Hope Chest for Daughter #2

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Blog series by Mainiac Matt updated 10-29-2016 05:32 PM 12 parts 10696 reads 80 comments total

Part 1: Design approved and construction details planned out....

02-07-2014 02:52 PM by Mainiac Matt | 11 comments »

Daughter #2 has “approved” the design of her hope chest. Here’s my rendered solid model…. I started from the same NYWS that I used for her sisters, but with the following skill builder changes: 1. outside edges will be joined with Lock Miter instead of tongue tenon and groove.2. rails and styles will be profiled and joined with a cope cut instead of mortise and tenon .3. panels will be raised and back cut instead of flat.4. feet will be cut with a taper, ins...

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Part 2: Drafted shop drawings

02-12-2014 01:35 AM by Mainiac Matt | 3 comments »

I cleaned up my solid model and created a 5 page set of shop drawings….

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Part 3: Hauled in wood from the barn to acclimate

03-30-2014 10:09 PM by Mainiac Matt | 9 comments »

This pile of lumber was given to my good friend after painting a house. They apparently are the cutoffs from a deck build some years earlier and sat piled under the deck. He in turn gifted them to me. 38 boards of 4/4×3-1/2×50” S4S My wood expert friends at work say it’s Honduran Mahogany. I’ve had it up in the barn loft for ~5 years since and today my A1 helper and I lugged it into the basement to get acclimated. We’re hoping to get started on t...

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Part 4: Stock prep day

04-19-2014 04:44 PM by Mainiac Matt | 11 comments »

Sorted boards to get the straightest ones, then hit them with a wire brush to get the dirt off of them. Jointer-jointer-planer-table saw Flat face – square and flat edge – parallel and flat opposite face – parallel square and flat opposite edge When ripping I was only taking a skim cut to minimize loss of width. This can be really messy with most of the sawdust blowing back on me, so I set up the shop vac with a funnel to catch most of it…. I stickered...

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Part 5: Top is glued up

04-22-2014 02:03 AM by Mainiac Matt | 13 comments »

I am very happy with the quality of cut I am getting with the Fussion blade, and have no reservations about gluing up the panels right off of the TS. Smoother and straighter than my jointer produces (granted, it’s a really old jointer). My daughter came down and cut the biscuit joints and assisted with the glue up. I’m so glad she did, as we needed to move fast. We were much better organized and prepared than my first build, yet were still challenged to get it clamped up qui...

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Part 6: Cleaned up the top and sanded.... almost blew it.

04-25-2014 06:34 PM by Mainiac Matt | 11 comments »

So this is the one tool in my shop that has time and time again brought me to the brink of catastrophe…. Within the first 60 seconds of sanding with 100 grit, I had put several depressions in the top. And of course, I started on the better of the two sides. :^( I had no problems using the belt sander on my first daughters hope chest in Red Oak, but lesson learned today…. Mahogany is not nearly as hard of a hard wood and Oak. Here’s what we used for the saveR...

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Part 7: Aftèr a long delay, we have bread boards

06-10-2016 01:12 AM by Mainiac Matt | 4 comments »

It’s been a 2 year delay, so I guess I better get going on this project again… The bread boards were previously planed at the same time as the top boards. I cut the dados with a slot cutting router bit on the router table. Then I cut the top to length on the TS with a panel sled. I cut the tennons on the ends with a hand router and a rabbiting bit with a guide bearing. I cut the slots short on the front side of the bread boards to hide the joint… One of...

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Part 8: Back at it...

10-09-2016 10:17 PM by Mainiac Matt | 8 comments »

I’ve finally wrapped up my last interfering project and have cleared the decks for action to get back into this project… My intention is to work it until completion… Broke out the raised panel set and reviewed my plans… Then I sorted my stock, selected boards for the long rails, cut off the checked ends, cut them to 3/4” over sized, and set up the style bit on my router table…. I used 13,000 rpm on the router (Porter Cable 3HP VS) and it cut eff...

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Part 9: gluing up panels with the new clamping cauls

10-12-2016 01:52 AM by Mainiac Matt | 0 comments »

Got a couple hours in the shop tonight. Sorting boards to match grain, color and shade, and then put together the first of several panel glue ups. It’s been >1 year since I joined and planed these, so I gave each board a quick rip on the TS to straighten the edges. The Fusion blade gave me a very clean cut that was ready for glue. First time using the new cauls (posted as a project some time ago if anyone wants to see more info) and they worked very well. I can hardly feel a se...

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Part 10: Panels Cleaned Up

10-23-2016 11:14 PM by Mainiac Matt | 2 comments »

I finished the 5 panel glue ups and put the clamping cauls and clamps away, and cleared the bench for the next step, cleaning up the panels. I wiped off as much of the glue that squeezed out off right away with wet paper towels, so the tops were in pretty good shape. The bottoms were a different story. I like to take the big boogers off by paring with a large 2” timber framing chisel, using it like a slick. Then I hit the joints with a card scraper. And I’m read...

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Part 11: How I prep card scrapers.

10-23-2016 11:37 PM by Mainiac Matt | 5 comments »

I make no claim to be a “real” galoot with the card scraper, but this process to renew the burr has worked for me. After a lot of use, the burr will get mangled and need to be created afresh. I start by setting up the scraper in a make shift jig using the bench vise and a couple scrap blocks of identical thickness. I set the scraper just above the blocks using a feeler gauge to get uniform height exposed. Then I file the old burr off with a mill file, using the jig to keep ...

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Part 12: panels cut to size and styles prepped

10-29-2016 05:32 PM by Mainiac Matt | 3 comments »

My first big mistake happened earlier this week when I set up the TS sled to cut my panels to size.One of these things is not like the other… 3/4” short to be precise… and of course it was the panel with the nicest wood figure. So after sulking for a few days, I went back into my design and made it 1.5” shorter, and cut the other side panels to match. I should have set up with a stop block like this the first time around… Then I moved on to prepping the st...

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