Showing posts with label project. Show all posts

Thursday, February 13, 2014

Bookcases Project The Shelves

Cant sleep, so Ill do another bookcases post.

I had to design the cases to fit an existing space between an outside wall with a door close to the wall the cases were going on, and a fireplace. There was also a doorway in the wall that was not centered. As a result, the two sides are different widths. The right side is about 51" wide and the left 42". That made the shelves on the right about 48" wide and that is a bit long for a simple shelf that will hold books. After considering various shelf designs, I settled on a torsion box design that would be light weight, but not too thick, and would be more than stiff enough to prevent sag.


Drawing of shelf with top skin removed.

I had two cauls (from Woodpecker) long enough clamp the edges of the shelves, but needed four more to be able to clamp the top and bottom surfaces. Couldnt buy more since they were "One Time" tools, so I just made some out of 2x4s. I wound up using two of the cauls along with a piece of 2x6 to make a jig that the shelves would be built and clamped upon. This came about from building the prototype and finding clamping the whole thing to be an exercise in frustration. The jig made assembly and clamping much easier.

The jig, cauls and some of the clamps ready to start making a shelf.

I first laid out the ribs and ends on the jig so they could be tacked together with my pin gun.

Ribs and ends laid out.

Tacking with the pin gun.

I then waxed the skin to prevent glue from messing it up for staining. Wont do that again with oak ply, as it is not easy to get it all out of the pores when you clean it with alcohol. The wood stained okay, but the problem showed up when finishing with the oil-modified-water based poly I use. I even sealed first with a de-waxed shellac, but still had a lot of orange peel that had to be scraped and refinished several times. If I ever do it again, Ill use packing tape to keep glue off, like I did on the wooden cauls.

The skin was placed on the jig with the waxed side down, glue was applied to the parts and they were laid out on the skin. Then the glue was applied for the other skin, and the skin slid in place under the clamp that was used temporarily to hold the edges together.

With that, the cauls and clamps were added and left on over night.

Next the shelf was cut to size, as I made them longer and wider than required. I then used a scraper to clean up any saw marks on the edges. A couple of stops to act as supports and two clamps in the SME on the edge of my bench made holding the shelf easy.

All that was left was trimming the edges down to the skin surface, sanding, staining, and finishing.

The final post gives a little background of the project and explains some of the decisions made.

Monday, February 10, 2014

Petersburg MI project The cherry bookcase

Im starting a new project! This is going to be a custom built in bookcase and fireplace surround, all out of cherry!
Im just starting so youll be able to follow this all the way through. The first picture is my drawing of the general layout of the project. The total size is going to be 20 wide, and floor to ceiling. Ill be framing in a new wall over the existing, because of some rough conditions on the existing. There is some stonework that needs to come out around the fireplace also.
If you look at the layout, youll find a larger opening at the bookcase area - this is to accomodate a flat screen tv mounted on a swing arm.

Ive bought a large amount of solid cherry from a local mill about a month or so ago, and its been acclimating in the shop. Today, Ive managed to get it run through the table saw and square up the edges. The rest of the week Ill be running them through the planer and joiner. The plan is to stain and finish as much as I can before I need to install anything. This will keep the amount of commotion in the customers house to a minimum.

Wednesday, February 5, 2014

Northville MI project finishing the kitchen

Part of the Northville project is to install new cabinet panels on the ends of all of the cabinets, uppers and lowers. Im also installing new base, that was painted and glazed to match the cabinet doors. Kudos to the homeowner for doing highlighting and painting touch ups throughout the project!

Ive started from the ground up by installing the new base. Then, Ive painted and glazed some filler strips to go behind the door panels. This will provide a stable base for the doors, and also give a nice finished look all the way around. This is one area you dont want to cut corners!

Here are some before and after pics of the island and surrounding areas. All endpanels are new additions as well as the base covering the old toekick areas...

Sunday, February 2, 2014

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Thursday, January 30, 2014

Today Simple woodshop project plans

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