03
Dec 17

Progress…

I actually managed to tick off almost every line on the to-do list for the week by Sunday night for a change. Before doing any “real” work though, I had to get the new interlopers off the bench. It’s been a while since I did framing-level work with 2x4s, but it’s like riding a bicycle…

…downhill on a wet slope towards a brick wall while blindfolded.

But since I didn’t care what the end product looked like, it was fast enough work…

Rough as 10-grit sandpaper, but it got them off the bench and me back to it. I might make something less… industrial at some point, but for now…

That’s the table legs profiled and rounded on the back (the front has to wait until the frames are glued up). Next to drill the holes for the tabletop attachment screws and that needed my big cordless drill…

I quite like that drill, it’s in magnificent condition for something that’s getting on for 70.

It is, by the way, a nice luxury to have a brace that’s dedicated to countersinking holes. You wouldn’t think it, but you tend to use it a lot…

And glueup. Hide glue again, hence the hot water bucket (hide glue and Irish winters don’t mix well). And that’s where I left it on Saturday evening.

On Sunday morning, I took off the clamps and things looked okay, so I got the tabletop up onto the bench and marked off the final sizes. Not much trimming needed in width, really just straightening up the edge there, but a good three inches came off the length because otherwise the table would be tippy.

I did try using the bandsaw to do the rough-cut there but it *really* didn’t like my new experimental bandsaw guides…

Teflon rod instead of the steel rod that had been there. Oh well. I might just have been overloading it with torque in the piece because it was so large it was almost unmanageable, so I’ll test it on some smaller pieces later and either leave or replace the teflon guides with the originals.

With it trimmed to size (at least roughly, the end grain is going to need a final session on the shooting board), it was on to smoothing the tabletop. Oddly the #4½ wasn’t getting it done even after touching up the blade on the diamond stones; I had it set to a really high cutting angle last time I was working with it, on some sapele; I guess it’s just not biting on the oak as a result, though I’m not sure why not. Oh well, out with the #4 instead and that got it done quite nicely. It’s not fully done; I want to use the #5 to smooth the underneath a bit, and attach the top and then I’ll come back and finish up the smoothing work on the top.

Then on to the next project and picking out the wood from the board to match the plans. This will be a blanket chest – if you know what that is, the scale might seem strange, but there’s a reason for it (just run with it being a very small chest for now). I had a 9×30″ oak board that I could get all the rails and stiles from, even if it has a nasty bow a few inches from one end; but I want a final thickness of three-quarters of an inch and it’s just over an inch now so I can get that bow out. The posts I already had gotten from some 8/4 oak at the end of last week.

The bandsaw might be fussy but it does let you get rips done fast… even if you then have to spend a while with the #5 to get the edges back to being clean again.

Just trying to get a feel for the overall size there (it will be smaller than this – the joints aren’t cut and the oak’s not thicknessed yet). There will also have to be panels, this is just the frame, but one thing at a time. And I have an idea for the floorboards as well.

Finally going to get to use the pigsticker on this one 🙂

All the grooves cut in the posts. I’m wondering whether to thickness the rails and stiles before or after grooving. I’m leaning towards after. I didn’t dive into the morticing either, it’s too late in the day at this point for that, I’d wind up morticing the wrong groove somehow.

So, last job of the day, glueing up a blank for another bandsaw box.

An offcut of walnut from a long rip that went badly (you can just see where the saw wandered there). It’s a bit small for anything else really, but for a bandsaw box it’s grand. Also, walnut. It’s basically cheating using this stuff (and at nearly €90 per cubic foot, it’s definitely pay-to-win cheating).

And I’ll leave things there for the evening. The last piece of hardware I need for the table should arrive on Monday, and I might be into the finishing before the end of the week if I’m lucky, as well as making progress on the chest and the bandsaw box.


27
Nov 17

Sounds okay

Couple of bits and bobs arrived in the post today:

Some brass-plated hinges for the next project, a silicone hose adapter to try to improve dust extraction from the bandsaw:

Beats a spring clamp and a bungee cord.
And this little doodad as well:

I’ve been wondering how bad the noise from the shed actually is for the neighbours you see. Enter the Uni-T UT353, a cheap little noise meter from Shenzen. And after a wee bit of experimentation, some pleasant results – the loudest thing with the bandsaw running is the vacuum cleaner that does dust extraction. It’s 87dbA in the shed itself with the door shut; 65dbA just outside on the decking; and it’s 55dbA back on the patio by the back door (for reference, it’s 65dbA inside the kitchen with junior watching Rescue Bots and the other usual sounds of life).

Now, start cutting wood and that does change a bit – 102dbA inside the shed, 83dbA on the decking and 74dbA back by the house. But that’s still only up there with a car driving past, not the you-definitely-need-hearing-protection levels that were my only experience of it so far (because I’m in the shed you see).

