LumberJocks

Working with recycled timber

  • Advertise with us
Blog series by robscastle updated 03-26-2015 07:53 AM 43 parts 37626 reads 100 comments total

Part 1: The basics

07-02-2013 08:11 AM by robscastle | 0 comments »

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. Commercia...

Read this entry »


Part 2: Shop management of recycled timber

07-02-2013 10:37 PM by robscastle | 3 comments »

Ok so you have got your recycled timber home. Depending on your circumstances the storage or immediate use is up to the individual. Handling and Storage Remember its recycled wood discarded from a supplier so there will be possibly exposed nails and screws which could injure you, so use protective gloves if required and watch when stepping on the pile for puncture risks. I forgot to mention earlier there is also a trend to use plastic pallets these days although not really of secon...

Read this entry »


Part 3: When you are onto something really good

07-03-2013 08:29 AM by robscastle | 1 comment »

OK this is something everybody into recycling should know. Some really brilliant tips. Attached to my Working with recycled timber blogs are excellent tips fellow LJs have taken the time to pass on, and they directly add additional knowledge to the subject matter I was covering. I personally think they are very worthwhile and are essential contributions to the WW knowledge bank, It provides the two heads are better than one (or in some cases three) for situations. So along wi...

Read this entry »


Part 4: Recovering / repairing or breaking down wood

07-04-2013 09:07 AM by robscastle | 2 comments »

There are lots of furniture items about which end up in a street clean up. I saw a blue painted set of drawers which appeared on vacant block near me some time ago, I didn’t take much notice of it but just watched it. It didn’t move for a couple of days so I went over and checked it out, when I opened a drawer I saw it was assembled using blind dovetails in it so I decided to bring it home. Once I got it back home and had a good look at it was worthwhile sanding the paint...

Read this entry »


Part 5: Some Recycled furniture Timber and Perils of Foreign Objects

07-08-2013 01:36 AM by robscastle | 2 comments »

In my last Blog I closed with a comment I was doing a refurbishment and had recovered some timber for reuse. So lets look at the results that can be obtained. Background. It was a pine cabinet which had been stained with a dark finish. The timber I worked with in this first section had already been dressed.So reducing stock below standard thickness and then attempting to use it in conjunction with other projects needs to be considered, as it may well end up being more problems tha...

Read this entry »


Part 6: TJB Woodie and Jessie Picture frame

07-16-2013 11:00 PM by robscastle | 1 comment »

I made this picture frame up after number four Son Toby and his lovely lady Ashlee visited over the weekend. Background: Outfits: We all went to a birthday party for number one son Adam’s son Rocky, it was a cowboy theme so that explains the outfits in the post. The Frame: The picture frame was inspired by Toby’s interest in “rustic” use of recycled timber. The timber: The timber used is Oregon/Douglas Fir and was in its previous life ...

Read this entry »


Part 7: 20 Stave Drum. Stock preparation

08-10-2013 09:17 AM by robscastle | 1 comment »

I have enough timber to reattempt making staves, in particular a 20 stave drum is the project. My last attempt to make staves gave me so much grief at the glue up stage I almost binned everything mid process in sheer frustration.It was only after walking away from the activity temporarily I found the confidence to try again.I eventually had a encouraging limited success with the activity. Then it was only just recently, after reading Julian’s Router Jig for Making Round Boxes a co...

Read this entry »


Part 8: 20 Stave Drum. Stave glue up

08-10-2013 09:54 AM by robscastle | 1 comment »

OK after laying out the staves and using painters tape to hold everything together I applied a bead of Tite Bond III glue to each stave edge and attempted to roll them up together to form the cylinder, well it did not work well staves fell off the tape so I had to apply painters tape on the inside to hold them together as I rolled them into the cylinder. The tape started breaking away and then started being a nuisance, so I quickly applied a run of electrical tape all around the outside to...

Read this entry »


Part 9: 20 Stave Drum. Routing the Staves

08-10-2013 10:42 AM by robscastle | 2 comments »

The drum cylinder section is now complete and reasonably ridged enough to handle. Now all I need is to decide what pattern to apply to the staves.Initially I was going to use my 3D router Carver but the narrow staves discounted it fairly early. I then thought about putting circles on each stave, but decided against it as being plain and boring after making the pattern and doing a test run and seeing the result. So I decided to go with an duplicated elongated pattern. I set about...

