Tuesday, October 20, 2020

Sharpening Station upright and proud

 No, I don't know what the title of this post means... I haven't done any work on the station tonight...  I did get the puppy outside to play with Jackson our neighbor Bernadoodle (Berner + Poodle), cooked my wife dinner (pan seared tilapia, sautéed Brussels sprouts, and Texas Toast) and watched some television. I did a really good job on dinner.

Front to back: Ripley and Jackson

This post is mostly because I took a couple of minutes before our Tuesday Sentinels of the Multiverse game to grab a couple more pictures of the sharpening station and I figured I'd share them now.

 This is the station up on its wheels showing off the trim in the front. There is supposed to be matching trim in the back but I forgot. Unfortunately my game is going probably until close to my bedtime so there wont be time tonight to duck into the shop, mill the piece and glue it on.

Yup, those are my shop pants hanging in the background of that shot. I have separate clothes for the workshop so I don't get glue on my everyday wear. It also helps segregate the dust and keep it in the workshop.

In the photo immediately above you can see that there's a little bit of a gap behind the rubber mat. That was supposed to get filled by more white oak trim. Unlike the front trim that is hiding the plywood edges this trim is going to sit on top of the plywood. The cabinet back will hide the plywood edges and itself be covered by the white oak trim on top. I'll try to remember to get a photo of that when I add it and the back.

I grabbed this photo because I mentioned yesterday how much better the t-nuts looked over the hex nuts I used initially. I still think they look better. I could have used threaded nuts but those are much more expensive and overkill for a shop project.

Anyway, that's all for tonight. Next steps are:

  • Drawers on the left
  • Shelves on the right
  • Sanding the case, easing the edges
  • Finish the trim around the top
  • Add a back
  • Add a door on the right covering the shelves

Monday, October 19, 2020

Sharpening Station starting to look like a cabinet on wheels

 I got surprising little work done on the sharpening station considering I had a long weekend. I ducked down into the shop Thursday night and got the panels sanded before I had to make dinner. It went pretty quick and there weren't any surprises. When I was sanding the plywood - the case top and bottom - I hit the faces where it joins to the side pretty hard with 80 grit sandpaper. This solved my problem with the tight fitting joints. They fit perfect.

Since everything was fitting I added glue to the joints and clamped everything up. Good joinery is awesome and everything came out perfectly square without any fiddling.

Friday I had to work and Saturday I had a lot of errands to do so I didn't get any shop time in. I did however get to Home Depot Friday evening to pick up some lag screws and t-nuts to help fasten the wheels onto the cabinet. Saturday I worked on putting my trailer back together - and promptly broke it again, had a doggie play date, mowed, stopped by a friend's house to help him identify tools he'd pulled out of his dad's basement... I did stuff...

Sunday I got started by routing a lip in the back of the sides so I can fasten a plywood back later. I left room behind the top, bottom and middle divider but I forgot to put a stopped rabbet in the sides. I threw a rabbeting bit into my router and started routing it out. I found the 7/8" edge a little challenging to keep the router balanced on so I added a scrap piece of poplar to give myself a little wider of an edge to follow.

The rabbeting bit didn't quite make it into the corner but a little quick chopping with a chisel made the corners all pretty.

After getting the rabbet for the back done I marked and drilled holes for my wheels. I thought about using t-nuts but realized I'd bought the wrong size. I'd bought 1/4 inch t-nuts but the mounting holes were 5/16 inch. I had 1 inch bolts so since they were going to stick through the bottom anyway I mounted the wheels with 5/16 inch x 1 inch bolts and nuts.

Yup, pretty ugly. I don't remember if I showed the wheels before but those are the wheels I am going to be using in the above photo. Yes, they are light weight and cheesy but this is a small cart so they should be fine. The entire cart probably weighs 20 pounds right now and even loaded up probably wont be over 100 lbs.

Unfortunately I had a surprise while adding the wheels. I was using my socket wrench to tighten down one of the nuts and when I bumped my hand into the side it moved. Gently knocking it with my hand popped the entire joint loose. Apparently I forgot to glue one of the joints in my rush Thursday night. 

Fortunately my glue is pretty runny so I was able to separate the joint just a little then squeeze a lot of glue into the back and let it dribble down to the bottom. A few clamps to bring everything back together and problem solved. Unfortunately I had a lot of glue squeeze out and it kind of made a mess I am going to need to come back and clean up.

This was the end of my working on the case for Sunday. I made some progress but not as much as I had envisioned.

Today (Monday) I went back to Home Depot and picked up some shorter 1/4 inch bolts. I figured I'd try the 1/4 inch t-nuts. On the first t-nut I drilled out holes for the prongs but on all the subsequent ones I just pounded them in. I know I've had problems before with the prongs bending over in the past but that might have been hardwood vs plywood. I was careful and had no problems. I even had almost enough lock washers for all the bolts. I was only short by two and if I remember and it is convenient I'll pick up more and add them before the cabinet gets full.

The inside looks much better with the t-nuts versus the hex nuts. I didn't get any good pictures of them but I'm sure they'll show up again when I start working on the inside of the cabinet.

I'd thought I would use some leftover cutting board to make runners for my drawers. Cutting the first one went fine. I cleaned up the little burrs and the cut edges with my low angle block plane. Unfortunately things started going sideways at that point. The blade started getting hot and was melting the cutting board rather than cutting it. Eventually my Saw Stop detected something wasn't right and shut down. It's a couple of hundred dollars if the brake fires so I figured I'd stop and switch to wood runners. Very sad but they should work fine.

I thought about calling it a day at that point but then I figured I should at least get something glued and clamped so I can have something drying overnight. So I picked some scraps of white oak to make the front trim from, planed it to thickness and ripped and cut it to width and length.

This stage worked okay but it again pointed to my sloppy job gluing the case Thursday night. The top/bottom setback wasn't consistent in all the corners.

It is sad but also relatively easy to fix. I might try using a hand plane or maybe I'll just sand the heck out of it.

This is where I left it for the evening - had to stop to make cheese steak sandwiches for dinner. I'll probably not be able to find any time tomorrow night but maybe I'll get back into the shop Wednesday or Thursday this week.

Tuesday, October 13, 2020

Sharpening Station Starting to Look Like a Cabinet

Saturday was a short workshop day but I wanted to get the side panels sanded and the frames glued up so I could do joinery work on Sunday and that's pretty much how the weekend worked out. Sanding the panels was pretty quick work. I'd already sanded them on my open ended drum sander to flatten them after glue up so all I needed to do was hit them with 80, 120, and 180 grit sandpaper on my random  orbit sander. With that done I glued up the side panels and checked them for square.

I really love the stub tenon and groove joinery method. With clean shoulders the panels just come together square naturally.

Since sanding and gluing didn't take that much time I started thinking about the next step which was going to be cutting joinery for the top and bottom panels. The grooves holding the top and bottom panels were going to be stopped grooves 1/2 inch from the top and the bottom. 

Making the joinery symmetrical made things easier in a couple of ways. First, I didn't have to worry about right and left as the panels could be flipped over or spun to fit. Second, I could use the same setup for cutting the top and bottom grooves.

Stopped grooves call for using a template and a router. With only 1/2" between the top and bottom and the panels I needed a special template to clamp in place. I finished up my Saturday getting that made with some scrap plywood glue and staples.

I ducked back into the basement in the evening to scrape glue.

Sunday I got most of the afternoon in the workshop. I did have a hard stop of a puppy play date late afternoon but I still had a number of hours to get stuff done. 

With the panels all glued up the next step was to cut joinery. I found a piece of cabinet grade maple veneer plywood offcut in my workshop that looked to be big enough to get a top and bottom panel and maybe the middle divider. I cut it to rough size then used an off cut to space my templates.

Top edge template

Getting the template spacing set

Full setup

Router setup

Stopped groove

Squaring end of groove

The pictures above do a pretty good job of showing my process. The template for the top/bottom edge was a piece of 3/4 inch plywood glued and stapled to a 1/2 inch piece of plywood. The 1/2 inch ply was cut to be 1/2 inch wider than the 3/4 inch so when I glued them together I just aligned on of the edges. Then when I clamped it to the top of the panel the top edge of the groove was automatically set without me needing to measure.

I set the width of the groove by taking an offcut and wedging it between the two halves the template. This is a really effective technique for getting a groove the exact width of your plywood. There are couple of effective table saw techniques for getting good fitting grooves but they all require more setup effort. If you've just got a few grooves to cut, this is the way to go.

