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Father - Daughter Project

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Blog series by Mainiac Matt updated 11-13-2013 11:51 PM 21 parts 25663 reads 74 comments total

Part 1: off to a good start

03-10-2012 04:28 AM by Mainiac Matt | 8 comments »

I promised my daughters I would build each one of them a hope chest some day. Well, my oldest is going to help me make hers. This will be her first experience in the shop and my first “real” furniture project. We’re going to build a slight deviation of the NYWS design. I gave her three choices of wood. I could buy QSWO. I have a pile of Honduran Mahogany that was salvaged from a deck job site. Or I could get a Red Oak timber left from the construction of our hou...

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Part 2: making some progress prepping the lumber

03-12-2012 02:41 AM by Mainiac Matt | 1 comment »

Status update… We’ve got eight 48” long boards done, and fortunately, only need one more. That will cover the top and the long rails. Then we’ll have to go back through our few remaining 7’ rough sawn boards and the cut offs from the boards we’ve already processed to get our short rails and the styles. There are so many knots and checks in the lumber, that we’re going to be cutting it close. I may half to get a sheet of 1/4” oak plywood for the panels.

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Part 3: Top glued up

03-31-2012 07:57 PM by Mainiac Matt | 6 comments »

Spent quite a while finishing up the top boards…. Planed them down in a batch to get exactly the same thickness…. Cut to 1” over finish length and then joined the edges again as needed to get all the neighbors nice and cozy. Called in my helper to cut buiscut joints every 6” Got everything laid out and set up, and went through a dry run glue up. Despite our best efforts to be totally prepared, it was a mad scramble to get her clamped up in time…...

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Part 4: Top is looking good.... ready for bread boards

04-07-2012 04:01 AM by Mainiac Matt | 1 comment »

I plumbed a 4” dc line to a recycled funnel hood on the bench for use with hand held power tool work and gave it a test run today…. That, along with the air filter on high and the shop vac hooked up the tiny dust port really did the trick. I still wore a NIOSH mask, but the air seemed very clear. I could sweep the top with a fox tail and the dust was sucked right into the pipe The top turned out better than I thought it would… hit it with 80, and then 100 grit on...

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Part 5: bread boards are done

05-06-2012 12:38 AM by Mainiac Matt | 7 comments »

Decided to do the groove in the bread boards on the router table with a slot cutter bit And then to do the tounge on the end grain of the top with a rabbet bit. I often find the parallel set up bars used with the machinist vice on my bench top mill come in handy for set ups. They are 1/8” thick, so in this case two of them inserted in the groove with a feeler guage leaf was snug as a bug in a rug. This allowed me to match the rabbet bit height to groove bottom. the resu...

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Part 6: Back at it

06-10-2013 12:04 AM by Mainiac Matt | 4 comments »

Now that schools winding down, my daughter has time to play… And now that I’ve got my TS refurb, and other shop projects done, I’m itchin’ to make things again…. We inspected the top panel we had glued up and were happy to see it was still flat. It did shrink ~1/16” in width and developed one small split, but otherwise looked good. So we sanded it again with 220 on the ROS (using the new down-draft out-feed table): My daughter selected cherry...

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Part 7: Top side finished

06-16-2013 12:28 AM by Mainiac Matt | 5 comments »

We’re lovin’ this Cherry tone Danish Oil…. We jitter bug sanded w/ 220 and then hand sanded w/ 220 Here’s the top side of the cover after two coats of finish:

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Part 8: progress on the styles...

07-26-2013 05:42 PM by Mainiac Matt | 3 comments »

Well my daughter has been away at camp and she’s volunteering at VBS when she gets back, so I decided that this project needed a jump start while she was gone…. Styles ripped and cut to final length…. I don’t have a fence with a stop, so this is how I get them all exactly the same… I have some metal working layout tools that I find quite handy for accurate set ups…. here I’m setting the depth of cut and setback for the groove cut in the fron...

