Archive for the 'Woodworking' Category
Friday, July 5th, 2013
I want my bathroom cabinets to “float”. The top one floats 2″ in the air on top of the bottom cabinet, and the bottom cabinet floats 3″ in the air off the ground. The right hand side can be screwed into the wall, but the left side needs support.
I welded up this bracket; it is bolted to the bottom and bolted to the pair of studs. It is quite sturdy!
The top slips on; for testing to get the position right, I clamped the bracket to the walls, and used a brace on the right side:
It is plenty sturdy and can easily hold my weight on the corner without dipping at all.
The bottom floating cupboard:
It probably wasn’t necessary to make it to literarily float in the air, and I could have used gap pieces to support each section; from a distance you can’t hardly tell if it is floating or not. But still, the concept is cool, and I think it looks good.
Tuesday, June 25th, 2013
Still working on stuff.
Playing with stains; left side is 1/2 cherry ply, right is cherry wood. Bottom has a maple gel stain, top has pennsylvania cherry gel stain.
Cutting all the face pieces to 1 5/8″:
1/2″ wide groove in the center of the 3/4″ piece of wood:
I then put a 45 on the inside, and a V groove with the router table 1/2″ from the outside:
I tanned the boards outside for about ~5-10 minutes to get them a little brown before gluing up. The inside cherry ply is still a little pinker.
It was tricky gluing them together to keep the miters straight; the first two were a bit off, so I just screwed a jig to my table and all the rest were dead straight:
The big cabinet door:
The 45′s have no spline or support; I will probably need to cut some slots and miter in a spline to make them stronger.
Here’s a few of the small drawer faces:
Sunday, June 9th, 2013
My woodworking project continues!
I planed a bunch of maple to 5/8″ thick my drawer thickness. I went with 5/8″ instead of 3/4″, since my top drawers should appear more “dainty” as they are small. I should have done 3/4″ for my larger bottom drawers, but it is too late for that decision.
I used my Leigh dovetail jig to cut the dovetails:
Since these drawers are small, I used 1/4″ maple ply (with a MDF core) for the bottom. My larger drawers will have 1/2″ ply bottoms.
The larger drawers I had to biscuit joint smaller pieces of wood together to get 9″ sides (they are tall!). I should have jointed them together before planing them; then I could have planed them together. Or maybe doing it this way was good and allowed me to work around tearout. I’m not sure what the best approach is. This worked pretty well…but I had to use a lot of clamps to get them aligned really well:
The drawer dovetails weren’t as tight on these…I must have messed up the jig a bit, or not done enough practice cuts on it. They did turn out pretty well, and I can clean them up.
I now have to get more maple for two more large drawers, and then I’ll be done building them all.
Sunday, May 26th, 2013
Tongue and groove practice; I have a height matched set. Note to self: Put the little rubber grommet inside the chuck. Place it on my table, and push the cutter into it until it bottoms out against the grommet. Then I can mount it in the router and it is always at the same height. Cut it with the “good face” down. Have the height set so there is a larger area on the bottom (slightly of, as seen here in the picture):
Here’s a trick I came up with for cutting a straight edge on plywood. The two sides were parallel, but one of the sides was rough from cutting it off with my circular saw. So, I used my parallel clamps to clamp them together and used a smooth side as a guide. I then could flip it and cut the other side.
Fitting of the joints; no glue here:
Gluing it up in small pieces; the face frame was last to be attached:
Stacked to get a feel for what it will be like:
Cupboard above it:
Time to make some drawers, and then all the faces for these cupboards/cabinets.
Tuesday, May 21st, 2013
Well, my bathroom remodel is coming along bit by bit.
I got a new cabinet saw to help with things. I went with the Saw Stop brand saw, which cost a ton, but will potentially save a finger if I accidentally touch the blade.
Most all my wood I purchased from Aura Hardwoods in San Jose. They have pretty decent prices, and a friendly staff. Although you sometimes have to ask for the good wood in the back. I was rifling through a bunch of pretty poor looking cherry plywood sheets trying to find a good one when a guy named Kirk came by and said he could go get a fresh stack with his fork lift from the back. So he pulled them out for me, and I grabbed 4 pristine sheets from the top of the pile. Thanks Kirk, I really appreciated that! I heard Macbeath may have better prices, but they are a bit further away and I haven’t tried them out yet. Southern Lumber is way too expensive. Global wood source has some good selection of different woods. Unfortunately I haven’t been able to find good A1 grade 1/2″ cherry ply, and could only find “Shop grade” (which I’m not sure exactly what that means).
Here’s some end panels for the bathroom sink cabinet:
I’m not so sure I like doing pocket hole stuff for these frames, but it worked out “okay”. I would have rather floated the interior panel inside of it..but I didn’t end up doing that.