You can see that I had a pencil line about 3/8 inch down from the top. I set my router bit depth by eye because I didn't really care exactly how deep they were. Since I had cut the plywood a little over-sized I would be able to cut it to fit later. I routed the grooves in two passes making sure the bearing was riding against the template on the first cut. I've made the mistake in the past of not checking and just routing into my template. 

These are stopped grooves so I again made a pencil mark and used my eye to determine when to stop. This isn't fine furniture it is a shop project, and any small sloppiness in the length of the groove will be hidden after I put trim covering the plywood edges.

After routing the grooves I had rounded ends so I pulled out my chisels and chopped the ends square. I used my cheap chisels that I had been using to practice with my Tormek. It went pretty smoothly.

I test fit the top and bottom panels then trimmed them to size.

My plans called for an off-center middle panel but after thinking about it I realized if I centered the middle panel I could use a dado blade in the table saw and do both panels with the same setup. I don't have pictures of this step but it is really the same process as cutting the grooves in the rails and stiles. Basically set the table saw fence so the blade takes out the middle of the dado. Flip the piece end-for-end and run it through again. You now have a centered dado/groove. If it isn't wide enough, nudge the fence over a hair and make another two passes. Repeat until the dado/groove is a perfect fit.

The only tricky part of this approach is remembering that any distance you move the fence is doubled in the width of the dado / groove.

Since this is a table saw technique it really only works on through cuts.

After all my joints were cut I did another dry fit.

This is only a dry fit. Friction is holding it together. Turns out my technique for getting a tight fit on the stopped grooves was a little too good. I could sand the grooves a little wider but I think that instead when I am sanding before the next stage of gluing I'll just hit the panels a little harder along the edges and see if that makes them fit better. If I happen to sand through the veneer it will not be that big of a deal because it will either be inside the cabinet, under the cabinet or even on top it will be covered by a rubber mat.

This is where it is at. If I can get some workshop time tomorrow night I'll do my sanding and maybe gluing. I haven't been able to get into the workshop during the week the last month or so but there's always hope.

Monday, October 5, 2020

Sharpening Station

As I mentioned in my "weekly" post I started on my sharpening station this weekend. It was a little bit of a journey to get to this point. I've been using my New Yankee workbench as a bench for the Tormek sharpening system. It works but has a couple of inadequacies. 

Primarily the issue is that it is too tall. The position required for grinding chisels and plane irons requires you to be above the Tormek. With the Tormek on my 35" bench I need to stand very close in order to control the grinding which is uncomfortable and I keep bumping into the wheel and getting wet.

The other issue is that the sharpening process with the Tormek is wet. It is a water wheel after all and water gets around and my New Yankee bench is covered in mdf which doesn't handle water well.

So I have several goals for the sharpening station: 
  • Water resistant
  • Shorter (the Tormek branded stand is 30")
  • Storage for sharpening supplies (including the Tormek accessories)
  • Mobile (needs to not be a stationary obstacle in the shop)
I bought a rubber mat for the Tormek. It was kinda pricy at close to $50 but once I got it I wasn't disappointed. This will be the basis for my waterproofing. I'll use this to cover the top of my station. It is large and heavy but it isn't "sticky" enough to not slip around on plywood. I'll "fix" this problem by building the stand with a lip around the top to hold the mat in place.

My initial plan was to build the sharpening station entirely out of plywood but then I'll have plywood exposed to water. I plan to put polyurethane on the station to help protect it from moisture but that'll only go so far. I've got a lot of leftover white oak from my Mission-style Dresser and it is rot resistant. I initially thought I would just make the lip out of the white oak but after thinking about it I decided I could make the entire sides out of it using a frame and panel technique. If I didn't have a load of mediocre quarter sawn white oak that I'm never going to use I would use plywood for this but I have it, I'm never going to make a "fine furniture" project out of white oak again so I may as well use it here.

So, at this point I had general dimensions...  The rubber mat is 13 1/2 inches by 21 inches so that defines the footprint of the stand. The Tormek branded stand is around 30" tall so that'll work for me too. I knew that I was going to make the sides out of quarter sawn white oak in a frame and panel configuration. 

I've got a plethora of casters just sitting around. I've got a set of light-duty 3" casters that will be perfect for a smallish cart. 

I was noodling around whether I wanted drawers or shelves inside the cabinet. I was a little worried about wide drawers not working smoothly. Shelves would be less utilitarian than drawers as stuff tends to just get shoved around on them in an unorganized fashion. In my sketching of different ideas I decided I could split the cabinet area and put drawers on one side and shelves on the other. Further I could make one of the shelves into a tray that rides on full extension slides. Then I can store the Tormek inside the cabinet when it isn't in use.

Yup, that is the full design. It will be plenty to work from. I thought about using this as an excuse to learn Google Sketchup. Then I realized that my current pencil and paper drafting is working just fine for me. I suppose if I cared to sell my designs I'd learn Sketchup but for now I'd rather be doing woodworking. Also, my pencil and paper is super portable.

Also yes, I realize I drew the stiles and rails backwards. It bothers me a little bit, but only a little bit.

So the sides will be 27 1/2 inches tall with a 1/2" lip at the top and the bottom. They'll be 15 inches wide to account for the 13 1/2 inches of the rubber mat plus 3/4 inches each for the front and back rail. Counting the rubber mat and the casters the top will be about 29 3/4 inches high. The total width for the cabinet will be 22 1/2 inches. That's 21 inches for the mat plus about 3/4 inches for each side.

I have dimensions written down for most of the major pieces but I'm going to be cutting most of them to fit so they're really just there for approximations. To get started I needed to know how wide the sides needed to be and that dimension is fixed by the size of the rubber mat. 13 1/2 inches plus 1 1/2 inches for the lip, or 15 inches. The height needs to be 30 inches finished height minus 3 inches for the casters plus 1/2" for the bottom lip (this will make more sense as I get further through the project). That math gives me a side height of 27 1/2 inches.

I started by pulling out one of my remaining white oak boards and cut two lengths that were about 25 inches long. This is easier said than done. The board was quite heavy being wide, thick, and long. Also, the middle of the board would have put me in the middle of my old workbench so it was quite awkward getting it into my primary shop. Once there I didn't feel like wrestling it onto my miter saw so I broke it down into smaller pieces using my Makita cordless circular saw. I really like my Milwaukee circular saw but the Makita has become my go-to saw because of its convenience.

I resawed the panels using my table saw taking multiple passes from each side. I then flattened them on my jointer and thicknessed them in my planer before gluing them up into panels. 

I dressed one edge of the boards I had cut out for the rails and stiles then cut them to rough length and width before flattening them on my jointer and thicknessed them in my planer. I believe that's about where I got to by Saturday dinner so I set the boards aside for the evening.

Sunday I sanded the panels flat. I considered sending them through the planer but I was afraid of chipping so instead I used my open ended sanding drum. I'd done a pretty good job gluing the panels flat so it only took three or four passes to get them good enough for shop furniture.

After getting the panels flat I cut the rails and stiles to final width and length. After that it was just a matter of getting grooves cut the entire length of the rails and stiles to fit the panels and cutting the stub tenons on the ends of the rails. I cut the stub tenons just a wee bit short so they wouldn't bottom out in the groove and a little thick so I could use my shoulder plane to tune them to a snug fit.

This process worked out fine until I realized that I needed to be a little more careful when trimming the stub tenons. Removing too much from one side would result in the rail and stile not having flush faces. Well, better to learn this lesson on shop furniture.

In any case after trimming the panels I dry fit everything and it is looking good.

I realized during the dry-fit process that I'd glued my book matched panel upside down. Oh well...  again, it is shop furniture that I am banging together quickly. And yet another lesson learned. I'm not going to fix it because I'd have to make a whole new panel. Also, it is shop furniture. It'll be fine.

One of my friends who is just getting into wood working was asking me recently about how stub tenons and groove joinery worked so I got a close up of the joint between the rail and stile.

This is a favorite joint of mine. It is super simple to make and holds up well for reasonable amounts of stress. The flat grain glue surface of the sides of the tenon to the walls of the groove provide excellent holding power. It is easy to cut on the table saw and really only requires two setups, one to cut the groove and one for the tenon.

