Showing posts with label woodworking. Show all posts
Showing posts with label woodworking. Show all posts

Sunday, February 6, 2011

A New Assembly Table

In March of 2009 Marc and I attended a Greene and Greene woodworking class at William Ng's school of Woodworking in California taught by Darrell Peart, you'll remember this from my post of March 12, 2009. During that class I saw some really nice outfeed tables that the school had constructed on their tablesaws. I liked the look of them quite a bit and the utility was astounding. I've been using a shopmade outfeed table attached to the back of my saw and a separate assembly table, I had the idea to combine the two into one table saving valuable shop space while adding much needed storage space.
I started with the idea of one long 12 inch wide cabinet that runs 6 feet long, in the front I used two 24 inch cabinets and added a 24 inch space with drawers in the middle.
I used 3/4 inch domestic Birch plywood for cabinets and drawers and base frame but used the back face of the plywood because I found it to be more visually appealing once finished. The base frame is 2 inches smaller than the cabinets and has heavy duty levelers at the corners. I edged the cabinets with 3/4 x 1/4 inch strips of walnut left over from a previous project. I secured the cabinets to the base and to the back cabinet and added a 24 inch floor where the drawers will go.
Once the cabinets were leveled I placed a sheet of 3/4 inch plywood cut down to 84 inches on top of them and secured it to the cabinets with screws. This effectively made all the cabinets into one strong unit. On top of the plywood I secured a sheet of MDF covered with melanine. I trimmed this flush to the plywood top with a flush trim bit on my router then edged it with 3/4 x 2 inch walnut glued and brad nailed in place.
I made drawers out of 3/4 inch ply with 1/2 inch bottoms and installed them with full pull out heavy duty slides. I hung the doors for the cabinets using European hinges then cut shelves for them and installed shelf pins to allow for adjustment. I created pulls for the cabinets and drawers using Walnut in the shop and screwed them in place.
The table is finished with Arm-R-Seal inside and out and looks fantastic in the shop. I routed two 3/4 x 3/8 inch slots in the table to allow the miter gauge and crosscut sled to travel beyond the edge of the saw. Other than the added storage the real upside is that I now have 3 extra feet of floor space in my shop and maybe I will stop slamming my hip into the corner of the tablesaw.


"Too often we enjoy the comfort of opinion without the discomfort of thought."
John F. Kennedy

Sunday, September 5, 2010

The Rest of the Beginning

You may remember the front of this cabinet from my post The Beginning from way back in December in which I created the door with a cherry tree motif using a bolection inlay technique which left the branches and blossoms lightly proud of the surface.

I started the rest of the cabinet by designing it using SketchUp, I continued the wood combination from the door, cherry for the sides, walnut for the shelves and the top/bottom, curly maple for the drawer and the back.
The box is joined with finger joints to highlight the contrasting woods, the shelves are let into the sides with dadoes. The back is 1/4 inch birch plywood with curly maple veneer. The drawer is curly maple with a 1 inch hole for a pull.

I used a 1/2 inch quarter round bit on the inside edge of the hinge side of the door then used a 1/4 inch brass rod attached from the top and the bottom as a pivot hinge. I used a cove bit to route a handle into the free side to keep the lines clean and simple. The door rests inside the edge of the top and bottom letting the walnut frame the door.

The finish is as simple as it comes, a few coats of Watco Danish Oil, Natural, followed by a rubbing with paste wax. I installed a french cleat to the back of the cabinet and attached it to the wall that way. I've very happy with the way this came out. I enjoy making Stickley, Limbert, and Greene & Green reproductions but sometimes it's really nice to design something yourself and see it come to life.



It's a job that's never started that takes the longest to finish.
J. R. R. Tolkien

Saturday, June 26, 2010

Maloof Inspired Rocker, Finale

Well friends and neighbors, here it is, the complete and finished rocker. After many weekends of work, some re-work, lots of shaping and lots and lots of sanding it's finally finished. Quite a few of you have asked, and yes, it is very comfortable. The seat feels great, the back slats curve just right to support my back, the arm rests are just the right curve to fit, well at least to fit me. Last but not least, it looks great in my living room.


