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Kamis, 10 November 2016

Walnut Chess Board w Drawers

Now that I have some more time to catch up on projects since I retired 7/1, I finished this chess board I promised my daughter to give her husband as a gift for his birthday.

Overall size is 16" x 16" x 3 1/2".

The board is constructed of wenge and maple and is set in the frame with clearance for wood movement. There are 2 support rails for the board and I drilled slots in those and mounted the top with screws like a table top. This should allow for wood movement without damage.

The pieces are held in a drawer on both ends of the board. Walnut dividers keep the pieces organized, green felt drawer liners in each.

I applied 2 coats of General Finishes Arm-R-Seal gloss with a coat of wax.

Senin, 17 Oktober 2016

The Windsor Institute Road Trip

I left Jackson, TN Thursday 7/8 and headed off to Hampton, NH and the Windsor Institute to take the 7/12 Sack Back chair class offered my Mike Dunbar and his team of instructors, Fred and Don. It is an intense, physical class, as there is minimum use of power tools (a drill, circular saw, and instructor operated bandsaw) in the preparation and assembly of this chair. I believe you can find a direct correlation in Tylenol sales in the NE and the dates of the chair classes. I was in with a group of great people from as close as Maine, from Canada, PA, NY, OH, OK, and as far achoice as Seoul, South Korea. We had a young man who just turned 11 years old in our class and he did an outstanding job. His father and instructors guided him along, but he didnt need any more help than the rest of us. I have a ton of photos I took to help me for the next time, but I will summarize the assembly here to give you and idea of what "start to finish" looks like. I can say this, if you every wanted to build one of these classic chairs, learn about the chair itself and the "whys" of the design elements, you will not find anything better than attending the Institute or anyone more knowledgeable than Mike Dunbar. Mike and his crew demystify as they teach so you not only understand what you are doing, but why you are doing it.

The Windsor Institute

Mike will send you a list of tools he recommends you need once your registration is completed. Show up on Monday with your tools, and you will get your bench location and thats is were you work for the remainder of the week.

Getting organized and ready to get going.

Seat blank, spindles, and stretchers

Believe it or not, what you see here will be a completed Sack Back chair by the end of the week. Yeah, I know, I didnt believe it either :)

Smoothing the seat blank. This seat is Eastern white pine. The blanks are glued up and ready to go, but you need to pay attention to the grain as it is very possible it will run in opposite directions. Got to love those shavings!!

Seat blank cut and ready to shape the inside. The cut in the middle is made by a circular saw set for a target depth of the seat in the middle.

"swing for a single-not a bunt" was the saying you heard over and over through out the room as we took the gutter adz to start shaping the seat. I guess a "home run" would eliminate one toe!! Chop, chop, chop.

Compass plane starts the smoothing process, after the scorp, this work will last a good part of the morning.

Ready for layout lines and drilling at this point

Getting busy on the 7 back spindles, rough shaping "green" red oak so it can dry for the final shaping on Thursday.

This steam unit is one of two that prepares the arm and bow for bending. Each student pairs up with a partner to bend these parts,

Arm and Bow in the furnace room where the conditions are set to dry these parts quickly enough that we can use them on Thursday and Friday.

Seat drilled and ready for leg and stretcher assembly

Legs and stretchers installed - nice stool you have there!

Arm stumps and short spindles dry fit, now this is starting to look like a chair.

"Hey...you got 10 minutes to get this done, we need you outside"

Remember what we started this process with? All that remains is to fit the bow over the spindles. Holes are drilled, spindles are cut to length and wedged.

Selasa, 20 September 2016

one way to shorten an antique model t door

so, im getting a lot of whered you get those doors? questions as people check out the new metal shop. like slate on the roofs, wide recycled doors are kind of my thing. the one above started out as half of a pair of 8 x 8 garage doors that i bought about 5 years ago from a guy up the road in pawlet, as he was tearing down an old garage on his property. as i recall, i paid a hundred bucks for the pair. click the photos to enlarge them ...

on the inside view, you can see how we cut and mitered the stiles and panels to shorten them.

the first one of that pair i used was on my garage at the house just after i bought them and i shortened that one to 7 feet too before i made the frame and hung it. in the photo below, i used the mason miter technique on the stile and rail intersections, but on the new metal shop, i decided to keep the cope and stick joints by shortening the stiles themselves and gluing them back together. in reality, either choice is fine.