Anyway, that's as far as I've gotten. I still need to sand the panels and the other hard to reach parts before gluing them up. Then I'll cut a couple of stopped grooves to hold the plywood top and bottom shelf and then a full width dado in the top and bottom to hold a middle divider. And then Bob's your uncle. All that will be left then is building some drawers, a tray on extension slides and a shelf and some trim. Easy peasy lemon squeezy.

Stay safe out there, wear a mask, keep physically distant, and stay in touch with your friends. Give them a phone call to let them know you are thinking of them. It'll make them happy and it will make you feel good and less isolated.

Sunday, October 4, 2020

Covid 19 week 29 - What's going on!

We're in week 29 of our Covid lockdown. Things have been looking pretty good in NYS in general; however, I just heard on the news today that several boroughs of NY City have had a large uptick in reported cases. I haven't looked closer yet; however, I just got news last week that my company will not ask us to return to the office before January. That's not terribly far off but it is a wait an see type of situation. Also, it was announced just this week that President Trump has tested positive for Corona virus and has been taken to Walter Reed Medical Center. Me, my wife, my dog, and all three of my cats are doing fine.

Next, why haven't I posted anything in the last month? Well, first...  it is summer and I don't do very much woodworking in the summer so not a lot has happened in the last month to talk about. Also, my new Dell laptop broke and yes I could have used my old laptop but it's slow and getting kind of flaky.

I was picking up my new laptop when the processor fan started making a horrible grinding noise. I quickly shut it down but the next time I booted it displayed an error screen saying the processor fan was not responding appropriately. Fortunately with some emails, on-line chats, and phone conversations the Dell first tier support sent me a box for shipping my laptop back to them. About seven days later I got my laptop back in perfect working order. Very happy with the Dell service (even though their first solution was updating the BIOS).

Anyway, I have gotten a few things done in the last month. I decided I'm going to build a hand tool workbench for my winter project this year. I pulled out my trailer to pick up lumber for the project, fixed it, broke it, then fixed it again. I picked up lumber for my workbench project this year. I picked up general purpose lumber for my winter shop projects. I started learning how to use my Tormek. And finally I started working on a shop cart for my sharpening system.

Hand Tool Workbench

I've been wanting a hand tool workbench for a number of years. I've been trying to learn how to use chisels and hand planes but not having anything reliable to hold down my work pieces has been a hinderance. Eventually I want a nice hardwood workbench with a leg vise and a tail vise...  but that's what I think I want. Having no real experience with workbenches I just think that's what I want. My plan is to build an inexpensive bench that I can fit a front vise and a tail vise to and hopefully learn better what I want for my ultimate workbench.

Christopher Schwartz is a workbench aficionado and has written several books on the matter. He's also written several articles for Popular Woodworking while he was editor there. One of the articles he wrote was how to build a workbench for $170 and I decided it would do. Of course that article is several years old. Also, he lives in the south where he can get Southern Yellow Pine. I had to settle for Douglas Fir and since there were a fair number of knots I bought extra. All-in-all I spent around $200 on lumber for the project. I haven't bought any vice hardware yet so my final price tag will be a bit higher.

The only real drama that happened on the trip to get the douglas fir was someone else in the store who wasn't wearing a mask who for some reason wanted to stop and talk to me about my purchase. I managed to be polite while wishing he'd go away. Also, I was wearing my own N95 mask. If you aren't wearing a mask, don't go up to strangers and talk to them!

I broke down some of the lumber and carried it down to my workshop. The rest of the lumber I wanted to leave in my garage but I also needed to get it out of the way. I made a dozen or so quick supports I could screw to the 2x4 studs along the back of my garage and got the remainder of the wood up off the floor.


I purchased a Harbor Freight 1720 Super Duty Folding Trailer several years ago when I sold my pickup truck. It has several good aspects and several unfortunate aspects. The biggest positive for me is that when I am done using it I can fold it into thirds and stand it on end. It fits into a footprint of about 2 ft x 5 ft. I have a niche in the back corner of my garage that it fits into perfectly and I can still fit my Forrester in my spot. 

The biggest downside is that it folds. It's heavy enough that when I am folding or unfolding it I am lifting weights that are within my ability to lift but if I slipped I would get hurt if it fell on me. It is also quite awkward for a single person to either fold or unfold. (The directions actually specify that it's a two person job and should not be done by a single person.)  I make it manageable by tying the back half the trailer to a rafter so I only have to lift the front half the trailer. However, this weight is also part of the problem. The amount of force to rip apart the trailer wiring is much less than the force to fold the trailer so if it catches on anything it gets ripped apart. I've had to fix the trailer wiring a half dozen times generally when the outside temperature is under 30 degrees F.

When I went to unfold my trailer for this wood pickup I noticed that somehow the hinges on the left side of the trailer had gotten torqued. I figured I would still be able to use the trailer until I got the hinge fixed but like every time I get the trailer out the lights didn't work. It's kind of a pain to crawl under the trailer to debug wiring issues so I folded it back into its vertical configuration. I debugged and fixed the lighting problems and figured I'd be all set to go to the lumber store. I'd missed my window for Saturday as they close early but figured I'd go Monday after work. I tried to prepare ahead of time by unfolding the trailer on Sunday so I'd be ready to go right after work. In the process of unfolding the knot in the rope holding the back came untied and the back half the trailer came crashing down smashing the right rear taillight. 

It was a dumb mistake and it was my fault. Of course the lights I'd just fixed no longer worked. When I tried refolding the trailer to get to the wiring I found that each time I was folding and unfolding the trailer I was just making the hinges worse. I ended up needing to take the hinge off and bolting the front and back half the trailer together. Also, the lights were still broke so instead of going to the lumber store I made a trip to Harbor Freight to purchase a new trailer light kit.

I ended up replacing the entire wiring harness. This time I soldered all wiring connections, added dielectric paste and used heat shrink tubing around each of them. Also, I had previously purchased some 2-wire weather proof connectors that I used to connect the front and back half the trailer. My plan is to disconnect the two halves the trailer before folding it and reconnecting them after unfolding it. This will require going under the trailer but I also bought a mechanics creeper from Harbor Freight so it isn't that big of a deal anymore to get underneath the trailer while it's unfolded.

It was actually quite pleasant working on the trailer in 60-70 degree F weather vs the 100+ degree F weather I originally assembled it in and the 20 degree F weather I had to fix the wiring in. 

Oddly the second most annoying thing about the trailer is that it is all bolted together. This is mostly only a problem because the frame is also the ground. Most of my wiring problems were related to having an open ground because one or more connections were loose. Also, to get the original wiring job to ground I had needed to thread copper wire around several of the bolts to get the front and back half the trailer to make a connection.

Fortunately one thing making all the wiring easier is a test box I'd made that allows me to plug my trailer into a 100 v wall outlet to test the lights. It would have been a nightmare if I'd had to hook it up to my truck each time I wanted to test it.

All in all I think I spent about three days futzing with the trailer and it still isn't completely fixed yet. To get replacement hinges I needed to mail order them. The box showed up Friday but instead of sending me front and back hinges, they just sent me two sets of front hinges. This wont work because the back hinges have a bend to them allowing them to fit around the front hinge. Karen, the woman I talked to when I called them about the incorrect order, was very nice and put in an order for replacement hinges. I'm figuring there is at least a 50-50 that I'll get the wrong hinges again.

General Purpose Lumber

What's general purpose lumber? Well, I like keeping a small amount of walnut, maple, red oak, and poplar hardwoods and baltic birch plywood in my shop. It's cheaper to just keep some around than to need something and have to run to the lumber store. Especially if it requires putting the trailer together.

So, I bought enough maple to make several more magazine boxes. I also picked up a single board of red oak and walnut and a couple boards of poplar. I bought a couple sheets of 1/2" and 1/4" Baltic birch. I don't have plans for them but I'm sure they'll get used for jigs and the such. I wanted to pick up some 1/4" MDF but they were out. Apparently it is one of the things that is hard to get.

The Tormek

I started practicing using the Tormek on my old cheap chisels and a plane blade I'd ruined trying to learn how to use water stones. It was day two and I got to use what I thought was the funniest accessory they'd included in the box. When I was unpacking it I found a yellow plastic "wallet" that when I opened it I found it contained a dozen or so band aids. Hilarious...  Then on day two or three of using the Tormek I accidentally dragged the back of one of my fingers across the plane blade I was sharpening while reaching for something else on my workbench. It initially just looked like a little scrape but by the time I got to my paper towels I was dripping blood.