The rockers came out great, and with the chair upside down I was able to run sandpaper along the whole underside creating a smooth gentle curve to rock on. One of my favorite details is the transition from the back legs to the rockers, take a second to enlarge the picture and take a look at it, but pictures don't do it justice, come over and run your fingers along the curves.


The organic shape of this style of rocker is what draws people to it, and it's true, they just can't help but touch it.








I tried very hard to make the arms match and to edge each one with a nice sharp hard line. The smooth transition from the front legs into the arm is something people that have seen it coment on, it really wasn't that difficult thanks to the instruction on the DVD and book.




Shaping the front leg into the seat smoothly was challenging but the joint itself was easy and it fit perfectly with the two matching router bits that Mr. Brock recommends.



The crestrail is the most visible part of the chair and therefore the part I wanted the most srtiking grain on, when I unpacked my walnut the very first day I set this piece aside for the crestrail. I think I made the right choice.




I have commented on Mr. Brock's DVD/Book throughout the process of building this rocking chair only in a positive way, please be assured that I have no connections with Mr. Brock other than a nice Email he sent me after my first blog post. I was given the DVD/Book as a Christmas gift. I found the instruction and plans to be spot on, the templates and jigs described in the book are not overly complicated and very useful, I would not attempt a rocker of this complexity without them. I do have one criticism of the DVD though, there is alot of time spent watching Mr. Brock work with accompaning guitar music, while the music is good, I feel that I would have been better served by voice over description of the process. I do realize that this is Mr. Brock's first DVD and I haven't viewd his DVD on building a Maloof low back dining chair, maybe you won't agree with me, it is after all just my opinion, but yeah, less music, more naration please. Mr. Brock is a professional woodworker and instructor, I could not have even attempted this project without his product, thank you Charles, you helped push this woodworker to a new level.

"Little by little, one travels far." - J.R.R. Tolkien

Monday, June 14, 2010

Maloof Inspired Rocker, Charles Brock Plans, part 7

Last weekend I started work on one of the most elegant, and probably the most important part of the Maloof inspired rocker, the rockers. This part of the build is a departure from the rest of the chair, it requires some bent lamination. Mr. Brock adds a strip of maple and ebony to his rockers for emphasis, but I decided that I wanted to stick with my total walnut theme.
The book and DVD shows Mr. Brock slicing the laminations of the band saw with jointing the stock in between each cut and cleaning up the cut with a drum sander. I decided to use the thin strip cutting accessory from Rockler, this in combination with my glue line rip blade on my tablesaw makes for easily repeatable strip cutting without having to clean up the stock between each cut and cleaning up the bandsaw on the sander. You may say that the loss of 1/8th of an inch with each cut is unacceptable, but since I'm cutting along the width, not the thickness of the stock this is less of an issue. I marked a triangle on the stock so that I could keep the laminates in order after cutting.
I had previously created the bending form using the template included in the book using the cut off of the curve for a caul. The stock for the rockers is roughed to 1 1/2 inch thick so I made the form out of 2 thicknesses 3/4 inch of MDF attached to a backer board. I covered all the contact surfaces with packing tape to keep the glue from sticking to the form. Using Titebond II glue for the extended open time I coated the top side of all but the top laminate. After laying the laminates in order on the form I used the top caul to pull in the bend at the center, applying pressure with F style clamps. Adding a few clamps lets you work back and forth to bring the laminates into contact with the bending form. The most difficult part is to create the back bend on the end of the rocker, this again is done by pulling the laminates into the form using a series of clamps. I used a deadblow hammer to knock the laminates flat into the form as I went. The set up was left to sit overnight.
Using left over stock from the laminates adder blocks 6 inches long are attached to the rocker after it is removed from the form. This allow the sweeping transition to be created from the leg to the rockers. Using a posterboard template for the curves I rough cut the transition of the legs to the rockers on the bandsaw after aligning the attachment points. I used a round over bit in my small router to shape the outside of each rocker and a smaller round over bit on the inside edges. Once both rockers are roughed out I cut the legs so that they would sit on the transition blocks using the technique Mr. Brock shows in the DVD. After a little trimming and fitting the rockers are attached to the rockers using 1/2 inch oak dowels.
I let the rocker attachment dry for a week, hey I had things to do, I started shaping the rockers and the transitions. Again I used my new favorite carving tool, the microplane, to form the rocker to leg transitions and the shape the taper on the back curves of the rockers. After the microplane I stepped down to rasps and files to smooth out the transitions, following this I started hand sanding starting at 120 grit, progressing to 150, 180, 220, 320, and 400, I followed this with 3M pads, maroon, grey and finally white.
With this, the construction of the rocker is complete! It has been a long road, I started the first weekend in April and here it is, the middle of June, I estimate around 120 hours into this build already, what with remaking the back legs once and the front legs twice and taking my time. I've learned a lot about making chairs and rockers, and more shaping wood. I've watched the DVD over and over and poured through the book. I want to say that I would not have been able to do this if it wasn't for Charles Brock's efforts with his DVD/book and website.
The next and final post will go over finishing the rocker and lessons learned while building it. I'll share with you more of my thoughts on the DVD/book and lots of pics of the finished rocker.



