My apologies for being so late with this follow-up to the first blog in this series. I had to do a lot of work to get our garden into shape for the spring/summer season and it went pretty slow for me this year as I am getting old and decrepit.
You might recall that I had finished coving the staves for this container on my table saw. This is only going to be a utilitarian item which will serve as a moveable 2nd leg a for wall hinged work bench and I only did the coving for my own benefit to see how it would work out for future containers. I don’t intend to round the outside as it is not necessary for it to look good for it’s use. I’m making this for my son’s hobby bicycle workshop.
The finished coving work leaves me with 13 staves in total. The roundness will not be perfect in this case as I could not get the profile I needed with my small diameter tablesaw blade without sacrificing the width of the bords. The result did come out good enough though to get an idea of what’s involved for other containers I might do in the future.
You can find a lots of articles and no doubt many Youtube videos showing how the coving is done on a table saw. This photo shows the coved staves prior to cutting the angles on the edges. See below.
Here is the bottom glued-up and marked out for cutting on the bandsaw. The inner ring is the inner diameter of the container and the outer ring is the total diameter of the bottom including the part between the rings that will be imbedded into the dados. See below.
The staves were all laid on my bench cove side down and taped all the glue vertical joints with a wide masking tape, then I made 5 crossbands of masking tape and curled the staves up to see how well it would go together. So far, so good. See below.
Next, the still taped staves were laid on the bench, cove side up this time, and the dado lines marked for the bottom and then cut lightly with a knife. See below.
The dado outline cuts were deepened with my shoulder knife. This long handled shop-made knife gives incredible leverage without much effort. My reason for doing the dados by hand was to get an even dado deepness throughout the curve of the coves. I didn’t feel that it was worth the time to rig some way to do this with a machine as it would have been way too time consuming compared to the 2 hours it took to complete the job with hand tools. See below.
A flat chisel with the bevel side down was used to remove the waste next to the upper and lower lines. The last photo shows the bevel up for removing the waste in the middle, but I used the bevel down for most of that work too. See below.
This photo shows how I managed to work comfortably at the front edge of the bench by letting each stave drop over the edge after it’s dado was finished. This also made it easy to remove the chips and dust that accumulated in the glue joint during the chiseling work. See below.
And lastly, the finished dados. You might notice that I went all the way through on one of them. I did this to remind you not to make the same mistake! See below.
The next installment will be the dry fit and the gluing. I hope you will not be expecting anything of beauty to result. thanks for reading.
-- Mike, an American living in Norway.