Friday, June 14, 2019

Box done

Well it still need more time for the finishing touches, but time is running out.
Last nite, as I was hoping, I glued and pinned the skirt feet bracket pieces.
Sorry for the compressor noises love, Oups

I took my time and slipped slide in the glue trying to locate the corners perfectly, as I knew they will fit.  My bright idea was to use the 23 ga pinner but the only pins I currently have (or more correctly,  located) were much on the short side, barely protruding past my skirt pieces.  I thought that should do the trick, just hold them in place long enough for the glue to grab.  And since unbeknownst to me, I was doing rubbed joint...should grab fast :-)

Was a tad frustrating, but managed to go around the box with my pieces and everything lined up at the corners beautifully.
And then I took this pic and my heart sank....

Pic I took at 2130
Oh shit, the box is rocking badly.

Am I ever glad I picked it up last nite...
Quickly pried off the two offending corners, measured around the box, I was off by less than 1/8.
What happened??  My box is square and same height around, my skirt pieces were clamped together, the two long ones then the two small ones to cleaned up the profile, and ensuring they came out the same.  But after they got an individual sanding to clean up some spots, they varied a bit in width on the flat part.  When I glued them, I made sure to line up the flat part to the box bottom.
Well Dah! Although, both long and short pieces were flat to each other, they were not quite the same between the pairs. Not by much but enough to throw me off.  One lesson learned the hard way.
Only problem now, is I'm not so sure anymore I have a strong glue bond all around.  Concern I have is, that is all that is supporting the whole weight of the box, the box is not resting on it, like I would had done if this was a piece of furniture (stronger that way, and negate my weight concerns).

I will reinforced the mitre corners with glue blocks which would be resting from the box bottom to the floor.  All the weight would be bear by them, relieving my weight worries...
How much does one ashes box weight?

3.666 Kg, it's a tad on the heavy side.
Between the dovetailed construction and the glue joint of the skirt/feet 
and the glue blocks under, should be plenty strong.

Slow morning, I was up late last nite, watching Toronto make NBA history and I had to drop off my car at 0800 at the dealership for the passenger air bag recall.
I am still tired, must be careful not to make any stupid mistakes so close to the end.

Trimmed the pieces on the stiles

Touch up my most used chisel in this built on my new slipstones 
which somehow followed me home during my yesterday chocolate run :-)

Ohhhh I like it.  Fast and wicked sharp.

This is the chisel I will be using for my mortise.

But first since I done the tenon before the mortise, I have to make sure 
they are straight every which way. Before cutting my mortise to match.

I would normally cut the mortise first, so this is kinda backward for me.

both tenon trimmed, ready for mortising

First we must adjust our mortise gauge to our tool.  Forget measurements, use the actual tools as references.

Setting the gauge pins close

I always do my final adjustments on a piece of scrap wood.
Strike lines and see where the chisel fall within.
In this pic, took me 3 tries (bottom LH corner), the top cut is the one

Now the real fun begin.  I am going to attempt to cut a slightly larger mortise than the existing groove.
But more worry some is the fact that I already cut my stiles to the right length, leaving me not enough meat at the ends, like I would had normally done.  Will need reinforcement.
First bright idea was to use the vise and back the thin wall by another piece.
Did not work too good, the work piece keep sliding down and I'm leery to break the groove walls, so I put in a spacer to reinforce them.

Nixed Plan A, going with Plan B.
Danger Danger Mr Robinson, there is no spacer in the back up piece !!

Instead I sandwiched it between pieces of scrap with a clamp and rest it on the top of the bench.

That worked good, I can torque it down without worries.
 Now got my mortise roughly as deep as I dare to make it.
It has to be below the groove bottom, for strength.
Testing the depth.

And checking on the actual tenon.

That is how far it would go, if I left my tenon at that length.
Then decided to cut a bit shorter my tenon.

And that is when the first fatal screw up happened, I clamp the piece in the vise to cut it then heard a sickening cracking noise...

Forgot to slip in a spacer inside the groove and my piece broke in two places

OK, so I'll just glued it back on with my new Gorilla instant glue I just bought, just in case...

I just glued in the bottom crack, once done, I'll glued in the other one

Seems to be taking forever to dry for a so called instant glue??

@#$%&?! Not an instant glue.  Could they print it smaller? Tabarnack!
It is just regular foamy Gorilla glue %$$#@

Quick trip to the store, bought some real instant glue.
Set in 10 seconds, that's more like it!

They sure looks alike don't they.
I did not screw in the blue top to pierce the tube in this pic.

Back on my mortises, I started the other one, and just as I noticed my back up piece was loose, I hit my chisel with the mallet and ...crack.  :-(

Not worth re-gluing, would need a new piece , longer to be able to do it properly.
Like I should had done in the first place.

At this point I gave up on the frame and panel idea for the cover.
Went outside to have a coffee with Jean, I told her what happened, and why there would be no cover for the box.  I am exhausted and I am starting to make too many mistakes that I knew better.
She said I cannot bring in just the box with no cover, so she talk me into just making a slab for the cover.  Ironically that was Plan A, but I went with a frame & panel, worrying about a large slab expanding/contracting.