"To practice any art, no matter how well or badly, is a way to make your soul grow. So do it." - Kurt Vonnegut, Jr.

Monday, May 24, 2010

Maloof Inspired Rocker, Charles Brock Plans 6

This weekend I got some good shop time since it was raining both days. I was able to get quite a bit done and I have to say that I'm really happy with the way this chair is looking.
I started by using the spindle pattern and marking out 7 spindles for the back of the chair. The good thing is that they are designed so that you can cut them out like nesting spoons, thus saving alot of wood. After bandsawing four from one board and three from another I cleaned up the cut marks on the spindle sander, how appropriate.




Next I took a posterboard cutout of the front profile of the spindles and transfered the marks to both sides of the spindles. I then took the stock back to the bandsaw and again to the spindle sander. Once everything was cleaned up and shaped correctly I marked a centerline on the front and back to aid in shaping and lines on the side to help me maintain the right shape. With a spindle resting on the table I used a roundover bit in my small router to shape the long top taper of the spindle. I then mounted the spindle in the vice and shaped a slight round on the front and a steep round on the back with the microplane, I also shaped a round on the short bottom taper.


After sanding each spindle with 60 grit on my random orbit sander I marked each to length and shaped the bottom with a 1/2 inch tapered dowel cutter and the top with a 3/8th inch tapered dowel cutter both of which Mr. Brock recommends in the DVD. With each spindle shaped and tapered I proceeded to sand them 80, 120, 180, and 220 grits.


With the spindles completed I sanded to headrest up to 220 grit and I sanded the inside of the back legs through 220 grit. After placing the spindles in place I attempted to fit the headrest but had to take it off a couple of times and trim and adjust a few of the spindles. Once everything was adjusted and fitted correctly I was able to screw the headrest in place. At this point I noticed that a couple of the spindles that had cut outs that did not exactly line up, so I marked the cut outs that needed to be adjusted and called it a weekend. Next weekend I plan on cutting the stock for the rockers and laminating them. At this point I cannot wait to start oiling this chair up and seeing the grain come to life.
"We are what we pretend to be, so we must be careful what we pretend to be."
- Kurt Vonnegut


Saturday, April 17, 2010

Maloof Inspired Rocker, Charles Brock Plans 3

Last weekend I went over to my friends shop to use his Harbor Freight lathe, well, it had died. Apparently the motor had given up on its short, dubious quality life. Unfortunately for me I didn't know anyone else locally that has a lathe and I needed to turn the front legs for my rocker, so I did what any woodworker would do, I bought myself one, I mean, I really did need it to complete this project, really. So I went over to The WoodWhisperer's Amazon store because it really is a painless way to support a great site and to keep Marc able to keep supplying us with fantastic videos.

