The undercabinet drawer project is moving right along. I got all of the stock cut to size. For the first time I did all of my measuring with my Woodpecker Precision Ruler and my marking knife. All of the cuts were made on my Dewalt SCMS. It was amazing that by utilizing this process my cuts were all on the "right" side of the line. If you don't own a precision rule and marking knife, I strongly recommend that you get one and start using it on layouts.
After all the stock was cut to length, I milled the box joints on the table saw and then cut the dados for the drawer bottoms. This was as far I got on the project Saturday.
Tomorrow, I will start cutting the bottoms and then assembly can begin after sanding of all pieces.
Another project that I've been working is getting my new EZ Smart System cutting guide setup. I installed the dust collector port on my Makita 5007MGA circular saw. It sure makes a big difference using the circular saw with dust collector in place.
Quote of the moment:
I have long been of the opinion that if work were such a splendid thing the rich would have kept more of it for themselves.
- Bruce Grocott
Sunday, September 14, 2008
Friday, September 5, 2008
Dispatch #28 Undercabinet Pullout Drawers - Update
Note: Pictures for this entry select :Photo Galleries>Flash Photo Gallery>Pullout Drawer Project
This week on my days off I started building the prototype drawer for the project. My first prototype (P1) was constructed using half lap joints. I didn't do a full glue up on P1, instead I used blue painters tape to put it together to see how it looks. I wasn't real happy with the results of P1 so I decided to build another using the box finger joint method.
Before I started P2, I decided to go ahead and mill all of the boards to final thickness of 1/2". It sure made a lot of new mulch for the concrete planters on the front of the garage.
In cutting the pieces of P2 to length I used my Woodpecker precision straight edge and a marking knife I picked up at Woodcraft. This method sure my cuts accurate.
I then numbered all of my corners using blue painters tape and a sharpie. This was to keep the orientation correct. I cut the finger joints on the table saw using my sled jig.
The bottom of the drawer was cut from 1/2" birch plywood. To cut the piece I used my new EZ Smart System rail and my Makita 5007MGA circular saw. This was my first opportunity to use the EZ system and I was well satisfied with it. All of my cuts were dead on accurate with the EZ rail. This eliminated having to use the table saw to cut pieces to final dimensions and saves stock.
I glued up P2 and after we had supper I installed the drawer slides on the box and then the rails inside the cabinet. The prototype was a great success so I will began production of the remaining drawer assemblies on my next day off.
Your comments are always welcome and don't forget to check out the pictures.
This week on my days off I started building the prototype drawer for the project. My first prototype (P1) was constructed using half lap joints. I didn't do a full glue up on P1, instead I used blue painters tape to put it together to see how it looks. I wasn't real happy with the results of P1 so I decided to build another using the box finger joint method.
Before I started P2, I decided to go ahead and mill all of the boards to final thickness of 1/2". It sure made a lot of new mulch for the concrete planters on the front of the garage.
In cutting the pieces of P2 to length I used my Woodpecker precision straight edge and a marking knife I picked up at Woodcraft. This method sure my cuts accurate.
I then numbered all of my corners using blue painters tape and a sharpie. This was to keep the orientation correct. I cut the finger joints on the table saw using my sled jig.
The bottom of the drawer was cut from 1/2" birch plywood. To cut the piece I used my new EZ Smart System rail and my Makita 5007MGA circular saw. This was my first opportunity to use the EZ system and I was well satisfied with it. All of my cuts were dead on accurate with the EZ rail. This eliminated having to use the table saw to cut pieces to final dimensions and saves stock.
I glued up P2 and after we had supper I installed the drawer slides on the box and then the rails inside the cabinet. The prototype was a great success so I will began production of the remaining drawer assemblies on my next day off.
Your comments are always welcome and don't forget to check out the pictures.