After looking over at my spare pieces left over, quickly figured out that the best combination that worked was by using the two long pieces for box No 2.
The resulting slab would have the right length but will be too wide and will have to be cut.
Will simply make new pieces later when I start No 2...later...much later

At 1630 my cover Plan C is starting to take shape.

While that cure, time to sand the box and give it its first coat of whatever.

Did some experiment on the side, with what I bought today and what I have on hand.  Need something that dry fast.  Settled on using my Howard refinisher Golden Oak colour.
I wanted something that would make the grain figure pop.

first coat wiped on.
Then I will simply polished it off with a wax compound.
Feed & Wax,  my other Howard product.

Using some small pine offcuts from a longer piece, I simply split them with a chisel, pared a bit then saw to proper length and glue in each corner.  Machined surfaces inside the corners.

The whole weight of Paul is going to rest on these four (4)
glue blocks, plus the skirt glue line.  Good to go.

After supper, took my new panel out of the clamps and scrapped the glue line, and off to the woodshop to run it thru the wide belt sander.

Then shot the edges with my LV LA jack plane.  That plane is pretty amazing on this figure maple, I can pull off whisper thin full shavings. Incidentally it is smoother sailing on the end grain than the long edge.  It quickly let you know which way it prefers.

Panel cut near final size then all edges were shot with the plane.

After rip to correct width, gave it a quick sanding with the Random Orbital sander with 150 grit and called it a day.

Ready to go back home.
In this shot angle the glue blocks are showing, hum.
Pare them smaller or paint black??

One hour later back home, tack rag then wipe of the same stain on the remainder of the box and let to air out outside.  Kind of strong smelly.  Hopefully will dissipate before tomorrow when I close the box one last time...

Later tonite, before going to bed I will give the whole thing a coat of Feed & Wax then buffed.
The only thing remaining are to drill some countersink holes for the cover screws and attach the plaque on the box.

That is it for the nite, having a cold one now.  Not going near the box nor touching it for a while, don't want to jinx it.

Bob, totally out of gas...running on empty.  Blogging is the only thing that keep me going and motivated.

Thursday, June 13, 2019

Box pretty well all done

Famous last words...
Today started slow, went to get a load of garden soil (peat moss, soil and other ingredients) in Aylesford at the best peat moss place, Annapolis Valley Peat Moss.  Their stuff is gorgeous and plants love it.  Heather only used that particular peat moss for her African Violets, which meant that when  we were posted away, I had to make at least one run back to the valley each year to get the stuff by the big bag.

Now we used the pick up truck, much cheaper.

One bucket load for $30, you do the math.
That is a lot of smaller bags at $3.95 ea :-) 

After we went for brunch at the Green Cafe here in town.  We love their breakfast and makes it a brunch.  Then a quick chocolate run to my favorite boutique in Annapolis Royal, Great expectations, were I always find some good tools.  I may have bought one or two, whatever tools and as usual no chocolates made it home alive :-)
Back home a quick nap and time to get cracking.

I look on line to get some ideas for my feet brackets

and made this quick and dirty bracket template

I used a 1/2 in Forstner bit

Then pack my stuff and off to the base woodshop we go.

What I brought

First order of business was to cut the chamfer on the top of my skirt boards.

Quick work with my LN LA jack

I shot my angle by hands no guide lines.
I was worry about matching at the corners, but to my surprise they came off great
on the first try.  Sometimes you get lucky I guess :-)
Either that or memory muscles kicked in.

I could had used a smaller scroll blade, but had to do with the 3/8 blade installed.
NO biggie just had to make more relief cuts.

One hour later, I had my 4 skirt/feet brackets done, tenons have been trimmed
and I glued in small pieces in the groove of the stiles in prevision to cut the mortises

I dunno who is doing this, but looks like he or she is learning about wood movement.
Yes wood cup and alternating the grain direction to compensate does not always work... 

Back home, Jean got the truck unloaded and its almost time to go to our monthly club 125, in support of the arena in town.  Half the year, the money goes to the fire hall, the other half the arena.
Good cause, good food, good company.

Tonite before going to bed, I plan to glue on the skirt boards, so tomorrow I can start the first coat of whatever on the box, and finish the cover.

That means cutting four (4) mortise in the stiles, raise the panel and assemble.
I got the feeling that tomorrow will be a long day in the shop.
Getting there slowly but surely.

Time to get clean up, see you on the flip side.

Bob, in the final stretch of his project

Wednesday, June 12, 2019

Life in the fast line

I did managed to glued the box last nite, and I attached the plywood, glued and nailed (brads).
We did not finished the extra mold brackets (kerfs), we both had a long day and went out for a late supper.  Did not felt like doing much after :-)
But my box got glued, late, but done.  I'm happy.

The scene last nite when I turned off the lights at 2310

Busy day today, Jean was doing a workshop on candle making at the Seniors & Elders gathering from 1000 until 1500.  It's about a 45 minutes drive from home so no shop time this morning, she wanted to be there by 0900 to set up

Jean doing her candle stuff.