So that’s nice to know. I don’t think I’ll be getting anything noisier (the sander is rated at 76dBA) and frankly I don’t want to; and I limit the hours I use the bandsaw to anyway because people have to work (and anyway, apart from the boxes, I don’t use it for much beyond rough cuts).

Tonight for example, I took some of that 8/4 oak which I’d rough-sawn (by hand because it wouldn’t fit in the bandsaw) to about 1′ lengths, and I trimmed off the damaged edges (pack straps tend to mangle those) using the bandsaw.

I should get the four pieces I need from that for the next project without much trouble. I just planed the sides flat and marked a centerline; I’ll cut that in half tomorrow and then in halves again, and then trim the depth on the bandsaw (because thicknessing from 8/4 to 6/4 is a bit much even for a scrub plane like Sid). I’m taking this slow in the (probably vain) hope that’ll minimise the wood suddenly jumping into twist or warp or cup or bow…

Then some mucking about with the legs and checking faces&edges and planning the profiling of the legs and whipping up a quick check-piece from a poplar scrap to see if the thing in my head looked the way I thought it would when I see it in real life:

I like the tapering off towards the back of the leg, not quite like an aerofoil shape but the same kind of idea. I think it’ll give it an interesting look (it won’t be quite so asymmetrical, but the size of that piece made it hard to hold which made it more awkward than it will be for a full-size leg).

And then I just laid out the tools for tomorrow and closed up the shed.

Quiet night tonight, I guess I’m just tired from the sudden arrival of winter…


22
Nov 17

Smells like respiratory irritants…

I seriously need a better sanding arrangement. Roll on black friday.

Not to mention, the goggles could be more comfortable.

But at least the boxes have seen progress…

About a third were done with shaping-level sanding, about another third just had to have drawer pulls fitted, and the remaining third were still being assembled or needed serious shaping (meaning another belt sander session).

Some sorting, some test fitting, and some glueing up later and then I left everything overnight to cure. The following day I found that one of the oak boxes had had a side slip during glue-up, so it needs more shaping on the belt sander, and two of the other boxes are in the same boat; the dremel came out to do some tweaking whereupon I discovered that my sanding mandrel was missing, presumed lost 🙁 Need to go pay five times the fair price for one now on the way home from work today. Gah.

But the rest of the glueups went well, several of the boxes were hand-sanded up to 240 grit and then I started on the finishing for some of them with danish oil for the ash and sapele boxes:

Gotta love the way that colour comes out…

The oak and poplar pencilbox got the danish oil as well; this one would be too hard to ebonise the oak part for so we’ll just go with the oil I think.

The small sapele box got finished while waiting on its drawer. Too little time to wait and do it all at once.

The ash is nice, but it really can’t hold up to the sapele. After the danish oil, I’ll be giving this a few coats of shellac and then some poly over the top for toughness and some paste wax and buffing for shine. The sapele and the oak&poplar will get something similar (but the ash and sapele get blond shellac while the oak&polar gets garnet or button shellac).

The other poplar boxes will just get a sanding sealer coat (aka blond shellac mixed down from a 2-pound cut to a 1/2-pound cut), then a light sanding with fine paper and then milk paint over that and then poly varnish and a wax buffing.

The oak boxes (including this oak and poplar one) will see the oak ebonised as before, with one small change – that foam in the oak shavings tea is washing-up liquid acting as a surfactant to spread the tea deeper into the wood grain (and I’ll do the same for the iron solution). Nice tip from custard on the UK woodworking forum, that.

That oak and poplar box might turn out interesting – the “drawer pull” is a flush extension of the box, and it’ll get the sanding sealer + milk paint treatment of the other poplar boxes; the contrast between the black of the ebonised oak and the colour of the milk paint might be interesting.

And that’s where I left it. After work today, there’s some shaping sanding to do on the belt sander, some finer hand sanding and then we’re into nothing but finishing because these have to be ready by Friday morning…

And then on Friday, it’s off to the timber yard to get some more oak and walnut (and maybe something else if they have anything interesting to hand). And after that, black friday sales and after talking to the guys using them, I think I won’t be getting one of the Record BDS150 sanders:

Which looked okay but which apparently have a disk that’s unusably small (and a faff to change the paper on), and a table that’s just a bit dodgy to use and set up. Instead, it looks more like getting one of the Triton oscillating belt/bobbin sanders:

It’s a clone of the original Rigid:

But the clones are smaller in footprint (several other makers from Grizzly to Rutlands to Clarke all make the same thing in different colours). You lose the mitre slot, but on the plus side, the clones would actually fit through the door of the shed, which is a positive. I’ll have to build a quick 2×4 storage stand to put the bandsaw on and the sander under though, there’s no room otherwise.

But on the other hand, it’s about 26dBA quieter than the belt-sander-and-holdfasts approach I’m stuck with now, and it actually *has* dust extraction. Which is kindof a good thing if you like, you know, breathing…