Sunday, August 31, 2008
Dispatch #27 Starting a New Project
This past week I began the kitchen cabinet pull out shelf project. These shelves will be installed in all but one of the lower kitchen cabinets. The only reason the one won't get the pull outs is that the door does not open fully due to the new dishwasher being a bit bigger than the old dishwasher. I will be installing a total of 12 pull outs.
The first problem I've encountered is that the cabinets were site built. The entire unit was built as one piece. This means there are no side wall to attach the drawer slides too except on one end of the cabinet.
The solution to this problem was to construct a mounting strip for the drawer slides to mount to. I measured the side next to the end wall and it needed 1-1/4" to bring it flush with the edge of the face frame. On the opposite side, the middle face frame was 2" wide. For the 1-1/4" thick piece I used a piece of 3/4 x 4" pine and added 3 pieces of 1/2" mdf as spaces. On the 2" thick piece I laminated two 3/4" x 4" with 3 ea 1/2" mdf blocks in between them. This gave me the 2" I need.
To fasten them to the cabinet shelves used my Kreg Pocket hole jig to drill 6 pocket holes on each face of the 2" thick pcs and 6 holes on the accessible side of the 1-1/4" piece. We will be staining the piece prior to installation so I can add a few dabs of glue to the bottom of the mounting strips when I install them. Between the glue and the pocket hole screws they should be secure.
Tomorrow is Labor Day and I plan taking the before pictures and the pictures of the mounting strips. They will be posted to the gallery tomorrow evening.
The first problem I've encountered is that the cabinets were site built. The entire unit was built as one piece. This means there are no side wall to attach the drawer slides too except on one end of the cabinet.
The solution to this problem was to construct a mounting strip for the drawer slides to mount to. I measured the side next to the end wall and it needed 1-1/4" to bring it flush with the edge of the face frame. On the opposite side, the middle face frame was 2" wide. For the 1-1/4" thick piece I used a piece of 3/4 x 4" pine and added 3 pieces of 1/2" mdf as spaces. On the 2" thick piece I laminated two 3/4" x 4" with 3 ea 1/2" mdf blocks in between them. This gave me the 2" I need.
To fasten them to the cabinet shelves used my Kreg Pocket hole jig to drill 6 pocket holes on each face of the 2" thick pcs and 6 holes on the accessible side of the 1-1/4" piece. We will be staining the piece prior to installation so I can add a few dabs of glue to the bottom of the mounting strips when I install them. Between the glue and the pocket hole screws they should be secure.
Tomorrow is Labor Day and I plan taking the before pictures and the pictures of the mounting strips. They will be posted to the gallery tomorrow evening.
Monday, August 18, 2008
Dispatch #26 Shop Update
Not a whole lot going on this past week. I continued the shop cleanup project. Did manage to get the air hose retractable reel mounted to the ceiling. I've had the reel since fall of 2007, but just never gotten round2it to install. It sure makes managing the air hose a whole lot easier.
Had a good "find" on ebay recently, picked up a Stanley 60-1/2 low angle block plane at a real nice price. Have to sharpen the blade a bit more, but it is gonna be a handy item. I'll get pictures of it posted soon in the Hand tool section.
On another note, I ordered the slides for the kitchen cabinet slideout draawer project. They are due in today via UPS. I got them from Grizzly.com for $9.95 ea which is about half of what the local HD BORG wanted for them. They are the same type that I used on the assembly table project and are a good value for the buck.
I'll be leaving Thursday morning heading for Atlanta to attend the The International Woodworking Machinery and Furniture Supply Fair at the Georgia Congress Trade Center. It is one of the largest woodworking events in the country.
Norm Abrams will be there signing autographs and I plan to take my first New Yankee Workshop book for him to autograph.
That's all for now, heading to Southaven, MS for my son's wedding today. More on that later.
Had a good "find" on ebay recently, picked up a Stanley 60-1/2 low angle block plane at a real nice price. Have to sharpen the blade a bit more, but it is gonna be a handy item. I'll get pictures of it posted soon in the Hand tool section.