We did not came back home until 1600, by then it was time for Zoe 19th birthday.
I dropped off Jean there and went to the woodshop with my box and lumber. Must be ready for at least one coat of something by Friday and it has to be dried by Saturday, the day of the celebration of life.  Tomorrow is Thursday, gulp!  Must work on it.

Spent about two hours at the shop it was quiet only had two short visit, it was a quick and efficient 2 hours.  Got my box sanded, got the top panel sanded and rough cut for the frame, cut new Stiles pieces for the frame with its tenon on each end. That took me some butt scratching, because of the existing deep groove in my frame pieces.  Its a tad too narrow to use as the mortise and cut a matching skinny tenon.  In the end I glued a piece in the groove no longer than the rail portion would be and cut a thicker tenon on each end.  Now I need to trim my tenon again and cut the matching mortise... later

After that mitered, my skirt boards around the box.  Need to finalize my template and cut the foot and miter the top of those skirt boards... later

The skirt boards are just sitting around the box.  
They will be much lower when attached.

And as I type this, I just realized it would had been wise to mark my boards, before taking them out and putting them inside the box, Oups.

After that, cleaned and packed it up and rejoined Jean at Zoe birthday party
Back home... later.   I am physically and mentally exhausted.

Tomorrow my goal is to finish and attach my skirt boards.
Clean up my tenons (stiles) then cut the mortise (rails).
That would leave me to finish the frame and raise the panel and after more sanding, start putting some sort of finish on it, probably Friday??  At the latest.
Almost there.

Bob, going for a beer and a nap, in whichever order it happens :-)

Tuesday, June 11, 2019

Dry fit and progress

This morning, finished cleaning up my last join (D1 to D2), then dry fitted the box.  Everything looks good, tight, no groaning or cracking.  Easily squared, I'm happy

The last join starting to come together.
Yap, I'm working on the floor again.

First dry fit. hand tight, some love tap with wooden mallet and it's square

Paul first dry fit inside his forever home

Next brunch then packed up the car with my box, some more wood to resaw and I have to make a bunch of wax mold stand in pine for Jean's project.

My plan is to sand the inside of the box, cut my plywood bottom, glue box and put on bottom.
Resaw and glue up material for the cover.
For the lid, I decided on a framed raise panel.
Must also figured out what Im am going to do for the foot and bottom trim.
It will depend greatly on what stock I have available.  All of which mean I may have to resaw some more.  My pile selection is getting slim.

Then time to take Rudy to the vet, for his annual check up, yes, just like us humans :-)
And after dropping off Rudy at home, it's off to the shop we go.

Today's load I'm taking to the wood shop

Including of course, my still dry fitted box

 First order of business was to resaw my figured maple boards I brought.  Following recent past performance, I first resaw a kerf on both sides on the Unisaw, to give a guide to the bandsaw blade, preventing cupping.

The big Bandsaw we used.  The Unisaws are behind the dust collector

Then it was off to the drum sander to quickly flatten my boards to a common dimension

From these boards, I selected the ones for my raise panel, machined stock for the skirt and the frame for the lid. I goofed when cross cutting my frame pieces, forgot to add some length for the joinery, Oups.  No biggie, got spare stock machined, and now I got a go/nogo gauge for the space between the tenons :-) Plywood bottom was measured with the box assembled, will become a smidgen larger once box is fully seated in all the joints.  Just enough to be able to flush it after assembly

Raise panel blank, book matched  and glued

The inside of the box boards were given a final sanding, before glue up.
Just did the inside, the outside will only be done after the box is glued.
I made sure to retrace my cryptic markings system on the other side, before disassembly

Now time for Jean's project.

Here is the set she wanted triplicated

It is designed to sandwich both halves of the polystyrene mold,
upside down, since we pour from the bottom.
The vertical brackets slide back and forth to accommodate various sizes of molds 

It was quick work to rip a bunch of scrap pine boards of various sizes to task.

The matching recess to stand them up was all cut on the small bandsaw

3 sets completed, minus one small detail...
The groove in the middle.  

The narrower I can get it with the tablesaw is about 1/8 in wide, with a thin kerf blade. 
She wants it thinner like the one she has.
Than mean using a handsaw to make that kind of kerf ?  Should be fun :-)
But just in case I brought a piece of scrap with a kerf from the Unisaw.  Will see if that's OK with her before I proceed.  These are needed for tomorrow morning, so may have to put in a longer nite in the shop :-)

2 hours later, I was back at home for supper.  I have processed all my pieces like I wanted.
Everything is back home, but...

Some assembly required.
The complete kit. 4 dovetailed boards, grooved stock for the lid frame, 
sized stock for the skirt and feet bracket, cut to size plywood bottom, and...

My resawn and book matched raise panel.
Much bigger than necessary, but then I got more latitude to choose the pattern

After supper, my objective is to glue the box, put on the bottom.
Finish the kerfs in her pine boards and start laying out the frame pieces.

Bob, trying to figured out what we do for supper?? Pickled cabbage!? Nah :-)