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Part 9: Styles are done

08-02-2013 06:17 PM by Mainiac Matt | 1 comment »

Set up router table to cut the lower mortice, with stop blocks at either both ends to establish the desired length.The key to this setup was that the fence was never moved the entire time the mortices and panel groove were cut, and the outside face of the workpiece was always against the fence. I used a 1:1 template for the curve cut. Cut mated pairs together on the band saw and lightly sanded. Next up will be cutting the tenons in the ends of the rails.

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Part 10: Tenons anyone?

08-04-2013 08:35 PM by Mainiac Matt | 4 comments »

I decided to do them on the router table, as the setup seemed to be easier and my dado blade isn’t so grand.

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Part 11: tweaked tenons and dry fit assembly

08-10-2013 03:30 PM by Mainiac Matt | 3 comments »

I paired each tenon to fit it’s mortise snugly and dry fit the assembly thus far. It’s starting to look like a hope chest and my “customer” is pretty happy.

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Part 12: Dry fit frame and final size panels

08-21-2013 10:52 PM by Mainiac Matt | 8 comments »

After sanding the panels we ripped and cross cut them to final size… I was a little nervous doing such a short and wide rip, but it went smoothly…. Since the miter slots on my new-to-me refurbished Jet cabinet saw don’t match my old Craftsman contractors saw, I need to make a new cross cut sled. Until then, I’ll have to use my Incra miter gage with a fence…. Next up was routing the lip with a rabbit bit. This was a bit of a challenge, as the pa...

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Part 13: Finishing up the panels

09-02-2013 12:58 AM by Mainiac Matt | 1 comment »

The inside edges of the raised panels have to be blunted as they stand proud on the inside and present a snag/scratch hazard. I used my dads old Craftsman router as it has a adjustable guide bearing… Here they are after two coats of Danish

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Part 14: Cut mortice for lock set

09-02-2013 01:12 AM by Mainiac Matt | 2 comments »

I finally got to use the mortiser I picked up from Craig’s List last year. I have it set up with a modified cross slide vise and it works great. I have the chisels VERY sharp and they cut the Red Oak like butter. A little hand chisel work to precise fit the lock set…. I used the router table to cut the clearance for the flange, but then I made a boo-boo… No way I can live with this, so I’ll have to square it up, patch it and re-cut the mortis...

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Part 15: Glued up some frames

09-03-2013 01:10 AM by Mainiac Matt | 2 comments »

Cut little foam blocks to keep the floating panels centered…. Test fit and now ready to glue up…

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Part 16: Name engraved on front style

09-08-2013 10:14 PM by Mainiac Matt | 3 comments »

I thought another way to make the project special would be to engrave some text or artwork. My daughter chose to simply put her name on the front rail… And she figured since it’s a hope chest, she’d only put her first and middle name, in anticipation that her last name will change some day (sniff, sniff). If you’ve followed some of my other projects, you know that I program for the CNCs at work and have access to use them after hours. We do mostly simple geometri...

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Part 17: Final panel glued up

09-08-2013 10:18 PM by Mainiac Matt | 2 comments »

Now that the engraving is done I could glue up the last frame…

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Part 18: Big event

09-24-2013 02:20 AM by Mainiac Matt | 3 comments »

It’s starting to look like a hope chest…

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Part 19: Final assembly and applying finish.

10-17-2013 12:53 AM by Mainiac Matt | 3 comments »

Glued up the for frames, added ledger to support bottom, and installed Next was final sanding, clean up and finishing with Danis Oil… bottom…

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Part 20: Hinges, lid stays & lock set

11-09-2013 06:58 PM by Mainiac Matt | 3 comments »

Getting close to wrapping this one up… I was sweating bullets that I would mount the lid cockeyed, or bungle the lid stay (which I did).... Cedar bottom done Hinges and stays… I like these lid stays from Rockler, but you have to pay very close attention to the installation geometry or the lid won’t close all the way. I goofed and have two unused screw holes to prove it

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Part 21: all done....

11-13-2013 11:51 PM by Mainiac Matt | 4 comments »

Cedar boards installed… Hinged top and lid stays…. lock and engraving…. And the proud woodworkers….

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