mason miter joinery at the red arrow

the first pair i bought at a tag sale in the 80s for $20. for the pair. they were already only 7 high and 4 wide. i used one on the front of the shop above, and one on the side door on the shop porch, below.

i think they came from the same manufacturer as the new pair, as all the joinery techniques and moldings appear to be the same ...

the joinery on the doors originally was 4, 1/2" dowels, about 6 inches long at each horizontal
and vertical intersection. invariably, the joints loosen and the dowels can be cut with a hand saw or fein tool and the rails removed.

i rejoined the stiles and the bottom rail with 8" timberlock screws as i couldnt spread the stiles enough to insert loose tenons or dowels ... worked fine, and im sure its at least as strong or stronger than the original dowel joinery.

i added a couple of dominos for alignment ...

and made a jig for gluing them up straight

mitering and regluing the panels and stiles was a cinch

and then we glued up the whole door and made some jambs .. love the antique wavy glass. and, ive also made new doors like this for new construction. i have some photos somewhere ... nothing like a generous entrance to add elegance to a building ...

Jumat, 29 Juli 2016

another one HOTP

my camera seems to have a hard time with these light maple burls, but heres a picture of a new coffee table we finished today. it needs a home, and it has a nice price to boot ... minimalist, industrial style steel base ... unground welds; natural steel finish. +/- 31" x 54" x 17" ... its good to go anytime ... give us a call .... click the photos to enlarge them ...

looks better in person ...

Selasa, 26 April 2016

home stretch on the new metal shop

when last we visited this project back in september, the carpenters had just finished getting the slate on the roof ... after that it was on to the siding and window trim outside, and the insulation, second floor radiant heat,and sheetrock inside. click the photos to enlarge them ..

it was kind of a thrill when the lights went on and siding was mostly finished ...

we still had to have the concrete professionals back to pour the slab for the

steel/blower/compressor shed ..

and we had to build the rather elaborate 20 long rack to store all the small in size, but 20 to 24 long raw materials ... fortunately, the carpenters were called achoice on another job for a day, which gave us time to figure out the rack before the roof went on .. mucho easier that choice ..

the shed is fitted here with a bronze color standing seam roof by donnie dorrs metal shop ..

and inside, we did some coloring, and reconfigured the chop saw tables into a mockup work table so we could figure out where to hang up the welding fume extractor. we ran the pipes to the blower thursday ..

boilers these days are amazing ... this little guy puts out 80,000 btus, enough to heat both floors, (+/- 1500 square feet in a vemont winter), and provide domestic hot water for the sink and bathroom. exhaust out in pvc pipe. no chimney ...

ahhh, the doors .. nobody made a cheap standard unit three doors wide, so we had to cobble these together with parts from a company whose name escapes me now .. we made up some quicky transoms from 8/4 pine and ordered up some custom thermopane to fill them.

there were a couple reasons for that configuration .. #1, you can open the doors totally in the summer like below, and should we move on at some point, the openings are framed to accept regular 9 x 7 commercial overhead doors .. presto, a heated, two car garage with a mother in law apartment above ... the plumbing and radiant for the second floor was roughed in before the sheetrock went up ..

a few notes below on the quicky transoms ...

9 3" x 16" plus the frames

essentially, the frames are butt jointed, timberlock construction, with applied moldings to accept the glass .. framed in the shop and screwed in over the door units .. cheap, easy, and fast ... you dont get that combo often enough ...

all for now ... sam is moving in this week

the steels there waiting for him

The happy graduating class of the 7/12/10 Sack Back class.

Everyone got there chairs completed and ready to head for home or where ever else they had scheduled for their trip. This was without a doubt one of the most memorable weeks I have ever spent in woodworking and I am looking forward to going back in the Spring to take the Writing Arm chair class.

I loaded up the chair and headed off to Cooperstown, NY to visit the Baseball Hall of Fame and Museum. When I get back to my shop in TN, I will finish cleaning the chair up and get ready to apply the Milk Paint finish. On the last leg of the "Windsor Chair Road trip" spending a week in Cincinnati, so it will be a week or so before I get to doing that. I will post some pictures of the finished chair

woodworking tools tips

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Kamis, 10 November 2016

Walnut Chess Board w Drawers

Senin, 17 Oktober 2016

The Windsor Institute Road Trip

Selasa, 20 September 2016

one way to shorten an antique model t door

Jumat, 29 Juli 2016

another one HOTP

Selasa, 26 April 2016

home stretch on the new metal shop

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