I wasn't too proud to use one of the Tormek supplied band aids. I did finish what I was doing, then when I was all done cleaned the wound and put on a better band aid. I'm not sure when it happened but at some point many years ago I got tired of never having an appropriate band aid for whatever wound I had so I have an extensive collection in my medicine cabinet.

Anyway, back to the Tormek...  I really need to write up an individual review for this but suffice it to say for now that I am liking it. It does tend to get water splashed around it. My 35" tall workbench is also too high to work at it comfortably. When grinding chisels and plane irons you need to be "above" the tool and since I am only 5'10" that means I need to stand closer to the tools and I kept bumping into it. It doesn't hurt, you can touch the wheel while it is spinning. I did get wet though and it felt awkward.

Tormek makes a stand that is currently selling for almost $800 (USD) on Amazon. But, I am a woodworker. I can make my own stand. I spent a number of weeks noodling around what I wanted in my stand and I came up with a final set of plans this last week. My stand is going to be 30" high (like the Tormek one). I'd originally thought to make it entirely of plywood but when considering the amount of water that might be around it I decided to wrap the top with white oak. After deciding to wrap the top in white oak I thought that I may as well use some of my leftover white oak from building my dresser to make frame and panel sides. The inside is going to have drawers on wooden (UHMW plastic) slides on the left half and shelves on the right half with a pull out tray where I could store the tormek if I wanted to.

This weekend I pulled out one of my leftover boards and turned it into two panels and rails and stiles. They're all milled but I still need to finish sand them and glue them up. I could use some watco danish oil to make them looked fumed but that seems a bit extravagant for a workshop project. Yes, I see the irony in saying that when I am using quarter sawn white oak. But I really didn't like the experience of working with it so that makes it scrap lumber and I may as well make something out of it rather than just let it sit taking up space.

In Summary

I've not necessarily been doing that much wood working but I have been preparing for being able to do a winter's worth of projects. I still need to get the trailer fixed so I can get my wife's parking spot back but if they don't send me the right hinges this time I'll figure out some way to get the trailer folded and make it work. I am really looking forward to having sharp hand tools and a workbench I can use them on.

Friday, September 4, 2020

Covid 19 week 22, 23, 24 - Walnut picture frames

 As I've been starting my blog posts with a covid update for the last five months, why not continue. Covid in the USA is still running rampant. There was the first confirmed case of re-infection reported this weekend. NYS is continuing to drive the infection rate to below 1% so we are actually reopening museums, schools, etc. Seems like if any state in our nation is in a place where schools could be reopened somewhat safely it would be in our state.

Week 22

We ordered some Korean week 22. I got the seafood pancake and my wife got Chicken Teriyaki. The Chicken Teriyaki may not be the most Korean dish (I think it is Japanese) but it's pretty tasty and it warms up well. This last weekend we ordered Italian from our local mom-and-pop restaurant. It was good but chicken Parmesan doesn't travel well and mine was a bit tepid by the time we got our food home. I didn't have to cook so that's good too.

Anyway to the more interesting things, I pulled a walnut board from my wood stack and cut two 24 inch lengths from it.  I want to make two 8x10 walnut frames to hold some water paintings we purchased on a trip to Saint Martin ten or more years ago. With a 24 inch length I could get an 8 inch side and a 10 inch side from each rip and have plenty of extra wood for my miters. 

After cleaning them up by jointing one side then running them through my planer I had two boards that were about 7 x 3/4 x 24 inches each. I'd not paid sufficient attention to the sections I'd cut out of the larger board and ended up with a large knot and some swirly grain in one of the boards. Fortunately, I'd also done some bad math. I'd forgotten I was going to go for a 5/8 inch rip cut which got me about seven lengths of walnut. Getting one piece of frame from each, that's not quite enough for two picture frames...  <---  and there was my bad math. I'd cut the boards to 24 inches so I actually had enough wood in one length for three frames (plus a little).

Enh, so be it. I put the knotty board aside and selected the two lengths with the most sap wood to make into a frame. I'd originally thought that I would make the frame 5/8 inch wide and 3/4 inch tall but after looking at it I decided to make it 3/4 inch wide and 5/8" tall. I cut the rabbets with two passes on my table saw then cut the miters using my new table saw miter sled.

Calculating the length of the frame is pretty easy. Each length needs to be the side's length (8 inches or 10 inches depending) plus twice the frame thickness. The frame thickness is the overall thickness (3/4 inch) minus the rabbet (1/4 inch) which gives me 1/2 inch thick frames. So my 10 inch side needed to be cut to an outer dimension of 11 inches plus 1/8 inch for wood expansion.  My 8 inch side needed to be cut to 9-1/8 inch.

The sample looked great.

It's summer...  That was pretty much the weekend.

Week 23

We ordered dinner out again this week. We ordered Italian from one of our local mom-and-pop restaurants. Again dinner was a bit tepid... I'm remembering why I never liked take-out pre-pandemic. It was still a nice change from our regular fare.

I took the rest of my frame pieces and went through much the same process as I did with my sample pieces with one minor difference. My sample pieces have square edges and I wanted to soften them a little bit. I took a couple of hours and a sanding pad and cleaned up all the faces and also rounded over the corners. To be honest when I started I thought it would be quicker than it was. Looking back I probably should have put a 1/8 inch round-over in my router table and zipped them through there.

After rounding the corners I cut my miters on my spiffy new table saw miter jig. The cutting process went fine; however, my corners were not nearly as nice as the prototype. This kind of thing happens to me a lot. It is a natural progression. The first samples I take a lot of care and the pieces come out fine. On the second batch I must be taking less care or it is that I am moving from cutting a single piece to making batch cuts.

Out of my second batch of three frames two came out okay and the third was bad. I was using blue painter's tape to hold the frames together while the glue was drying. After pulling the tape I figured we could use two but the third was bad enough that I decided to pull it apart. A trick I learned a few years ago is that if your glue is set but not necessarily completely dry you can throw you project in a microwave to reheat the remaining water in the glue which allows you to pull the project apart.

After pulling the third frame apart I scrapped whatever glue I could from the frames. Then after giving the glue over night to set I trimmed about 1/64 inch from each end of the frame pieces and reglued the frame. It still didn't go together quite right so I am wondering if maybe the frame pieces might be slightly twisted or warped.

Miter joints really need to be reinforced somehow. Professional framers used to put a nail through the corner and then fill the nail holes with wood putty. Now days there are cool staplers that will hammer a waffle cut piece of metal through the back of the frame across the miter. The easy way for a home woodworker who doesn't have that kind of tool is to cut a spline in the corner. There are many ways to cut miters and many types of jigs to hold the work piece while making the cut. Mine is a table saw jig that rides on my fence. One side is set up for cutting tenons and panels, the other side has a V-shaped fence that holds my miter pieces at the right angle for cutting a spline.

So, I set up my jig and cut slots in each corner of all my frames for holding splines. I went ahead and cut slots in my just glued up frame as well even though it was still being held together with tape. It seemed to work just fine.

The next step was to cut the splines. In the past I've always just set my fence really close to my saw blade and used my narrow push stick to complete cuts. This is a non-ideal way to cut thin strips as it is more difficult to control work pieces. This time I made a thin strip cutting jig. It amounts to a piece of plywood that can run between the fence and the blade with a "heel" the pushes the wood through. This eliminates the need to keep resetting the fence as your board gets narrower and gives more control over the off-cut by moving it away from the fence. 

Mine worked out fairly well but there was still a tendency for the spline to want to rise up. I think I might add an adjustable strip of wood that will act as a hold down.

I used a 45 degree table saw jig to cut the long lengths of spline into shorter pieces appropriate for gluing into the frames. By cutting the splines at a 45 degree angle I was able to get more pieces out of a strip. I'd cut off one spline then flip the strip over to cut off a triangle shaped spline. I cut my strips to be slightly thicker than needed and then hand sanded each spline to fit the groove in the frame.

Unfortunately while my freshly glued frame survived having the spline slot cut it didn't survive me trying to wedge the spline into the groove. I was already disappointed with the frame so I just shoved everything together and hoped it would come out okay.

Week 24

Did I order takeout again? Yes I did! We had Thai. It was tasty.