Cabinet face frame, showing the tongue and groove joints and pocket hole stuff:
Top floating piece coming together:
Glue-up was crazy. I learned that I should do it in small bits, and not go for all of it at once. It was too much, and I didn’t have enough clamps! I bought 4 more good clamps once I went through this fiasco:
Saturday, March 19th, 2011
How about a tour of my garage shop?
Work desk and tools hanging on the wall:
The fan in the window is used to exhaust fumes from welding and other things:
Nuts, bolts and Bengal cat:
JET drill press:
MATCO welder (I bought it used) and oxy-acetylne setup behind it to the left:
Grizzly G0555 wood bandsaw. Works well for the small shop, although a few times I have wanted a wider throat.
Grizzly 8″ jointer; I bought a good large jointer, but I have only used it a few times so far:
The dust collection system lives behind the garage in a little shed I built just for it. Here is a post when I setup dust collection in the shop. The buttons on the wall turn it on and off:
1990 Enco Milling machine. Awesome! I bought it used, but it has been working great since I did some tune ups on the belt.
Milling tooling and accessories:
Powder coating oven given to me by Eric (thanks!). On top of it is my powder coating supplies. The 50 amp outlet for it on it is also used to charge my car. To the top right of it in the gray box is an American Rotary phase converter than generates 3 phase for the mill.
Southbend lathe from the 1950′s
Misc storage and stuff:
The latest addition; Grizzly 36″ slip roll:
Router table to the right of the table saw. Underneath is a jig saw and router:
Grizzly horizontal metal bandsaw with swivel head. One of the most used tools for metalworking, and definitely a must have for doing any kind of metal work. The swivel head is also GREAT.
Grizzly G0444 contractor table saw. A little underpowered, and eventually I will get a full size cabinet saw with a riving knife (for extra safety):
Overall, I have bought a lot of Grizzly tools. They are fairly priced, and I find the quality to be quite good for shop use. I have had no real problems with the Grizzly tools. They are definitely better than the Enco brand tools (although, the mill I have is of decent quality), and light years ahead of Harbor Freight tools (which I won’t buy, unless it is for a one time project).
Monday, April 5th, 2010
Our house in Aptos needed a new fireplace mantel. The prior owner had taken out the mantel and insert, so I needed something that looked nice. There was a huge area that needed to be surrounded by something, and I couldn’t just paint it in, as the paint would be really hard to match. Here’s a “before” picture taken with my iPhone:
After taking some dimensions, I whipped out Sketchup and did some work with various designs that I liked and came up with this:
I constructed the mantel out of two sandwich bread pieces of 3/4 MDF, with some spacers in the middle. I then nailed on a nice looking trim piece on the edge to make it all look nice. The square pillars were also made of out MDF; just simple 3 sided squares with false backs (all butt joints, with a 16d nailer and glue holding it together — it is incredibly strong and sturdy). The pillars are screwed to studs and the floor. The mantel was then screwed to the pillars, the wall (where available) and steel studs on top of the fireplace portion that protrudes out from the wall.
I pre-pained everything before attaching it to the wall. Initially I painted it a light gray/blue color that Louise picked out to match some of specks in the paint.
I didn’t like it, and it looked too dark (she agreed, after seeing it), and decided to start over on painting. This set me back quite a few hours, but I’m glad I did. I went with a more traditional white color, and framed the sides with some more trim pieces. It turned out great!
The fireplace insert is from Santa Cruz Spas and Stoves, and the install of the stove was done by Jon Marden.
Wednesday, December 23rd, 2009
Louise and I need a shoe rack that looks nice. I decided to design something pretty in Sketchup. Here is what I came up with while on vacation:
The vertical side pieces have a slight curve to them, and the bottom pieces have a slight arch. I’m planning on using cherry for the outside, and staining the outer pieces slightly darker than the inside sheet pieces (which will be 1/2″ cherry ply). The shelves will be 3/4″ maple. The overall size will be 52″ tall by 28″ wide by 16″ deep.
Download the Sketchup file (coming soon, email me to get it).
Thursday, December 11th, 2008
Here’s the big pile of maple and poplar that I got for the project:
Building the face frame was super fast and easy to do with pocket jointery:
Thursday, December 11th, 2008
I wanted to start work on my built in dressers for the upstairs, but first I needed an out feed table for the tablesaw. I wanted something that doubled as a work space, and added some additional storage. I also wanted a built-in sanding table, but I decided to do that another day.
So, using some pocket hole joints, old 2x4s and 2x6s ripped clean and glued together, I made a really rock solid outfeed table. The top is two pieces of 3/4″ MDF glued and screwed together, with counter top stuff on the top to protect it and add a smooth surface to slide pieces of wood on.
It went together really fast, and has already been a great help. In particular, it makes sawing long pieces much safer, as they just catch onto the outfeed table instead of dropping down.
In the above picture, you can also see the updated router table that I made.