Once the turning was complete, and I was covered it Walnut chips, the front legs looked great in place and the chair is starting to look like a chair. Now onto the back legs, probably the most difficult part of the build so far. After creating the tapering jig that Mr. Brock describes in the book, I tapered the adder blocks on the rear legs to give the proper splay.





Then I cut the tenons on the table saw and rounded the inside corner on the router table. After a little fitting and fine tuning with my small router plane and some paring with a chisel the back legs fit nice and tight with just the right amount of splay.




With both rear legs in place and the front legs on it's really looking like a chair, tomorrow I'll drill some holes to attach the legs. Mr. Brock calls for a Miller stepped bit for the attachments of the front and rear legs, and also the headrest. I have some more cutting to do on the rear legs on the bandsaw and a little more shaping to do on the seat.
You'll notice the Rockler Bench cookies on my table, I've found these perfect for holding the coopered seat for shaping, in the DVD Mr. Brock uses what looks like a cradle custom made to hold the seat, but since I'm just making the one chair making a special jig to hold the seat seemed like overkill to me. I simply place the cookies on the table and set the seat on them, the cookies hold the seat securely when shaping and sanding. Next week, the arms, wish me luck.
"When a man is wrapped up in himself, he makes a pretty small package."
- John Ruskin

Sunday, April 11, 2010

Maloof Inspired Rocker, Charles Brock Plans, 2

This weekend I worked on the seat, the front legs, and the back legs. I also rewatched the DVD yet again, it really is an invaluable tool. The first thing I did was to dust off my biscuit joiner and look all around the shop, I know I had some biscuits around here somewhere. In the DVD Mr. Brock uses Dominoes but he does suggest that you could use biscuits or dowels, they really are just to align the coopered seat. After checking seat for size I used a plane to trim off a few hundreds of an inch off of each of the ends. Once I was happy with everything I measured and marked for the joinery and cut it on the tablesaw. Using the 1/2 inch slotting bit that Mr. Brock recommends I trimmed the tenons for the legs. I trimmed excess material from the seat using the bandsaw then, using plenty of glue, clamped it up.
While the seat was cooking I picked some nicely figured Walnut for the front legs and cut them to size. Mr. Brock's instructions for laying out the mortises for the front legs were very easy to follow. I cut them to size then adjusted the fit with a router plane. Once this was complete I used the provided template to mark the front legs and cut the waste away on the bandsaw.
Once I took the seat out of the clamps the fun started, using an angle grinder and a Galahad carving wheel, I carved out the seat to a shape I liked then refined it with with a sanding wheel, a micro plane, and finally worked my way to 60 grit sandpaper on my Festool sander. I have to say that I never thought much about sanders until I got to use this unit with it's attached vacuum, does a better, cleaner job that any sander I've ever used, I have some DeWalt random orbit sanders that I used to attach to my shopvac, but it doesn't compare. I wanted to see how the seat was going to look so I splashed some mineral spirits on it and WOW!, it is beautiful.
The next thing I did was to select a board for the back legs and rough cut, then trimmed them out on the bandsaw, following this I attached the pattern and cleaned them up on the router table. The instructions call for an adder block to be glued to the inside of each leg, this was the last thing I did this weekend, stay tuned for more updates. Oh a last note, Charles Brock picked up my last post and linked it from his website! Unfortunately somehow my "about me" section had gotten turned off so he had no idea what my name was, and at the end of my post I added a quote from Douglas Adams, but I didn't put quotation marks around it, so, Mr. Brock called me Doug..., well, who really cares, I'm just psyched that he picked up my post.
"Always be wary of any helpful item that weighs less than its operating manual."
Terry Pratchett

