I had a lot of work, home stuff, and travel to distract me from the project recently, but after discovering my neighbor in the house behind was a woodworker and also a lumberjock, I was inspired to do some work last night.
I figured out my cutting plan, and cut the board to the rough chunks that I’ll rip into individual pieces hopefully tonight or during the weekend. If my measurements are correct, I should be able to eliminate the sapwood with some creative layout of the parts.
I also hit the boards with the orbital sander—I wanted 1/2” stock, and bought the board S3S, but of course there were still mill marks and rough spots from the milling. Did a 60/80/120 progression and they came out nice and smooth. I didn’t measure if they really ended up 1/2” or (likely) a little more, but the only place that really matters is where the through tenons extend proud of the legs, and I have some extra length built into the layout and will dry fit and trim them once it’s all said and done.
I DID discover that my vacuum hose does NOT fit into the adapter of my sander—the hose end is tapered down to fit into the extensions of the vacuum, and it ends up the same size as the sander interface it’s supposed to attach to. I’m suspecting there’s some kind of hose adapter, but need to check that. So the workshop is covered in dust, and the overhead air cleaner was nice and full this morning. Ahhhh for a real dust collector :)
Second part of the effort was figuring out the cutouts that will support the bottles. I thought of (and got input for) a variety of techniques, including holes saws, forstner bits, hand cutting, etc. I think for the small (bottle neck) racks I can use a 1 1/4” forstner, but the back holes (3 1/2”) were the issue I was trying to solve. Ended up laying out an MDF template that I’ll use with a flush trim router bit. As you can see from the cutoff, I used my circle cutting jig on the bandsaw and cut more than a semicircle, then trimmed off the excess on the tablesaw.
Should be able to put that on the stock, trace the line, rough cut on the bandsaw, and then smooth it up on the router table. Repeat x9.
Next step: rough cutting the boards into the individual parts, and creation of a similar flush-trim template for the curved sides rails.
-- Todd (Denver, CO -- Highlands)