Read this entry »


Part 10: Attaching the base, base trim and a reinforcing ring

08-13-2013 02:20 AM by robscastle | 2 comments »

The drum project is progressing well. The base was cut from a piece of 15mm ply and attached with a “few” screws and glue. I sat the drum on the ply traced a line around the outside and cut the profile out on the bandsaw then ran a straight bearing mounted router bit around the edge to cut it back parallel and smooth I had some concerns about the segments at the top breaking off if somebody stood on the drum so I made a reinforcing ring to support them all. I h...

Read this entry »


Part 11: Sometimes things do not go well

08-13-2013 07:45 AM by robscastle | 1 comment »

Yesterday I spent all day sawing up a couple of hardwood pallet slats. I was trying to make a octagonal 20 deg slope sides tray. I must have spent countless hours sawing up material to ensure I could do what I had imagined. However when I thought I had the system down pat I had sections going off at different planes. So I sawed everything up again and met with the same result. I then Googled wood working stave work and found some formulas worthy of a Prince Phillip design award...

Read this entry »


Part 12: sanding Activity and the results

08-14-2013 09:33 AM by robscastle | 2 comments »

I scavenged this piece of Huon Pine from a renovation some time ago, we were pulling out some old cupboards and doors. Its the bottom panel from a door and if you check my Door what door? Blog you will see it there. Size was 620 mm x 450 mm x 10mm There was about eight layers of paint/varnish on each side. With a half sheet sander and 4 x sheets of 40 grit I set to work The A side in progress The B Side I didn’t take a in progress shot The A side finishe...

Read this entry »


Part 13: Hidden Feature !

08-25-2013 09:24 AM by robscastle | 4 comments »

Here is a series of shots I took when working the timber for my octagonal trays. You may remember, (if you read it that is) of a previous blog highlighting the remaining metal from power driven nails linked with wire. Well here are the photos showing the FOD exposed after I has sawn it up, and another showing embedded metal in other places except the nail holes. Picture No 1. Showing residual metal lying inside the nail hole and only visible after cutting with the saw.Not sure if ...

Read this entry »


Part 14: Concrete Cancer almost got me

09-18-2013 11:13 PM by robscastle | 3 comments »

After a day at Degoose’s shop checking out his CNC and getting the new Spa powered up I returned home with yet another boot load of his fine timber. I unloaded everything and stashed it all away and then went to go inside to relax and some refreshments, however as I stepped onto the first step of the stairs it almost broke in half! What the !! I thought how could that be? Checking underneath I saw the reason metal corrosion had fractured the step beyond repair So ...

Read this entry »


Part 15: When working on Step No 2 a sanding surprise

09-19-2013 05:54 AM by robscastle | 3 comments »

If you read my Concrete Cancer Blog you would have seen the ongoing work that I needed to do in step repair. Well I found yet another piece of timber in my stash suitable for step No 2 It was in a reasonable condition, a couple of screw holes but nothing obvious FO wise, but will require a jointer and thicknesser run to remove some slight twist before installation. So I began preparing it much the same as with Step No 1 before.Again I am not sure what the timber is but it weight a &...

Read this entry »


Part 16: Step 2 complete

09-20-2013 07:15 AM by robscastle | 2 comments »

Well we now have two wooden steps the stairs they look a bit odd with a top and bottom step made from timber, but we will have to live with it for a while. You saw the screw removal in the previous blog, so I will not bore you with and repeats. The process After removing the two broken screws I cut four plugs from the offcut and inserted them. Reason being I wanted to use the timber with the damaged side facing up. Did the sander routine again only I started with 32 Grit this tim...

Read this entry »


Part 17: Pallet Step stools

12-11-2013 08:04 AM by robscastle | 6 comments »

I submitted a repair procedure for Potato Crates for our local chip manufacturer. The potato Crate is a skid with four sides on 1.2m x 1.2m x 1.3m high all hardwood construction with angle iron cover strips on the four corners. It holds 900 kgs of potatoes as they are unloaded from road transport, then inbound for the cool room before processing, usually within 24hr of arrival they are in Chip Packet ready for distribution! There is a shot of a couple at the Processing Plant ...