On another note, I ordered the slides for the kitchen cabinet slideout draawer project. They are due in today via UPS. I got them from Grizzly.com for $9.95 ea which is about half of what the local HD BORG wanted for them. They are the same type that I used on the assembly table project and are a good value for the buck.
I'll be leaving Thursday morning heading for Atlanta to attend the The International Woodworking Machinery and Furniture Supply Fair at the Georgia Congress Trade Center. It is one of the largest woodworking events in the country.
Norm Abrams will be there signing autographs and I plan to take my first New Yankee Workshop book for him to autograph.
That's all for now, heading to Southaven, MS for my son's wedding today. More on that later.
Tuesday, August 12, 2008
Dispatch #25 Trip to the Hardwood Center
Today we made a trek over to Scottsboro to the Hardwood Center. All I can say is WOW!! They had species of wood I've never even heard of before. There were some Africa Mahogany that was a good 22" wide and had the most beautiful texture and delightful to the touch.
Our mission today was to find some 1/2" thick stock for construction of the pull out shelves in the lower kitchen cabinets. After walking through the Hardwood Center's warehouse and oohing & hahing over all of the wood, we settled on some basswood. It is appox 9/16" thick by 4" wide. It came in random lengths and we managed to find about 100 LF that will be usable. They had a great price I thought on the basswood at .83 per LF. In fact all of their hardwood prices seemed very reasonable.
We also checked out their hardwood plywood and saw some great domestically produced hardwood ply. Will sure keep that and all of the wood in mind for future projects. I would highly recommend anyone within driving distance of Scottsboro, AL to make a trip over there if you need quality hardwoods for any project. They also produce hardwood flooring, molding (both stock & custom order). If you are restoring an antique home they can even take a sample of you existing molding and make a cutter knife to produce new molding to match. Visit their website at Hardwood Center
We got rain most of the day here in Florence, I was suppose to go over and watch UNA's football team practice this afternoon, but due to the rain we postponed till tomorrow evening. That works out even better since they will be scrimmaging then. So I made good use of my time and done a little cleanup in the shop. I removed all the items from one section of my pegboard in preparation of removing it. I plan on replacing it with five 16" x 32" cabinets that I already have on hand. These were originally storage shelves for thick computer printouts at Sequoyah Nuclear Plant. I purchased them several years ago for $5.00 at a TVA sealed bid sale. They are made of Walnut Veneered dimensional lumber with a plywood back on them. I'm going to cut doors to fit and then install the doors with euro hinges. I'm debating on whether to paint the cabinets white or leave them walnut and then stain the doors to match.
I plan on hanging the cabinets on the wall using a french cleat at the top and a strip at the bottom edge. A drywall screw will be driven in to the bottom strip to prevent the cabinet from accidentally being knocked loose. Pictures of this project will be posted shortly in the photo gallery.
As always your comments are welcome.
Our mission today was to find some 1/2" thick stock for construction of the pull out shelves in the lower kitchen cabinets. After walking through the Hardwood Center's warehouse and oohing & hahing over all of the wood, we settled on some basswood. It is appox 9/16" thick by 4" wide. It came in random lengths and we managed to find about 100 LF that will be usable. They had a great price I thought on the basswood at .83 per LF. In fact all of their hardwood prices seemed very reasonable.
We also checked out their hardwood plywood and saw some great domestically produced hardwood ply. Will sure keep that and all of the wood in mind for future projects. I would highly recommend anyone within driving distance of Scottsboro, AL to make a trip over there if you need quality hardwoods for any project. They also produce hardwood flooring, molding (both stock & custom order). If you are restoring an antique home they can even take a sample of you existing molding and make a cutter knife to produce new molding to match. Visit their website at Hardwood Center
We got rain most of the day here in Florence, I was suppose to go over and watch UNA's football team practice this afternoon, but due to the rain we postponed till tomorrow evening. That works out even better since they will be scrimmaging then. So I made good use of my time and done a little cleanup in the shop. I removed all the items from one section of my pegboard in preparation of removing it. I plan on replacing it with five 16" x 32" cabinets that I already have on hand. These were originally storage shelves for thick computer printouts at Sequoyah Nuclear Plant. I purchased them several years ago for $5.00 at a TVA sealed bid sale. They are made of Walnut Veneered dimensional lumber with a plywood back on them. I'm going to cut doors to fit and then install the doors with euro hinges. I'm debating on whether to paint the cabinets white or leave them walnut and then stain the doors to match.