Tuesday, March 30, 2010

Limbert #366 Bookcase Finished



The last couple of weekends I spent most of my time finishing the Limbert bookcase, if you're not familiar with my finishing process check out my post on it here. It takes a few days to complete with drying time in between, so while I was waiting I was working on my Shaker table for The Woodwhisperer Guild March Woodworkers Fighting Cancer build. It was kind of nice having two projects going on at the same time, if I got bored with sanding I could switch over to tapering the legs of the table, if I didn't have much time I could work on the drawer. I decided to go with a medium brown finish for the bookcase so I started with medium brown dye and I used brown Mahogany gel stain for the over stain. I took the time to finish the backing plywood prior to attaching it to the back of the case with 1/2 inch staples to allow for any wood movement.
Once the dark wax was mostly dry I had a friend help me carry it into the house, all that quartersawn white oak is heavy. After letting the wax cure overnight I couldn't wait to set up my vintage Kodak camera collection on the top and fill the bookcase with my woodworking and photography books that have been piled on my dining room table for months. Then I decompressed some of my other bookcases leaving me with a whole empty shelf to expand in to.
I was very happy with the way this project came together, I started with just some pictures and measurements, used Sketchup to make them into a workable plan and went on from there. One detail that I didn't cover in my
previous posts is the bevel on the edge of the adjustable shelves, its a nice little touch that you can see in the pictures or some of the antiques. I created the bevel the same way I did on the top of the Shaker table, I adjusted the angle of my tablesaw to 12.5 degrees and set the fence 1/2 inch away from the blade. Using a tall fence and a magnetic featherboard I carefully moved the shelves vertically past the blade. Cuts like this almost always leave burn marks so a little clean up with a low angle smoothing plane was in order. Every time I make something I learn something new, sometimes something big, sometimes something small, I noticed with this bookcase sitting near my last one that my sanding and finishing have improved. I learned on this one that it is easier to finish a bookcase with the back not attached, a lot easier.

"Happiness is not something ready made. It comes from your own actions."
- His Holiness the Dalai Lama



Sunday, March 7, 2010

Limbert #366 Bookcase, Part 2

Last weekend I cut and routed the dadoes and grooves in the sides of the Limbert #366 bookcase. During the week I took a few hours and, using the template I marked out the cutouts and the bottom lift. After drilling a few access holes and cutting the waste out with a jigsaw I used the template and a 3/4 inch pattern cutting bit to clean up the cuts. I also cut the adjustable shelves to size and added the bevel on the front of each shelf.
Saturday I cut and glued up the top for my cherry Shaker table for the Woodwhisperer Guild Woodworkers Fighting Cancer build, then I moved on to sanding the bookcase. I ran the complete sanding schedule I use for white oak, starting with 60 grit, then 80, 120 and finally 180 grit. Between 120 and 180 grit on the inside of the sides I drilled the shelf pin holes for the adjustable shelves. I don't use a fancy template for this, I have a section of pegboard with two lines of holes 8 inches apart marked every 2 inches. With this I use a 1/4 inch brad point drill bit with a stop collar in place to drill 1/2 inch deep holes. I've used this on many projects and have never had problems with it, its simple, its cheap and I can make custom templates for any project.
The final dryfit was done after hand fitting each part, a few clamps were used to hold everything together and tight while I took measurements to insure that everything was square. I took the rest of the afternoon to make a taper cutting jig for the tablesaw inspired by Marc's live Guild event as I would need to cut long tapers for the Shaker table.
Today I had to run to Lowes to get some oak ply for the back of the bookcase, all of the pictures of the original that I could find show a plywood back so why not? I gathered my long clamps and glue bottle and completed the glueup. After a couple of hours of drying I flipped the bookcase onto its face and measured for the plywood back. After cutting and sanding the plywood I placed it and attached it with some blue tape for the pictures leaving it unattached to make finishing easier.
I took the rest of the day to cut the mortises in the Shaker table and taper the legs. Also I took the top for the table out of the clamps and rough sanded it.
One of the features that attracted me to this particular bookcase is the detail on top of the piece. The small fixed shelf and the cutouts along with the solid wood back and the large fixed top shelf are very nice and would make a perfect place for me to keep part of my vintage Kodak camera collection. I can't wait to complete the finish and get this bookcase in the house.