Read this entry »


Part 18: Pallet Mower Shed

12-27-2013 10:28 PM by robscastle | 7 comments »

I was able to collect some metal pallets and conventional pallets from a business near by. I spoke with the owner and he has pleased that somebody could, 1 Take them away, and 2. Make use of it all. So after a few trips home I have it all in the yard, much to the annoyance of Aurora, best get it all de nailed stacked and put to use PDQ! So I used an angle grinder to cut the front section out of two of the metal frames and use one to stack reclaimed timber in. The other I cut ...

Read this entry »


Part 19: Pine and Jarrah Boxes Preparing the stock

03-14-2014 05:06 AM by robscastle | 2 comments »

I was trying to tidy up again as our house is getting lots of clutter, mainly from me bringing home stray pieces of timber I find. I thought I had better look very closely at my stash of recycled timbers. I had heaps so I pulled out about 28 pieces of various lengths and dimensions I ran them through on the table saw to true them up and then commenced thicknessing them. I ended up with enough stock to make the boxes. I then decided to add panels in the sides from more r...

Read this entry »


Part 20: Pine and Jarrah Boxes making the frames

03-14-2014 05:52 AM by robscastle | 1 comment »

After preparing all the materials I then found that I had too many different widths and not enough of the one size, so I resawed the three 88mm width on their own to match the 9x I had at 83mm Although I was as mean as possible with the thicknesser the final thickness ended up being 16mm so I am on the very minimum work thickness to be able to do panel work. Joints were the next decision, after all there were only going to be work boxes so I didn’t want to spend too much time on f...

Read this entry »


Part 21: Pine and jarrah Boxes Making the panels

03-14-2014 06:41 AM by robscastle | 1 comment »

Upon cutting all the profiles and dry assembling everything it was now time to fit the panel inserts. From the split stock I prepared there was quite a bit of additional work required getting them all to 6mm thickness. The thicknesser was initially used to get the material to a useable state, it worked well although the timber is very hard. Its previous life as a potato crate certainly seasoned it well, there was absolutely no distortion upon splitting the material. I changed the cut...

Read this entry »


Part 22: Pine and Jarrah Boxes pre assembly fit up

03-14-2014 06:56 AM by robscastle | 1 comment »

Once the glue up of the panels had been allowed to dry overnight it was time to lay everything out and ensure every thing fits up OK. Prior to assembly squareness was checked again and minor sawing to size undertaken.The finger joints needed a slight tweeking to get everything on a level base line an correct fit up. Once the final assembly checks were completed a final sanding was undertaken starting with 180 grit and finishing with 320 grit to remove glue residue and some minor spl...

Read this entry »


Part 23: Pine and Jarrah boxes finishing

03-14-2014 07:06 AM by robscastle | 3 comments »

Once the boxes were finally assembled the jig came out again this time the mystery four holes in jig and red circles were used to finish off the assembly. The four holes are inbuilt carry handles and the red circles a predrill locators for the final screws.I used countersunk climacoat 32mm screws, one in each finger joint. The carry handles were radiused with a round over bit in the trimmer and then a coat of shellac applied. OMG its back to cleaning up again ! Enjoy

Read this entry »


Part 24: Pallet Timber Low table making the frame

05-09-2014 11:13 AM by robscastle | 2 comments »

On Friday I spent most of the day doing joints, that’s wooden joints not the plant variety! I originally started with the intention to build the Classic Japanese style table featured in the Australian Woodsmith Magazine Issue 107. I wanted to see if I was competent enough to make the joints so I prototyped the Front and End Stretcher in some recycled pine. Here is a picture of the stretchers and the associated Magazine The end stretcher is complete1:1 scale, where as the...

Read this entry »


Part 25: Pallet Timber Low table finishing and lining the frame

05-10-2014 09:43 AM by robscastle | 3 comments »

I sanded the frame and commenced fitting a base and then lining it. I cut a piece of 6mm MDF for the base and covered it with textile,Added a retaining strip on the bottom to hold it in place then made four sides from 4mm MDF to complete the lining job. The lining including the base can be removed and replaced without the use of tools if required to be changed. You may notice a small gap on the ends, I didn’t pay too much attention to it initially, silly move! as ...