I didn't get a lot of stuff done in the workshop this weekend. I started trimming the splines using my new flexible flush cut saw. It's a short flexible pull saw where the teeth have no set. This allows you to run the saw right against a finish piece without scratching it up. To be honest, since my next newest handsaw is probably 25 years old it was really nice to use a sharp saw.

After cutting the splines short the next step is to trim them perfectly flush. The way I've seen this done on TV is using a super sharp chisel to slice the end grain of the spline flush. I have chisels but they aren't sharp and sharp chisels are a must for this operation. 

Sharpening is my huckleberry. I have a slow speed grinder. I have oil stones. I have water stones. I have diamond stones. I have sandpaper...  I'm just not very good at it. I've been saving tool budget money for a while not and decided to get a Tormek T4 sharpening system. It's a wet grinding wheel on one side and a leather honing wheel on the other. The benefit of a wet grinding wheel is that you don't have to worry about the steel over heating. With the slow speed of the wheel and the addition of the water it is literal impossible for the steel to overheat.

So I read the instructions...  yeah, I know...  But it's a power tool and misusing it could hurt the tool, my chisels, or even me. Then after setting up the Tormek I started practicing on my older cheaper chisels. These chisels have been used hard and one of them got dropped on my concrete floor by a workshop guest. Yeah, I know... I try to be more discerning who I let use my tools now days.

I haven't actually finished sharpening them yet. Still trying to learn how to use the tool. But I almost cut myself on one of the chisels after flattening the back. I figured it wouldn't hurt to see how it would do in walnut end grain so I pared all my splines flush. Now I just need to go back with a sanding pad and clean them up.

What's next

I'm heading into a four day weekend. It is Labor Day here in the USA and with a little paid time off I am getting a four day weekend. I'm hoping to finish learning the basics of using my Tormek and maybe get my hand tools sharpened. I also want to get the walnut frames sanded and painted. I also want to get a shadow box made to display some old circuit boards I have currently sitting on a shelf.

My winter project this year is going to be a traditional hand tool workbench. I need to get my plans made for that, figure out what wood I am going to build it out of and get that purchased. However, that's probably not going to be this weekend.

I still owe my blog a write up of my miter jig. I may as well add some pictures of my spline cutting jig while I am at it. I'll have another write up for the picture frames I am making.

[Edit 2020-10-04 I'm not going to bother doing a write up for my miter jig. Michael Alm already has an excellent video on his latest version (posted this weekend) so if you are interested, just go watch that.]

Sunday, August 9, 2020

Covid 19 week 20, 21 - Rando projects

On the Covid front...  I had my first take-out in four months these last two weeks. Last weekend we ordered and ate some buffalo wings. They were good but not as good as I expected them to be after four months of no fried foods. While stopping by my local Woodcraft - more on this later - I also grabbed a couple of caramel frappachinos. Today our pork chops didn't thaw in time for dinner so we ordered Thai from a local restaurant. It was pretty good.


We have several fine lumber yards in the area. Some of them carry finishing supplies but when it comes to specialized woodworking tools Woodcraft is the best place for me to go. I needed some poly - General Finishes Oil and Urethane is my go-to here - and  I also picked up a Tormek T4 sharpener for sharpening my plane blades and chisels.

Is it excessive? Maybe...  I've tried learning how to sharpen my chisels and planes by hand. I've use oil stones, water stones, sand paper, etc. (no, not the scary sharp method...  yes I know about it... no, I haven't tried it). The nice thing about the Tormek is that it has jigs for properly sharpening all kinds of tools including kitchen knives.

My wife and I are quarantining all items coming into our house for three days so I just got the box out of quarantine this weekend and pulled the manuals. I'll let you know what I think of it after I get it fired up.


I finished my gaming console console but I'm still doing woodworking. Mostly I am trying to finish up small projects I started but didn't finish. As I said in my last post these projects include the hobby supplies storage cabinet I built for my wife and the gaming table accessories for my friend.

Last weekend I completed putting the finish on the drawer fronts and two more of the trays and got them in place. I'm not exactly happy with the spacing I got on the drawer fronts but it'll look fine from my house. Yes, I realize it is in my house but it's in my wife's hobby room and I almost never go in there.

Last weekend I also finished milling the parts for the gaming table accessories. I got the slot covers glued in place and found some 3/16 inch steel rod that I cut into 3/4 inch lengths to act as handles to the lock mechanism. I got all the pieces sanded and out into the garage last weekend but I didn't start putting polyurethane on them until this weekend. I've got two coats at this point so given that my technique needs many coats I figure I'll have the finishing completed sometime late this week. It is supposed to be hot over the next couple of days so depending on how hot an humid it is in the morning it may take longer. We will see.

My next "me" project is picture frames. We've been accumulating art over the last fifteen or so years and I always say that I'll build a frame rather than pay someone else to do it for us. Well that's a long standing "small" project I am going to get done. The nice thing is it won't take much wood so I won't have to risk going to a lumber store.

I've got a couple of 8x10's water color paintings that we bought in St. Maartin ten or so years ago. I think they'd look really nice in a black walnut frame. My wife has a small 5x7 ink drawing of a cat that I think would look nice in a black frame. Neither one of the frames need to be bulky so they'll be a good start.

One of the things that I'll need to be able to do is cut the pieces accurately. I do have a 45 degree table saw jig but I remembered seeing a video by Michael Alm a few weeks ago where he had a better jig (you could skip to the 3 minute mark but it'd be better to watch the full video). Since I could be more sure that a new jig would cut a better mitered corner I figured I'd build my own version of the Michael Alm jig (though, I'll bet he got his idea from somewhere else).

I finished mine today and cut my initial test frame. It looks pretty good especially considering it was cut out of scrap.

The last thing I got done today was making a setup template for my Kubb set. It's basically some paracord with loops tied in it that when laid out it forms a triangle making up half the pitch. It's explained better on the Kubb blog post. At first I thought I was going to need help and a long tape measure but then I remembered I'd already made one. I just laid out the one I already had in the yard and used it as a template for my new one.

In Summary

I had a couple of pretty relaxed weeks. I got a few hours into the workshop and made really good progress towards finishing up a couple of projects. I got some photos of my new table saw miter jig but I'll save that for its own post later this week.

Sunday, July 26, 2020

Covid 19 Week 19 - Finishing projects is fun!


I play board games. This isn't a great admission. It isn't like this is Board Gaming Anonymous with a twelve step unproven treatment for wayward board gamers. I play board games and recently I've been enjoying a card game called Sentinels of the Multiverse. The game has so much depth beyond just a couple of cardboard heroes and villains. The creators have been telling stories to each other for years (maybe decades) of super heroes and villains. Basically writing comic books in their stories. It really gives you the feeling that you are playing a comic book super hero.

Anyway, a few years ago they started a podcast where they talk about different aspects of the game. Mostly they are talking about the back stories of the characters in the game, telling or making up the stories in the comic books.

The point? I'm getting there...  I'm a bit behind in pod casts but I am catching up to the present. I'm caught up in all my science pod casts other than Astronomy Cast. In my fun pod casts (pretty much just Sentinels) I just got to March. They're just now experiencing what we all experienced four months ago. If made me a bit introspective about my blog. Anyone reading this not in real-time will be basically looking back on whatever I write with the benefit of retrospection.

Of course since the internet is forever, some researcher in ten years will find this blog and make it a data point in their paper. Some historian will find it again in a hundred years and then take some quote from my blog and then generalize it to "here's how people in the USA felt about Covid in 2020." I just want to:
a) apologize to those people reading this blog in the near future who already know what awaits us
b) say hello and welcome to both the researcher and the historian (Hi!)

Covid? Not much of a change from last week. NYS is showing a very slight rise in the incident rate. Governor Cuomo is talking about shutting down bars and restaurants. Most of the rest of the nation appears to have out of control Covid infections. Most of the states that aren't out of control are on the verge of going out of control. I am very thankful that our state is taking this serious and is taking measures to keep us all safe.


Gaming Console Console

I just finished my Gaming Console Console! I'm very excited. I texted pictures of it to all my woodworking buddies and other people who might care. Or at least care enough about me to say, "Hey dude, nice cabinet."

Hobby Storage Cabinet

With the big project out of the way, I'm shifting into finishing up the small projects that I got started but haven't yet finished. I mentioned in previous weeks that I am putting the final touches on the drawers and trays in the hobby storage cabinet. I've got veneer and finish on four of the eight trays and am in the process of putting polyurethane on another two. This weekend I sanded the false fronts for the drawers flat, sanded them smooth and started putting polyurethane on them.

