169 ·
OSB Ute Box

I had to get moving on this project due to my original box just about expiring.

Wood Flooring Gas Rectangle Hardwood


The OSB is part of the Smiths packing crate I hauled home, I have never worked with this material before so it was all a learning exercise for me as well!

The markings on the OSB indicate Norbord Sterling OSB2 so it should be OK.

Tire Wheel Truck Vehicle Automotive tire


The replacement box is slightly bigger due to maximising the OSB sheet dimensions I had.

First up I cut all the sections needed

Rectangle Wood Artifact Beige Flooring


I may not use the narrow strips but I am not sure yet. These was cut as a direct copy from the original.

I rebated all the pieces and used my corner clamps and an "Occy" strap to hold the frame together and left it overnight for the glue to dry.

Wood Rectangle Hardwood Wood stain Flooring


I then fitted the base and left it overnight to dry, I did have to resaw it due to forgetting the rebate made the overall size smaller.

Wood Road surface Flooring Gas Rectangle


I then fitted the inside with quad, and as I had some moulding I had made some time ago which was "just lying about" I decided to use it as well.

Rectangle Wood Gas Flooring Hardwood


The moulding was a series of short lengths so I had to join them in a couple of places.

Wood Rectangle Natural material Hardwood Building material


The narrow strips in the cut list I replaced with thicker material under the box as standoffs. The remainder were for the ends and side trim.

Rectangle Wood Table Flooring Hardwood


This is as far as I have progressed today.

A closing shot of the frame sitting on the existing box.

Plant Rectangle Wood Grass Natural material
 

Attachments

#170 ·
OSB Ute Box

I had to get moving on this project due to my original box just about expiring.



The OSB is part of the Smiths packing crate I hauled home, I have never worked with this material before so it was all a learning exercise for me as well!

The markings on the OSB indicate Norbord Sterling OSB2 so it should be OK.



The replacement box is slightly bigger due to maximising the OSB sheet dimensions I had.

First up I cut all the sections needed



I may not use the narrow strips but I am not sure yet. These was cut as a direct copy from the original.

I rebated all the pieces and used my corner clamps and an "Occy" strap to hold the frame together and left it overnight for the glue to dry.



I then fitted the base and left it overnight to dry, I did have to resaw it due to forgetting the rebate made the overall size smaller.



I then fitted the inside with quad, and as I had some moulding I had made some time ago which was "just lying about" I decided to use it as well.



The moulding was a series of short lengths so I had to join them in a couple of places.



The narrow strips in the cut list I replaced with thicker material under the box as standoffs. The remainder were for the ends and side trim.



This is as far as I have progressed today.

A closing shot of the frame sitting on the existing box.

2 years ago I worked in a building that made OSB.
ALL the office furniture and counters in front office were made from OSB.
I had never thought much of that material until I saw those desks.
The guy also made a large conference table using same material layered to 2" thickness.
I WISH I WOULD have taken pictures.
Apperently over the years the glues were changed to waterproff resins. The OSB now is much better than 30 years ago.
I really like the stuff you are making from re-cycled material.
 

Attachments

#172 ·
Edna's Kitchen Work Benches making the tops

The tops are six sections of pine planks reverse glue jointed (RGJ) lengthwise and breadboarded ends. Additional lengths of timber were then added to increase the edge thickness.

Here is a couple of shots of the RGJ glue up

Musical instrument Wood Hardwood Plywood Composite material


Wood Rectangle Table Gas Hardwood


Then it was on to the breadboarded ends and thickness fillers.
Initally I was going to add the fillers later but believe it or not I only had one pair of clamps long enough to do the job.
So it was slow progress today

Wood Gas Composite material Engineering Auto part


Once the glue was dry the clamps came off and the tops were test fitted to the bases then cut to size and again dry fitted to the bases and left overnight.

Wood Floor Gas Hardwood Wood stain


Wood Table Wood stain Floor Hardwood


Next comes the surface sanding and edge profiling.
 

Attachments

#173 ·
Edna's Kitchen Work Benches making the tops

The tops are six sections of pine planks reverse glue jointed (RGJ) lengthwise and breadboarded ends. Additional lengths of timber were then added to increase the edge thickness.

Here is a couple of shots of the RGJ glue up

Musical instrument Wood Hardwood Plywood Composite material


Wood Rectangle Table Gas Hardwood


Then it was on to the breadboarded ends and thickness fillers.
Initally I was going to add the fillers later but believe it or not I only had one pair of clamps long enough to do the job.
So it was slow progress today

Wood Gas Composite material Engineering Auto part


Once the glue was dry the clamps came off and the tops were test fitted to the bases then cut to size and again dry fitted to the bases and left overnight.

Wood Floor Gas Hardwood Wood stain


Wood Table Wood stain Floor Hardwood


Next comes the surface sanding and edge profiling.
Coming along very nicely…
 

Attachments

#178 ·
Edna's Kitchen Benches Surface preparation

Today saw the tops profiled and sanded, however when I blew all the dust off I found the nail hole filler decided they need to leave as well,

So yet another step required when working with recycled timber is introduced.

I plugged all the nail holes again only this time glued in tooth picks! lets see these little critters get away !

Wood Rectangle Natural material Table Wood stain


And the second top

Wood Table Rectangle Bench Flooring


While they were drying I turned my attention to the frames,

The tops will be attached to the frames using pocket hole joinery so I preped them first.

Light Outdoor furniture Wood Outdoor table Outdoor bench


They were sanded and checked for missing filler again and then stained.

Plant Outdoor furniture Wood Wood stain Grass


Enough for today: Next will be a second inspection and if all is OK complete the staining and then the final finishing
 

Attachments

#179 ·
Edna's Kitchen Benches Surface preparation

Today saw the tops profiled and sanded, however when I blew all the dust off I found the nail hole filler decided they need to leave as well,

So yet another step required when working with recycled timber is introduced.

I plugged all the nail holes again only this time glued in tooth picks! lets see these little critters get away !

Wood Rectangle Natural material Table Wood stain


And the second top

Wood Table Rectangle Bench Flooring


While they were drying I turned my attention to the frames,

The tops will be attached to the frames using pocket hole joinery so I preped them first.

Light Outdoor furniture Wood Outdoor table Outdoor bench


They were sanded and checked for missing filler again and then stained.

Plant Outdoor furniture Wood Wood stain Grass


Enough for today: Next will be a second inspection and if all is OK complete the staining and then the final finishing
nice looking tables.
 

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