Read this entry »


Part 26: Pallet timber low table constructing the top

05-11-2014 09:33 AM by robscastle | 1 comment »

Nice day today, great weather and Mothers Day as well. Managed to get some woodworking in without drawing the crabs noise wise on Sunday. The construction of the table top required some lengths of 19mm thick pine to be purchased. The quality left a lot to be desired and I think 30% ended up as scrap. Any way I chose to build it using a reverse glue joint, spent quite a bit of time setting up a perfect match up. The bit: Its a bit suitable for widths from14mm to 40 mm, yo...

Read this entry »


Part 27: Making tapered legs

05-11-2014 10:22 AM by robscastle | 3 comments »

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. Step 4. Once the glue has set its then time for the ripping to sta...

Read this entry »


Part 28: PTLT The finishing coats commences. and some retro work completed

05-25-2014 11:40 AM by robscastle | 0 comments »

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 I should have done this much earlier but I thought it would be OK so left it , however it was causing all so...

Read this entry »


Part 29: PTLT fitting hinges to the top

05-25-2014 12:04 PM by robscastle | 1 comment »

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. 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 p...

Read this entry »


Part 30: PTLT I was ready to post as finished !!

06-03-2014 11:15 PM by robscastle | 1 comment »

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

Read this entry »


Part 31: PTLT Hinge rework

06-04-2014 05:13 AM by robscastle | 3 comments »

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 Simply a matter of recessing them This is only a prototype to enable me to complete my PTLT top with no opening gap when closed It appears that the...

Read this entry »


Part 32: PTLT fixed section and hinge rework

06-08-2014 08:39 AM by robscastle | 3 comments »

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. Due to the material being removed from the edge of original...

Read this entry »


Part 33: The Poor Man's Joint...inhale and remember you are still alive

08-10-2014 03:28 AM by robscastle | 8 comments »

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 t...

Read this entry »


Part 34: A Gate for No 1 Son

01-26-2015 05:43 AM by robscastle | 4 comments »

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. 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. It looked to be a pine gen...

Read this entry »


Part 35: 1800 x700 Work bench

02-16-2015 06:27 AM by robscastle | 3 comments »

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 ...

Read this entry »


Part 36: AKs ToolMakers Chest the begining Pt 1

03-02-2015 06:06 AM by robscastle | 2 comments »

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...

Read this entry »


Part 37: AKs ToolMakers Chest Thicknessing Pt 2

03-02-2015 06:16 AM by robscastle | 2 comments »

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 The smaller sections most certainly are pine, and again cleaned up OK I intend to use the long piece for the top and sides the piece with the hole...

Read this entry »


Part 38: AKs ToolMakers Chest Drawer Making Pt 3

03-04-2015 08:07 AM by robscastle | 3 comments »

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. The plan worked but not completely, it did not work fully for a couple of reasons, firstly I should not have rebated the ti...

Read this entry »


Part 39: AKs ToolMakers Chest Tweeking the joints Pt 4

03-05-2015 07:29 AM by robscastle | 2 comments »

We left off the Chest yesterday after making the 6×30mm 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 ...

Read this entry »


Part 40: AKs ToolMakers Chest Filling Sanding and Routing 9 Drawers

03-05-2015 10:35 AM by robscastle | 3 comments »

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 ...

Read this entry »


Part 41: AKs ToolMakers Chest Carcass Assembly

03-19-2015 07:27 AM by robscastle | 2 comments »

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 ke...

Read this entry »


Part 42: AKs ToolMakers Chest Making the Front Panel Door

03-25-2015 08:38 AM by robscastle | 3 comments »

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. 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. With a satisfactory fit production went ahead. First up I...

Read this entry »


Part 43: AKs ToolMakers Chest Door Panel Production and Final Assembly

03-26-2015 07:53 AM by robscastle | 1 comment »

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 a...

Read this entry »



DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics

HomeRefurbers.com