I plan on hanging the cabinets on the wall using a french cleat at the top and a strip at the bottom edge. A drywall screw will be driven in to the bottom strip to prevent the cabinet from accidentally being knocked loose. Pictures of this project will be posted shortly in the photo gallery.
As always your comments are welcome.
Sunday, August 10, 2008
Dispatch #24 Happenings this week
Not much going on this week after the completion of the assembly table. I worked on cleaning up the shop and putting stuff away. On Friday and Saturday I constructed a couple of clamp racks to hang my Cabinet clamps and F style clamps from. Based them on plans from one of my woodworking books. It rack will hold 12 clamps, I mounted them right inside the garage door in what has been wasted wall space. The longer clamps went on the top rack and the shorter ones on the bottom rack. I still need more clamp storage though. When I redo the pegboard wall I plan to install a couple of more clamp racks on that wall in the corner next to where I installed the first two.
I begin taking measurements for my next project which is the pull out drawers for the kitchen cabinets. I will be installing 13 drawers total. I plan on ordering the 100lb full extension slides from Grizzly. Those are the ones I used on the assembly table and they worked very well.
We are going Tuesday over to the Hardwood Center in Scottsboro, AL and select the wood to construct the drawers from. Still don't know if we're going to use dimensional lumber or plywood. More on that later.
That's it for now.
I begin taking measurements for my next project which is the pull out drawers for the kitchen cabinets. I will be installing 13 drawers total. I plan on ordering the 100lb full extension slides from Grizzly. Those are the ones I used on the assembly table and they worked very well.
We are going Tuesday over to the Hardwood Center in Scottsboro, AL and select the wood to construct the drawers from. Still don't know if we're going to use dimensional lumber or plywood. More on that later.
That's it for now.
Sunday, August 3, 2008
Dispatch #23 Assembly Table - Update
Work continued on the table since my last post. I got all of the finger joints cut and the drawers assembled. I had one snafu when I got one of the deep drawer sides reversed and cut the dado for the drawer bottom on the wrong side. I had to re-make that one. The installation of the drawers slides was not near as difficult as I expected. Using the tips I gleaned from The Wood Whisperer's podcast they went in fairly easy. I did find out why he installed his drawer slides prior to putting the top on. It would have been a whole lot easier to have installed them with access from the top. Especially the top drawer slide, it was tight getting it in to say the least. I wouldn't have installed the top at the point that I did except there wasn't enough room to work with the top on the sawhorses and trying to assembly the cabinet at the same time.
I also cut the two cabinet doors and installed them with the Euro hinges. I previously had purchased a double template jig from Rockler with drill guides. This jig worked really well once I dialed it in on some scrap plywood. I cut the adjustable shelves and installed them. The drawer handles and knobs that I had selected were also installed.
Tonight I started on the final assembly work prior to staining. I cut the walnut plugs from a piece of rough sawed walnut that is about 20 years old. It has been in my basement for the last 10 years. I cut two of the four oak boards for trimming the edges of the top. Tomorrow's project will be to cut the other two boards to length and then rip all four to final width. The countersinks for the plugs and pilot holes for the screws will also be drilled on the drill press.