Fitting the drawer false fronts got interesting when I remembered that when I was putting shelves in the cabinet I wasn't perfect. One side of the drawer opening is about 1/8 inch lower than the other. Since the drawers are level with the case bottom the bottom drawer front is rectangular. The top one needed to be fitted and have about 1/8 inch more taken off the left side. I thought about pulling out my tapering jig but instead I decided to mark a line and use a hand plane to shape it.

I'm not really a hand tool woodworker yet but I would like to be. I don't want to be a pure hand tool woodworker; however, some things are easier done by hand than spending 20 minutes to set up a tool.

It worked out great. I was very happy with the result and it fit great.

Those pieces are out in the garage getting finish on them.


I also started putting an outdoor penetrating oil finish on my Kubb set. I was sloppy with the first coat. I debated skipping the second coat but it was nice out today so I put a second coat on all the pieces. They look a lot better.

The first coat took most of a week to dry to the touch so I suspect the second coat will as well.

Gaming Table Accessories

I'm pretty sure I've mentioned previously that a friend of mine has one of those cool game tables that has a removable top with a recessed playing surface. These kinds of tables allow you to leave a game in progress but still use the table as a table. Anyway, the company that built his table went out of business and the accessories are no longer available. He asked me if I could make him a couple extra cup holders so I am.

I've been working on this for probably six months or more. It was a bit lower on my priority list. In any case, I'm going to finish them now. This weekend I milled a groove for the latches that keep the accessories from falling out of the slot in the table skirt. I had to do a bunch of back routing so I took it very slowly.

I'm hoping to mill the latch pieces and maybe start gluing the latch covers into the accessories tomorrow night. With any luck this will go quickly from here on out.

Saturday, July 25, 2020

Gaming Console Console DONE!

My Gaming Console Console is done! Yes, I am extremely happy. I'm happy it is done. I am happy that it came out as well as it did. I am happy that I tried a couple of new things and they all worked out.

New cabinet all loaded up

New cabinet shelves
I'm pretty sure I mentioned in a previous post debating between glass and plexiglass and finally deciding on glass. You can see in the photo immediately above that the glass is a little shimmery. That's due to the bubbles in the glass.

If you are wondering why something looks a little off, it's probably the pull on the top drawer. When I bought the pulls from Lee Valley I bought the Mission style knobs that are on the bottom two drawers and the door and I also bought some pulls called "Rio". I really like the styling on the Rio knobs but they are just too large for the cabinet. One of the Mission style knobs was miss-threaded and has been sent back to Lee Valley for replacement. The Rio knob is standing in until the replacement arrives.

How is the Lee Valley replacement process? So far, it is super easy. They have a PDF you can download and fill out itemizing the parts being returned. They'll refund shipping if you ship the item back yourself. Alternately you can print a shipping label that includes postage. I went this route. I think it was Wednesday that I put it into the mail. I'll let you know how long it takes to get a replacement.

Prototype on the left, new one on the right
Yeah, there is some dust on the glass in the above photo. I'd just brought the door up from my workshop. 

Installing the glass was interesting. This is the first time I've made a door with glass in it. I was a bit worried about hammering nails into the glass stops but then I remembered that the glass only cost $15. If I break it I can just buy another piece. As it was, everything went fine. I found some 18 ga wire nails that were 5/8 inch long. I put some tape on my smallest drill bit to mark it about 1/2 inch long, just shorter than the nail. I pre-drilled all the nail holes through the glass stop and into the frame just shorter than the nail. The holes were a slip fit for the nail so I hand pressed them in as far as they would go then just tapped then home with my smallest hammer. I didn't bother using my nail set to recess them.

Since I'd mounted the door in the cabinet once already for fitting, mounting it this time just required putting the hinges on the door then putting it in the cabinet. To add the spring catch I figured about where I wanted to mount the male part on the door, marked it with a white pencil, transferred that mark to the cabinet and inset the female part approximately as deep as I thought it should be. Turns out it was just about perfect so I left it as it was.

The last thing I had to do was take the shelves to my router table to route a recess into the bottom to lock the shelves to the shelf pins. I used a 1/2 inch (or was it a 5/8 inch) bit to make a 1/4 inch deep recess. I was fortunate in that my shelf pins were spaced exactly the same in the front and the back so the same router table setup allowed me to route all four recesses. The only downside was I needed to back-route two of the recesses on each shelf. It worked fine, I was just super careful to take it slow and make sure the shelf didn't get away from me.

Anyway, it is done. I looked back through my blog and it looks like I started it just about the same week that Covid became a concern here in NY. Let's call it about 20 weeks from start to finish. These kind of projects always feel like they should just take me a weekend or two in the beginning; however, I never end up spending full weekends in my shop so the projects stretch longer (much longer) than a couple of weekends. But as I started this paragraph, it is finally done.

Next, it is summer time. I've still got some small projects to finish. I also have to start thinking about what I want to build next winter and start my planning. Maybe doors for my dust collector closet. Maybe a real workbench. Maybe more magazine boxes. We'll see...

Stay safe everyone!

Covid 19 Week 18 - Gaming Console Console Assembled

I decided! I decided to go with glass for the gaming console console door. The only glass my glass guy had that wasn't just clear was glass that has some bubbles in it. It's much more clear than I was hoping for but I'm hoping that it breaks up the outlines of the game consoles inside the cabinet. Mostly I'm getting to the stage where I just want the project done. I don't have a stream of people walking past my consoles every day to remark on the beauty of the glass in the door. Also, since I am using glass stops I can always easily replace the glass later if I change my mind.

Speaking of glass stops, I milled them out of one of my off cuts over the weekend. My glass stops need to be about 1/4 inch square and I need about 60 inches of them. I took one of my straight grained off cuts and resawed it twice (three times?) to get four pieces. The pieces were so wibbly-wobbly that I used my drum sander to clean them up and thickness them. This worked pretty well.

Our weather has been pretty nice (highs of the low 80's) over the last few days so I've been able to get two or three coats of polyurethane per day. I gave them about six or nine coats. They're going to stand a little proud of the inside of the door.

I had enough pieces of the cabinet finished to start assembly so I did. I started by adding the top to the case. That wasn't too bad. I just had to be careful to not drill through the top when drilling pilot holes. I flipped the top upside down on a pair of saw horses (actually two pairs of stacked saw ponies), set the case upside down on top to get it centered and squared up then drilled pilot holes using the holes I drilled in the top rails way back at the beginning of this project. I wrapped a piece of tape around the drill bit to act as a depth stop.

I'd previously fit the drawer fronts before finishing them. I was smart and marked the drawer fronts and the drawer boxes so I'd know where they fit in the stack of drawers and so I could match up the false fronts with the appropriate drawer box.

Unfortunately I was too smart. I'd made my marks on the faces that would be screwed together so after fastening the fronts onto the boxes I could no longer tell which one was which. Figuring that really they just needed to look good I decided to just go trial and error rather than taking them apart.

A little trial and error and I got the top two drawers looking right. Unfortunately somehow I'd misaligned the false front on the bottom drawer. I really don't know how this happened but it was extra frustrating because now that I had the top and back on the case I didn't have easy access to fix it from the top or the back. I had to awkwardly reach in from the front. Especially annoying since it took me two tries redrilling and setting screws to get it right. All is well that ends well, right? Well, if the extra holes inside the drawer bother me, I can just make a new one.

The next crisis came when I went to add the pulls onto the drawers. One of them didn't go on straight like I had cross threaded it but when I double checked I'd threaded it correctly, the pull was just mis drilled/threaded. Fortunately I had a spare. Well not a spare, but I had the pull meant for the door that I could use, and I did. I'll have to contact lee valley about getting a replacement. I've never had to use their customer service before so this'll be a first for me. I'll let you know how it goes. I'll use a spare knob on the door until I get a replacement.

The last thing I noticed when sliding my shelves into place is that they are very slippy. They're not likely to get a lot of forces other than gravity acting on them just sitting in the cabinet but I can just envision the top shelf slipping for some reason (moving the cabinet maybe) and crashing down on the middle shelf and then having a mess of shelves and game consoles smashing through my glass door. To mitigate the risk I'm just going to mill some detents into the bottoms of the shelves so they'll have a positive stop.

