If you only count hours in the shop I've been making good progress on the Radial Arm Saw Cart. If you go by calendar it hasn't been that great. Regardless, last weekend I got the panels shaped.
My first step was to shape the tall outer panel as seen below.
I cut the first rail slot by hand but then I got a little smarter and made a jig. I took one of the longer rail offcuts and cut it into three pieces. I then glued them back together to make a router template. To cut the rest of the slots in the panel I carefully measured, clamped the template in place, removed most of the waste with my jig saw, then trimmed to the exact size with a half inch pattern bit in my router.
|Middle Panel and extra support rail|
My first task this weekend was to drill the holes for the handles. I'd bought 1" black pipe for these and fortunately I thought to measure it. It's 1" inner diameter so the actual outer dimension was about 1-5/16". I don't have a Forstner bit that size so I just used a 1-3/8" bit. They'll be a bit loose but that's better than being too tight or not fitting at all.
|Tall side panel glue up|
I did use a lot of clamps gluing up the two side panels. I may have had the nailer ready but I didn't have any cauls ready. I did have the rails for the cart though so I used a couple of them to try to spread pressure across the panel. I noticed I didn't have any glue squeeze out on the bottom though so I took the other two rails and used them to put some pressure more in the middle of the panel. It isn't pretty but it worked.
As you can see from the above photo I needed a cross clamp to bring everything square but it was pretty close regardless. This was just making a very slight adjustment.
I glued up a couple of blocks to support the wheels, again sanding the finish where they were glued on. I intentionally left them a bit short of the rail so when I add drawers I'll have space to add the drawer rails.
And voila, done except for drawers I will add much later and a top.
And with the top...
I was intending to make the top out of a singe piece of wood/plywood but I happened to have two pieces of scrap panel that I could cut down and only "waste" a little bit of wood. I figured it would work as a temporary top and if it doesn't work I'll replace it later.
I had my neighbor - we'll call him Steve to protect his identity - come over and help me lift the saw onto the cart.
It still needs drawers and a table for the saw but at least it is up off the ground and is on a cart that will be easily mobile. I planned on putting adjustable feet on the leg side. I think I am going to wait a while before I put them on though. It seems to sit pretty stable so far.
I intended on putting of drawers for a while but then I came across a recycle bin full of accessories for the saw. I don't know when I am going to use them but it would probably be best to keep them with the saw. Maybe I'll add a quick shelf and see if I can fit the bin underneath.
We'll see... For now, it is done.