Recently using a piece of the scrap plywood used on the cabinet I tested all of the stains I had to see how they looked on the Birch plywood. I also tested the recipe mix that was in Fine Woodworking using the Pratt & Lambert gloss poly. The P&L mix was nice but with Tongue Oil it was just too red on the birch. I finally decided on the Minwax Honey Maple. It is a light colored stain with just a hint of maple color and it's the look I was going for.
Pictures will be posted in the Photo Gallery on my website Dave's Saw Dust Pile very soon.
As always, your questins or comments are welcome.
I also cut the two cabinet doors and installed them with the Euro hinges. I previously had purchased a double template jig from Rockler with drill guides. This jig worked really well once I dialed it in on some scrap plywood. I cut the adjustable shelves and installed them. The drawer handles and knobs that I had selected were also installed.
Tonight I started on the final assembly work prior to staining. I cut the walnut plugs from a piece of rough sawed walnut that is about 20 years old. It has been in my basement for the last 10 years. I cut two of the four oak boards for trimming the edges of the top. Tomorrow's project will be to cut the other two boards to length and then rip all four to final width. The countersinks for the plugs and pilot holes for the screws will also be drilled on the drill press.
Recently using a piece of the scrap plywood used on the cabinet I tested all of the stains I had to see how they looked on the Birch plywood. I also tested the recipe mix that was in Fine Woodworking using the Pratt & Lambert gloss poly. The P&L mix was nice but with Tongue Oil it was just too red on the birch. I finally decided on the Minwax Honey Maple. It is a light colored stain with just a hint of maple color and it's the look I was going for.
Pictures will be posted in the Photo Gallery on my website Dave's Saw Dust Pile very soon.
As always, your questins or comments are welcome.
Saturday, July 26, 2008
Dispatch #22 Assembly Table - Update
Haven't gotten to work on the project very much in the last week or so. On my two days off this past week I did get to work one of the days in the shop up until about 5 PM. The second off day was spent having a colonoscopy at the hospital and recuperating from the procedure.
I got all of the drawer components milled and the finger joints cut. I glued up three of the drawers for one side. After the glue had dried overnight, I installed the drawer slides and put in the drawers. They all worked out very nice.
Having to work most of the day today and till 7 tomorrow, so won't get much done until my next off day which is Monday.
For updated pictures, check out my photos on the website Dave's Sawdust Pile
I got all of the drawer components milled and the finger joints cut. I glued up three of the drawers for one side. After the glue had dried overnight, I installed the drawer slides and put in the drawers. They all worked out very nice.
Having to work most of the day today and till 7 tomorrow, so won't get much done until my next off day which is Monday.
For updated pictures, check out my photos on the website Dave's Sawdust Pile
Dispatch #21 My New Website
Hey folks, have setup my new website. I will still be posting to this blog, but in the future all of my pictures will be posted on the website under "Photo Gallery"
Wednesday, July 16, 2008
Dispatch #20 Assembly Table - Update
I continue to work on the table yesterday and again today. Yesterday I finished gluing the main partitions and the stiffener partitions. I also installed the four stretchers across the top.
Today I install the casters. These are the ones I purchased from Woodcrafter. I was duly impressed by these casters when I turned the table right side up. These are the best rolling casters I've ever used. And, the locking mechanism on them are exceptional. Even with top installed the table was easy to roll and when locked I could not get it to move. All I can say is WOW!!, I'll use this type again.
I got the top installed today also. I used 4 Spax screws on each side to attach the top to the stretchers. I think this will hold the table top in place without a problem.
I received my Freud Box Joint Dado blades today so I'll be able to start on the drawer boxes tomorrow.
Here are the progress pictures for today:
Today I install the casters. These are the ones I purchased from Woodcrafter. I was duly impressed by these casters when I turned the table right side up. These are the best rolling casters I've ever used. And, the locking mechanism on them are exceptional. Even with top installed the table was easy to roll and when locked I could not get it to move. All I can say is WOW!!, I'll use this type again.
I got the top installed today also. I used 4 Spax screws on each side to attach the top to the stretchers. I think this will hold the table top in place without a problem.
