23
Nov 17

Finishing experiment

All the major work is done now, everything’s glued up (though the last of the oak boxes is still curing really) and the prep finishing is either done or in train…

The poplar boxes have all had a coat of sanding sealer here (again, just blonde shellac cut down from a 2# cut to a half-pound cut), and the outer box of one has been test-finished with red milk paint (more on that in a moment). The oak boxes have all been given a coat of the oak tea (with surfactant) and they got another early this morning. The poplar drawer front on the oak-and-poplar box got a coat of sanding sealer.
The oak-and-poplar pencil box, the sapele boxes and the ash boxes all got another coat of danish oil and after the excess was wiped off and it had had a while to set up, they all got a coat of shellac (blond 2# shellac for the ash boxes; garnet #2 shellac for the sapele and the oak&poplar boxes). Tonight they’ll get a quick light sanding from worn 240grit paper and we’ll see if they need another coat or if I’ll go straight to poly (I wouldn’t for furniture, but these are quickly-made trinkets…).

Milk paint is neat stuff, at least in how it’s made up – you buy the powder (this is Causeway Sunset by The Crafty Bird in case anyone’s interested, I’ve had it a while and wanted to use it on something but never had the chance till now), and then you make it up on the fly as you need it, just mixing it with an equal amount of water (or in this case, a little less water to powder for a thicker mix). Make it up in a paper cup, apply from that cup, discard that cup. No half-full small tins of latex with the painted-on lids and the dribbles clogging up the shed for years before you finally give in and throw them out.

The downside is that the colours aren’t as bright as you get with latex-based paints, but some people prefer pastels and earthy shades. And even if you don’t, they can still be kindof striking:

Haven’t messed with colour enhance filters here, I promise. There’s white balancing and that’s all (and the white wall and the parchment paper give a decent white sample for the filter to latch onto) so the colour’s pretty true – it really is that jarring when wet. It dries to a chalky light pink, but when you put a topcoat on it, it darkens up again. We’ll see how well it copes, it got a spray of poly this morning and I think it’ll need another tonight.

And the branding is done as well 😀
There’s still felt to glue on, but that’s the very last step, done over the finish. Not sure if this’ll make it for Friday morning, but it might for Friday afternoon…


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…


03
Nov 17

Flattening and boxes

So, started off flattening the apron. This went pretty well after I switched over to the #5 and sharpened it up a bit. The narrower blade means less pushing effort and that seemed to help a lot. And then it was time to thickness down from an inch to 3/4 of an inch.

This is not my favourite activity. And honestly, if they made an induction motor benchtop thicknesser I’d have bought one already, but unfortunately they’re all universal motor things — and lunchbox thicknessers, even if you fit them with helical blades and all the fancy doo-dads, are just too damn noisy to run in a housing estate. You’ll wind up triggering a torch-and-pitchfork party of your very own if you do that round here once too often. So until I have a larger shed and room for a larger, possibly older, floorstanding planer/thicknesser, I have to do this part by hand. At least Sid makes the task easier with his ridiculous level of camber…

Anyway, the board was a manageable size, so push hard and on we go. And switching over to the #5 for the last mm or so to arrive in a controlled manner and…

Flat and at thickness. I gauged out for the two aprons and set it aside and ripped down the middle a little later on with the bandsaw (using the new tuffsaws blade – makes a rather surprising difference, those things, much cleaner cut and less drift).

Then on to mucking about…

So the glue-up was messy and there are steps all over, but apparently that’s to be expected. Next step, sand the badgers off everything with my handy dandy disk sander. Which I don’t have one of. Bugger. Well…

Sod it, I started this thing on a bandsaw, might as well keep up the machine operator vibe…

Didn’t want to keep all of your fingers, did you?

Hm. Not terrible for a first try. Slap some shellac on it…

And some felt for the inside lining and call it done:

Well, not absolutely awful. Okay, so it is if you look close – there’s no room in there, the edges aren’t parallel, the drawer’s a bit gappy, and so on. But it was fun to try it and I have some ideas for a nicer one. Need more practice though, I keep getting lost in the sequence of cuts on these things. Well, in that vein…

This one might be interesting, I used the new tuffsaws fine-tooth blade. Much smoother cut, but I don’t think the bandsaw will ever be a precision tool. Hell of a lot friendlier to the nose when you plug it into the dust collection though…