So close to being done. I need to install the glass in the door, drill a hole for the door pull and install a temporary pull, install the door and latch, and finally cut some detents in the shelves. That's a long list of things but they're all relatively small.

That's where I am at with the gaming console console. A few hours this weekend and it should be done-done. Well, except for the door pull which probably wont be here by then.

I did get a bit of other stuff done over the weekend. I got two more false fronts glues to the trays in the storage cabinet. I got enough coats of polyurethane on them to call them done and put them into the cabinet tonight. Tomorrow is supposed to be thunderstorms and it is also a workshop night so I'll probably start another two.

I put also put a coat of outdoor finish onto my Kubb set. It was really hot in my garage when I applied it. Hot enough that my wife came out to check on me to see if I'd passed out. It was also a pretty messy job. I managed to not get the finish all over everything but I didn't do the neatest job on the set. I haven't decided yet if I am going to put the second recommended coat.

Anyway, that's all for the last week.

Friday, July 17, 2020

Covid 19 week 16 & 17 - More Console, plus, plus

Oh my gosh, it's been two weeks since I posted last. Well, it isn't because I've been busy doing woodworking and it isn't because I got sick.

Let's do the Covid update...  New York State is doing fine. Our infection rate across the state is between 1% and 2% fluctuating by the day and week. We're still not fully reopened; however, on the rare occasion I've been out of the house you wouldn't be able to tell that we were all practicing safe distancing by the number of cars on the road. After all, they must all be going somewhere.

I had to go to Home Depot to pick up a wax ring for one of my toilets that started leaking. I figured if I had to be there anyway I may as well pick up some other supplies that have been on my list. Apparently everyone else also thought Friday afternoon at 4p was the time to go buy paint too. Well, other than an older woman who didn't understand distancing it all worked out okay. At least so far...

Anyway, I've been putting my standard wipe on polyurethane on my Gaming Console Console. It's been going a bit slowly because we had about four or six days of 90 degree F weather and at best I could sometimes put a coat on in the morning before work. Even then there were some mornings I skipped it due to the heat and humidity.

Even with the hot weather I was able to finish the polyurethane on my case, door, drawer fronts, and shelves. The last - sort of - step is to get some polyurethane on the case back and then assemble. I say it is sort of the last step because I still need to get some glass for the door and then put it in with some glass stops I haven't milled yet. I'm still waffling on whether to go with glass or frosted plexi-glass.

Over the weekend I only put a few hours into the workshop. It's summer and we had a couple of beautiful days to spend outside. Well, we got some rain too but the weather cooled down to bearable temperatures. What I did spend time on this weekend was some shop cleaning and trying to get some of the small projects that built up out of the way, or at least moved forward.

Remember the hobby storage cabinet I made for my wife? The plan was to put some 1/4 inch hardwood veneer on the trays and 3/4 inch hardwood false fronts on the bottom drawers. Aren't they all drawers? Sure, in a way. But I have drawer slides on the bottom two and the top eight are just loose fit and sit on a shelf. It's also convenient to distinguish between the two types by calling them drawers and trays. The trays are also a lot shallower.

Anyway, I finished ripping my red oak into 3/8 inch panels and planed them down to about 1/4 inch and sanded them to 80 grit. Next I needed to mill 3x5 card holder slots. The current trays have 3x5 cards clipped to them using a binder clip. It's unattractive and wont work after I add the 1/4 inch oak. So, the idea was to cut out a window slightly smaller than 3x5, then route out space on the back of the veneer to slide the card into.

I made a template.

I used this to trace out the window shape that I then cut out using my jigsaw and band saw. I used both tools because my jigsaw set up enough vibration in the thin veneer that it was causing the oak to splinter and break. So I used the jigsaw to make the vertical cuts and the band saw to clean out the waste at the bottom. I then used a rabbeting bit to clean out the card slot on the back of the veneer.

Then it was just a matter of sanding up through 180 grit with my random orbit sander and rounding over the square edges with my sanding block.

Since the cabinet is fully loaded we just emptied two trays, a 4 inch and a 6 inch which I added the veneer to and then while I was putting polyurethane on the gaming console console I also put some on the veneer. I didn't bother putting poly on the actual trays.

So, two trays are now done and I have another 4 inch and 6 inch tray in the workshop ready to have veneer applied to the front. I've also glued up two 3/4 inch thick panels to turn into fronts for the drawers. I really like the look of the two poplar drawer handles I made but I think I'll probably make two new ones out of red oak so they match. Or maybe I'll make them out of a contrasting wood like walnut if I still have any.

The other thing I worked on over the last two weeks were some cup holders for a friend's table. He has one of those gaming tables with a removable lid that has a channel along the skirt that accessories can be locked into. What I was working on this last week was making the slot to hold a peg that is used to lock the holder in place. I've had this project in progress for much of the last six months to a year. Time to get them finished.

This coming weekend? Glass in the gaming console console door and mounting it in place. Finish those cup holders for my friend. More tray and drawer fronts for the hobby supply cabinet.

The Gaming Console Console is almost done. Hopefully it'll all be done this week.

Tuesday, June 30, 2020

Covid 19 week 15 - More finishing

Covid 19 update...  New York State is still reopening slowly. Pretty much all of NYS is in phase 4 which allows most businesses to be open. We can actually go into stores now to buy things. Most are requiring people to wear masks and in the limited times I've been out with just a few exceptions people are doing that.

This last weekend was beautiful. There was some intermittent rain but the temperatures were quite mild for this time of year. I started putting my normal wipe on polyurethane on the top, the case, and one of the shelves. I would have liked to do everything at once but I just don't have enough room in my garage nor do I have enough horizontal surfaces to lay everything out at once. I got about five coats on over the weekend, and a couple more coats on yesterday and today.

The carcass is done excepting the bottom. Yeah okay...  I know that means the carcass isn't done. I've done all the delicate parts that need to have care taken to make sure I don't get drips, sags, etc. I cannot just slop it on the bottom but I'll have to be really sloppy to make a mistake now.

The shelf is done. Sure it could use another couple of coats but it's done enough. It's going to be inside a cabinet behind a door.

The top isn't done yet. It's gotten as many coats as the carcass and  the shelf but it's going to suffer the most use and abuse. I want the top to have a nice thick coat of polyurethane to protect it. Might be a little overkill since it already has nicks and dents that were me making boneheaded mistakes during construction. But that's water under the bridge. May as well protect it from future dents and dings.

That's pretty much all the woodworking I got done over the weekend. We had multiple puppy play dates. I mowed my yard. I cleaned my workshop. I got other stuff done, it just wasn't an all-woodworking all-the-time weekend. It's summer time here in upstate New York and I've got to enjoy the weather while it is here.

Since it is summer I'm past the end of my woodworking season which is typically November through May though I have to admit I usually go a bit long due to over committing to projects. While I wont be spending as much time in my shop over the next few months I still need some small projects for bad weather days. I need to finish putting false fronts on the trays in my wife's storage cabinet. I've got a cup holder a friend asked me to build for him. Oh, and some picture frames. These projects should be sufficient for awhile anyway.

The last consideration I have is what to do with the temporary console I built as a prototype. I had two different takers for my temporary console but both people backed out. One of them got another piece of real furniture, the other decided it wasn't nice enough. So be it...  It's served its purpose which was to see if the proportions I picked were adequate and pleasing. I don't really need another horizontal surface in my house so I'm probably going to break it down into scrap wood.

So next is probably another week of polyurethane. I've got to make the glass stops for my door. I need to decide if I want to buy the only piece of textured glass my glass guy has or if I am going to use the piece of plexiglass I bought a few weeks ago at home depot.

What? No pictures again?


I'll post pictures in a couple of weeks when everything has been poly'd and assembled.

Tuesday, June 23, 2020

Covid 19 week 14 - finishing the case

I started the weekend off strong. Friday afternoon I called my local woodworking store and ordered a 40" metal ruler and I called my glass guy to order glass for the door. Unfortunately my glass guy didn't have any textured glass that was suitable for my project and my local woodworking store didn't have any mineral spirits. So, when I was out doing my running around doing my best to stay away from people I ducked into my local Home Depot and picked up a piece of plexi-glass and a gallon of mineral spirits. I didn't want a gallon but that's all they had.

Friday evening I jointed and planed the boards for the shelves and planed the toe kick down to about 3/4 inch thick. Then I glued up the shelves.