I received my Freud Box Joint Dado blades today so I'll be able to start on the drawer boxes tomorrow.
Here are the progress pictures for today:
Monday, July 14, 2008
Dispatch #19 Assembly Table - Update
Started last evening cutting out the panels for the cabinet that the torsion box assembly table top will be on. I got the 2 end panels and the middle panel cut out. Today, I cut out the bottom and then routed the dado for each side joint and the middle partition joint. Since I'm putting mine on casters, I'm adding stiffeners from the side panels to the middle partition. I routed the dado in the bottom with my router and then used the dado blade on the table side to do the sides and middle pcs. I couldn't use the table saw on the bottom due to it being bowed. Hopefully, I will be able to pull the bow out when I glue up.
I decided to have an adjustable shelf in the cabinet side so I got all of those holes drilled. I then cut the top stretchers. The original plans called for 3 but I decided to go with 4 to help prevent racking of the unit when it's moved. Tomorrow I'll continue the build and hopefully get the carcass glued up. Clickable thumbnails below.
I decided to have an adjustable shelf in the cabinet side so I got all of those holes drilled. I then cut the top stretchers. The original plans called for 3 but I decided to go with 4 to help prevent racking of the unit when it's moved. Tomorrow I'll continue the build and hopefully get the carcass glued up. Clickable thumbnails below.
Wednesday, July 9, 2008
Dispatch #18 New project - Torsion Box Assembly Table
Started on 7/8/08 building a dead flat torsion box assembly table. This will be my primary work surface for building all future woodworking projects. It gives me a reference point to begin with that I know is "dead flat".
The top is constructed out of 1/2" MDF top and bottom skins with the interior honeycomb also being 1/2" MDF. The outside perimeter pieces are 3/4" MDF. This makes for an extremely strong yet light weight (to a certain extent)top. It is 4" thick x 48" x 48". This is the same design used to build aircraft wings.
I will be starting on the base in a few days. Have to work some crazy shifts the next couple of days. Have to work from 10 to 7. Messes up the day on both ends.
The top is constructed out of 1/2" MDF top and bottom skins with the interior honeycomb also being 1/2" MDF. The outside perimeter pieces are 3/4" MDF. This makes for an extremely strong yet light weight (to a certain extent)top. It is 4" thick x 48" x 48". This is the same design used to build aircraft wings.
I will be starting on the base in a few days. Have to work some crazy shifts the next couple of days. Have to work from 10 to 7. Messes up the day on both ends.
Tuesday, July 8, 2008
Dispatch #17 VICTORY DECLARED
As of today we have declared VICTORY on our den remodel project. I completed the punch list today. Debra is putting the finish coat on the wooden battens for the sunroom doors so they will be ready to install in a couple of day. I compiled a short video of the before and after of the remodel project.
Please leave a comment if you like.
Please leave a comment if you like.
Sunday, July 6, 2008
Disptach #16 Cross Cut Sled - Completed
The cross cut sled is not officially completed. I constructed a prototype box joint jig face for it and made my first box joint using some scrap 1/4" plywood. I made the cuts using an old adjustable width Craftsman Dado blade which is very lame on accuracy. I was able to cut a fairly tight joint using it though by dialing in with the Kreg Micro Adjuster. I have placed a order for a Freud Box Joint Dado blade that will cut perfect 1/4" & 3/8" flat bottom slots. When I receive it I will make the finally faces for constructing box joints. The beauty of this jig is that faces with different sizes of box joints (Height & width) can be made and switched out easily by removing two screws.
This entry is a test of using a YouTube created video in my blog. Excuse the rough edges.
Watch a short video of pictures from the build of the sled.
More Photos here: Cross Cut Sled
This entry is a test of using a YouTube created video in my blog. Excuse the rough edges.
Watch a short video of pictures from the build of the sled.