"Take everything you like seriously, except yourselves."
Rudyard Kipling

Sunday, February 28, 2010

Limbert #366 Bookcase



When I started my journey into Arts and Crafts furniture I was of course drawn to Stickley's designs, his being the most common in the literature. As I got further along I discovered Charles Limbert and his unique take on furniture. Limbert was a student of European designers, particularly Charles Rennie Mackintosh of the Glasgow school, his designs are noted by cutouts and curves. I've made many Limbert pieces and blogged about them here. I found this bookcase in a reprint of an early 1900's Limbert catalog and searched online auction catalogs until I found this one.
Limbert produced this model with and without a door, and in a double wide version. The single door version fits the size that I want, its 64 inches tall, 12 inches deep and 30 inches wide. I'm not sure if I will add the door or not, but for now I'm proceeding with the assumption that I won't have a door. I took the photo into Google Sketchup and with the know dimensions produced a plan that I've uploaded in The Wood Whisperer Community.
From this model I produced a cutlist and exploded details of the parts. Saturday was spent preparing the Quartersawn White Oak stock and gluing up the parts, I also created a template for the rectangular cutouts at the top of the bookcase and the small lift at the bottom. Sunday I took everything out of the clamps and cleaned off the boards. I trimmed each piece down to the correct size and cut the 3/8th inch dado along the back of the sides and on the top and bottom shelves. Using a T-square guide and a plunge router I cut the dadoes for the top and bottom shelves and for the small shelf. I switched to the router guide and a 3/8th inch bit and cut the mortises for the top and bottom aprons. After squaring up the end of the small shelf dado with a chisel I cut the tenons on the aprons using the dado blade still in the tablesaw.
After doing a little fitting of the pieces with a routerplane and chisel I was able to complete an initial dryfit before calling it a day. I wanted to get a good start on this build because starting next weekend I'll be beginning the Guild March Shaker table project as part of Woodworker's fighting cancer. I'll be recording my progress of the Shaker table and continuing on with this project so look for updates.
"First things first, but not neccessarily in that order." - Dr. Who

Monday, December 28, 2009

The Beginning

I know that I can make a nice wall cabinet, the challenge with this project was the inlay that I had thought of for the door. That being said, I decided to start with what for me is usually the end, the door. This is going to be a stand alone wall cabinet to replace a smaller one in my bedroom, it's made from Cherry and I wanted to incorporate a bolection inlay of a Japanese Cherry tree on the door. I've never done a bolection inlay before and wasn't sure if I could pull it off well enough so I wanted to complete the inlay first to leave me multiple options with the design if I couldn't pull it off.
I started by selecting an interesting grain pattern and cutting it to size of the planned door. I wanted the underlying grain to mimic the mountains that you would see in the background of a Japanese print.