With the prep work from Friday night I was able to use my new ruler to trace out an arc on the toe kick and cut it to shape on my band saw. I went real slow and cut very close to the line. Then sanding...  I cleaned up the curve on my oscillating spindle sander, then I used the off-cut and some 150 grit sandpaper to fair the curve.

I then broke out my random orbit sander and cleaned up the faces of the toe kick and the shelves. It was a lot of sanding but frankly the Sapele cleans up a lot faster than the white oak of my previous projects so it wasn't that bad. I did have to use some 60 grit sandpaper on one of the two shelves but it still went pretty quickly.

To finish up the day I glued the toe kick to the bottom of the case.

Sunday morning was our weekly puppy play date. Jackson from across the street and Yogi from around the corner came over and more or less sat in the shade together with my pooch for a couple of hours. There was some light playing but it was really too hot for the dogs to do much more than some half-hearted stick chewing.

Sunday afternoon was final sanding of all the edges and basically getting the parts ready for finish. I rescued my saw ponies from my finishing room that my wife is using as an office during this pandemic and set them up in the garage. I started cleaning up the pieces with shop towels and the mineral spirits I'd bought on Friday. It was miserably hot in the garage. I was just able to bear it but the biggest issue I had was the sweat dripping on the work pieces as I was trying to clean them off. I did my best and only got a couple of drips on everything. I hoped for the best.

"The best" was not what I got. After the mineral spirits evaporated I found that I had a number of blotches in various parts of the project. I had been wearing gloves but apparently they left marks on the projects. I waited overnight to see if perhaps it was just the mineral spirits taking a long time to evaporate but alas, Monday morning the blotches were still there. I grabbed some 180 grit sandpaper and went to town. It was pretty warm but again I managed to keep my drips of sweat off the project. After sanding out the blotches I again ran a shop towel with mineral spirits over everything to clean the dust off.

After work Monday afternoon I went out to check on how everything looked and while the blotches were really gone it looked like all the wiping down had done was smear the dust all over the project. It was extra apparent on the side panels I'd already finished. So, it was time for more shop towels and mineral spirits. This time with nitrile gloves instead of synthetic vinyl. I'm kind of thinking that perhaps the mineral spirits degraded the synthetic vinyl and is what caused the blotching. Moral of this story is to not be lazy and walk up the extra flight of stairs to get the appropriate kind of gloves for the project at hand.

Anyhow I digress...  This time - with nitrile gloves - I made sure to refresh and replace my paper shop towel frequently and kept wiping down the surfaces until I was picking up very little residue. It took a while and was hard on my feeble wrists but I think the project is actually ready for finish.

Then today (Tuesday) while looking at the project I remembered that I was going to add a magnet to the door which required me adding a block of wood to mount the magnet in. My original plan was to use a door catch from Lee Valley. Specifically one of these spring catches. The problem was that the springs are actually pretty strong and I just needed a little bit of force to keep the door closed, not a lot. A tiny magnet would work just fine.

Then this afternoon I was looking at the catch I realized that I could reduce the amount of force needed to separate the spring catches by using a pair of pliers to pinch the sides of the triangle together (sorry, no pictures today - you'll just have to look at the picture in the link above and use your imagination.) It seemed to work so I'm going to use the catch rather than wedge a block and a magnet into place. Yay, back to being ready to put finish on.

But, no finish today. It's been hot and humid today so I didn't want to risk the finish curing weirdly. At least the rain will be good for my yard. It's been getting pretty dry. Hopefully we'll have some nice weather later this week and I can start putting my finish on. I'm still a couple of weeks away from finishing this project but the end is in sight.

Monday, June 22, 2020

Covid 19 week 12 & 13 - Gaming Console Console Progresses

Well, it has been almost three full months since NY State went on Pause. Deaths in our state have decreased from our high of almost a thousand a day to low double digits. The state is doing around 55 thousand Covid 19 tests every day and across the state the infection rate is around 1%. This is down from a much higher number but I don't think comparing infection rates from when the only people getting tests were ones showing symptoms to now where pretty much everyone can get one if they want to is reasonable.

In any case, our state is opening back up. Slowly, but it is opening.

I did get into the shop this last weekend for a few hours. Unfortunately my Saturday hours were impeded by a sudden puppy play date and other unfortunate circumstances. I'd just finished changing into my workshop clothes when the phone buzzed with the neighbors wanting to get our dogs together. It was a very pleasant afternoon but it kind of took up all my shop time sitting in the yard watching the pups play and chatting.

After the play date and dinner I did get into the shop for a little bit. I basically just got things set up for Sunday so I could hit the ground running. With the drawers, top, and case pretty much done all that's left for construction is the door and the shelves. Shelves are trivial so I wanted to get the door done next.

I started by setting up my router table with a rabbeting bit set to take a 1/4" wide rabbet to hold the glass. I then started taking about 1/32 inch off at a time until I had a 1/4 inch wide by 3/8 inch deep rabbet. This obviously left me with rounded corners. Cleaning up rounded corners isn't my strength but even my sloppy jobs work and practice makes better. I set my calipers to the width of each rail and stile and used them to mark the line I needed to chisel to.

Then this is where the unfortunate thing happened. I got the first corner done and was starting on the second when the power went out. When I first set up my workshop I did a few things to deal with this kind of situation. I'd made sure the lights in my workshop were on a separate circuit from my workshop so if I managed to overload the circuit by running too many tools I'd still have lights. I'd also put an emergency light next to the stairs out of my shop so that I'd have light in case I'd lost all power. My fear was using a power tool that needed time to wind down when the power went out. I wanted to have enough light to be able to stop whatever I was doing and get out of my shop safely.

Unfortunately the emergency light quit working a number of years ago and I'd removed it. No worries, I'd just wait until the generator turned on. The generator did turn on but that's when I learned that my workshop lights were not on the generator panel. So be it...  Fortunately I didn't have too many of my mobile tools pulled out and I had a relatively clear shot to the stairs. I just waited for my eyes to adjust and carefully walked to the stairs. Next time I have an electrician over to the house I'm going to have them put my workshop overhead lights onto the generator.

Anyway, turns out it was only half our block that lost power...  My neighbors across the street having power didn't help me any so I mowed my yard. By the time I was done we had power back.

That evening I got back into the shop to finish chopping the corners square.

I think I did okay...

The door still needed to be fit to the opening. The door as I built it only had a 1/16 inch gap at the widest in the opening. Why do I say, "at the widest"? Well, while the door is square the case is only mostly square. Over the width of the opening the door gap ranged from around 1/16 inch to around 1/64 inch. If I was better at hand planing I'd just whip one of my block planes out and clean up the door to fit. Since I am not I used my table saw sled with shims to give the door enough angle to take off about what I needed.

I sacrificed one of my decks of cards to get my shims... Well... Truth be told, I only sacrificed the cards numbered 2 through 8 and made the rest of the deck into a Euchre deck. I was too tired to want to start cutting my door that evening but I did check to see if the cards would work as shims and it certainly looked like they would.

In any case, this worked fairly well. I set the door on my sled and kept adding cards until it looked like I was going to take off enough to make the door side fit the opening. It actually worked out pretty good. I took it slow and careful and took a little bit off all sides of the door to keep it relatively even.

I used my new shims to make sure the door had the right gaps all around.

Now, to be honest I don't remember exactly which days I did the following work on. I did get into the shop a number of evenings and the weekend of week 13.

I mounted the door by using a little bit of tape on the case side of the hinges, then once the door was in the right place I just pushed the door over hard enough to get the hinges to stick. After removing the door I could use my new punch tool to mark the center of the screw holes. I could then remove the hinges and use the divots left by the punch to drill holes for the screws.

Anticipating adding and removing the door a number of times I mounted the hinges to the case using some temporary wood screws to make sure I didn't mess up the final ones. Unfortunately the bit I chose for pilot holes was a bit too small so I pulled out a larger bit, enlarged the holes then mounted the hinges to the case. With the hinges mounted I put the door back in the case and used shims to hold it in place. I was then able to reach in through the back of the cabinet and use my new punch to mark where the screw holes belonged in the door. Then it was just a matter of pulling the door, drilling pilot holes then mounting it.

At the end of one of my workshop days I put together a jig for drilling the holes in the drawer fronts. The next day I removed the drawer fronts and sanded them to 180 grit then used my jig to drill holes for the drawer pulls.

At this point I have a mostly completed case. All that's left on the case is the back and the toe kick.