More Photos here: Cross Cut Sled
Monday, June 30, 2008
Dispatch #15 Making Sawdust
Started construction of the cross cut sled for my tablesaw last week. I'm generally following the plans as shown in the current issue of Shop Notes. I'm using 1/2" & 3/4" MDF instead of the plywood that the author of the article used. From all I've read MDF is very stable and won't warp like plywood does.
I picked up an Incra miter track from the Rockler store for the slide. It has a good fit in the track and when installed following their directions it is adjustable from the top of the sled thus insuring a method to keep the sled in square with the blade.
So far I've cut the base out and installed the rear fence which is the most critical aspect. I have taken some pictures but have off loaded them from the camera yet.
Today I will work on installing the front fence and other components before I have to go to work at 4:00 pm
I picked up an Incra miter track from the Rockler store for the slide. It has a good fit in the track and when installed following their directions it is adjustable from the top of the sled thus insuring a method to keep the sled in square with the blade.
So far I've cut the base out and installed the rear fence which is the most critical aspect. I have taken some pictures but have off loaded them from the camera yet.
Today I will work on installing the front fence and other components before I have to go to work at 4:00 pm
Wednesday, June 25, 2008
Dispatch #14 Den Remodel Project - Update
Haven't gotten to work much lately on the project. Tasks accomplished since last post have been continued installation of the trim such as floor to tile transition pieces for the foyer and hall way doors. Also got the last piece of the Hardibacker board installed around the fireplace and grouted in the joints with the thinset mortar. Ready to start installing the marble tile later this evening.
I have been working on tuning my tablesaw even more. I worked on getting the blade aligned this past Monday evening and have now gotten it so that there is only .002 difference between the front and back alignment. As we used to say at TVA "That's close enough for government work". It amazing though how much better it cuts getting it dialed in.
We attended the BF Avery Antique Tractor Show (B.F. Avery) this past weekend in Edinbough, IN. While we were there we went on into Indianapolis and visited the Rockler Woodworking Store. I spent about an hour going through and touching and admiring everything. They managed to get a a nice chunk of change from me for a few things I just couldn't live with out.
I picked up a couple of items that I'll need to build my cross cut sled for the table saw. I'm ready to start on that very soon. After I get it completed, then I will start on my assembly table. It sure is going to be nice to have a dead flat table to work off of. My biggest challenge will be to keep the clutter off of it like what inhabits my two workbenches. Gotta work on getting them cleaned of also. More latter.
I have been working on tuning my tablesaw even more. I worked on getting the blade aligned this past Monday evening and have now gotten it so that there is only .002 difference between the front and back alignment. As we used to say at TVA "That's close enough for government work". It amazing though how much better it cuts getting it dialed in.
We attended the BF Avery Antique Tractor Show (B.F. Avery) this past weekend in Edinbough, IN. While we were there we went on into Indianapolis and visited the Rockler Woodworking Store. I spent about an hour going through and touching and admiring everything. They managed to get a a nice chunk of change from me for a few things I just couldn't live with out.
I picked up a couple of items that I'll need to build my cross cut sled for the table saw. I'm ready to start on that very soon. After I get it completed, then I will start on my assembly table. It sure is going to be nice to have a dead flat table to work off of. My biggest challenge will be to keep the clutter off of it like what inhabits my two workbenches. Gotta work on getting them cleaned of also. More latter.
Friday, June 13, 2008
Dispatch #13 Den Remodel Project - Update
Things have really progressed the last few days. We have moved all of the furniture back into the den and Debra has been busy cleaning and putting her decorations back in place. My son and his girlfriend came over from Southaven, MS this week and while he was here we moved the mantle back into place. I got that installed and glued the last pieces of the Hardibacker board on the edges of the brick. After we get back from the Avery Tractor Show on the 23rd I finishing installing the tile surround for the fireplace. Then all will be left is to caulk it in good and touch up the paint.
Still have a few items on my punch list such as reinstall the doorbell. Have a temporary one in place now so it's not critical.