With the grain pattern set I sketched out a Cherry tree on large graph paper, at this point I had in my mind how I was going to do the wood of the tree but I still wasn't sure about the blossoms. I cut the sketch of the trunk into smaller components and using spray adhesive I attached them to pieces of 3/16 inch thick walnut aligning the grain in pleasing ways. After cutting out all the pieces on the scroll saw I used double sided tape to hole the walnut to the door and outlined them with a sharp Exacto knife. Working with one component at time I then routed a 1/16th inch deep relief into the door. After fitting the piece I then would move on to the next piece, completing the tree in a few days between finishing up Christmas projects. I still had in my mind that I would cut the blossoms and without routing glue them to the door and shape them with my Foredom power carver. I tried this method as a test and was very disappointed. The small blossoms were very hard to cut on the scroll saw and attempting to shape them scarred up the base wood. I gave up on this approach.
As often happens I had an epiphany in the shower, I'd go abstract and simple. After I dried off and dressed I went out into the shop and using a 3/8th inch plug cutter I cut a scrap of curly maple into plugs. I drilled some 3/8th inch holes into some scrap cherry and drove the plugs in. I trimmed the plugs with a chisel and shaped them with a sanding block. I noticed that there was a slight space around the plugs and that all of one size would look odd, so I undersized the drill bit by 1/64th of an inch and tried that. The plugs fit very tight and after trimming and shaping there was no space around the plug. I then moved to the drill press and cut 3/8th and 1/4 inch plugs from a block of curly maple. I started placing holes where they looked good and plugging them, I kept adding them here and there until I was happy. After trimming them and sanding the plugs and the trunk I decided that the project was a success and the wall cabinet could proceed with this design. More to come as the cabinet takes shape.

"The beginning is the most important part of the work." - Plato

Friday, October 30, 2009

Limbert #234 Tabourette, Part 1




My neighbor asked me to make her an end table and a coffee table in the arts and crafts style to go in her bungalow. I showed her some of the completed pieces in my house and she was drawn more to the Limbert style. I did some more research in my books and online and came up with this little tabourette as an end table, I showed her the pictures and described my idea for a coffee table that would compliment the design of the end table. Coffee tables weren't a part of American homes in the 1900's but I took a Limbert cocktail table and lowered it and changed it some to make it a coffee table, more on that in a later post.
In previous posts I have described my method of scaling plans from pictures but luckily I was able to find descriptions of this table along with dimensions, which are 16"x16"x18" tall. These relate to the widest measurements, the top which will be square. From this and the photos I came up with the dimensions in the picture at the left.

Using Google Sketchup I created a model of the table along with dimensioned elevations, I was also able to look at the components and come up with construction details such as how to connect the sides.


After removing the stock from the clamps and trimming it to size I took this template I made up from the plan above and marked out the areas to be cut out. After removing the bulk of the waste with a jigsaw for the cut outs and the bandsaw for the bottom I carefully aligned the template to the inside of each side piece and screwed it in place. Using a template like this for routing is always good, you can attach it with double sided tape or if piece has a hidden side you can just screw the template to the stock. I used a 1/2 inch pattern cutting bit in the router table to give the cutouts the proper radius at the corners. After this I cut a 45 degree miter on each side of the side pieces.


What followed was some sanding and a little hand work on the cutouts then I glued the miters together using the miter cutoffs as glue blocks a little time cooking in the clamps while I sanded the top. A final sanding on everything inside and out and attaching the top with figure 8 table irons, a little more touch up sanding and a cleaning finished up this project for the weekend and now all that is left if finishing. My neighbor looked at the finish samples that I keep and picked the middle range of the five I have so when I start on the finish I just turn over the sample and the "recipe" is written on the back. For more on my arts and crafts finish and a look at the samples see this post.
" Be who you are and say what you feel because those who mind don't matter, and those that matter don't mind." Dr. Seuss

Saturday, October 24, 2009

Music Stand part 3

This weekend I started out by sanding all the flat surfaces of the mahogany ribs and then taking to the edges and curves off everything with a folded piece of sandpaper . There are no pictures of this because I don't like getting dust all over my camera. Once I started to assemble the music stand I didn't think that I would need to clamp the ribs into the stand because the fit was tight enough that the last they took a gentle rap with a deadblow hammer to drive each one that final smidge, but I decided to err on the safe side and clamped each rib in place just in case the glue would piston one of the ribs out as it set up.

After a little more hand sanding and the first two coats of Watco Natural Danish Oil I decided to take the stand out onto the lawn for a better shot. I think it turned out great so far, with many more coats of Danish Oil and a coat of wax this stand will glow.



“Be who you are and say what you feel because those who mind don’t matter and those who matter don’t mind.” ~Dr. Seuss