I did manage to spend nearly a whole day cleaning on my workshop. Damn what a mess, sawdust was everywhere. There was crap piled on every flat surface and was one hell of a mess. I made a major dent in it but still need to spend lots more time straighten up. Things will be better when I can get time now to build some shop cabinets and my assembly table. The assembly table will have a drawers and a coupe of storage sections that will help tremendously. Here is what the assembly table will look like. Assembly Table
While I was cleaning I collected a few items to sell on Craigslist. I listed my old Sears Router and Table, the 14.4 volt Ryobi set, and the molding head cutter for the Radial Arm Saw I no longer have. Sold the Router and table today, so I'm off to a good start. Still have a few more items to list.
Hopefully tomorrow I'll get some more pictures taken and uploaded.
Still have a few items on my punch list such as reinstall the doorbell. Have a temporary one in place now so it's not critical.
I did manage to spend nearly a whole day cleaning on my workshop. Damn what a mess, sawdust was everywhere. There was crap piled on every flat surface and was one hell of a mess. I made a major dent in it but still need to spend lots more time straighten up. Things will be better when I can get time now to build some shop cabinets and my assembly table. The assembly table will have a drawers and a coupe of storage sections that will help tremendously. Here is what the assembly table will look like. Assembly Table
While I was cleaning I collected a few items to sell on Craigslist. I listed my old Sears Router and Table, the 14.4 volt Ryobi set, and the molding head cutter for the Radial Arm Saw I no longer have. Sold the Router and table today, so I'm off to a good start. Still have a few more items to list.
Hopefully tomorrow I'll get some more pictures taken and uploaded.
Monday, June 9, 2008
Dispatch #12 Den Remodel Project - Update
Since the last update things have progressed nicely. The laminate flooring
[URL=http://i14.photobucket.com/albums/a333/130Pitboss/sawdust%20pile/100_3076.jpg][IMG]http://i14.photobucket.com/albums/a333/130Pitboss/sawdust%20pile/th_100_3076.jpg[/IMG][/URL]
has been installed, all baseboards, door & window casing has been installed. All the trim has been caulked and touched up with paint. I installed the wooden transition strips between the den and kitchen flooring.
[URL=http://i14.photobucket.com/albums/a333/130Pitboss/sawdust%20pile/100_3076.jpg][IMG]http://i14.photobucket.com/albums/a333/130Pitboss/sawdust%20pile/th_100_3076.jpg[/IMG][/URL]
has been installed, all baseboards, door & window casing has been installed. All the trim has been caulked and touched up with paint. I installed the wooden transition strips between the den and kitchen flooring.
Saturday, May 31, 2008
Dispatch #11 Den Remodel Project - Update
Work continued this week on the den. Haven't had much time to work on things due to my work schedule. I was able to trim out the doorway from the foyer and the doorway into the hallway. Debra has gotten nearly all of the door frames and the french doors primed with the Kilz. Today I'll be installing trim on the right set of french doors and have to plane the edge on the french door going to the sun room. Won't be able to do a whole lot since I have to be at work at 1:00 pm. My next off day is Tuesday, so hopefully I'll be able to attack at full speed.
Tuesday, May 27, 2008
Dispatch #10 Den Remodel Project - Update
Monday, May 26, 2008 was a milestone in the den remodel project. I completed the installation of the hardwood flooring. Now the trim work begins.
I had to mill several 1/4 x 3/4 strips to flush out the door frames. Since the original walls were of 1/4" paneling, all of the door casings had been installed to flush to it. After I installed the 1/2" Sheetrock this would have left a 1/4" gap between the door casing and the door molding. So, to the table saw I went.
I picked up a piece of 3/4" S4S clear pine at the HD last week just for this purpose. I ran both edges across the jointer several times to true up the edges. I then started ripping 5/16" strips off the edges. Then these 5/16" strips were run through the thickness planner and milled down to identical 1/4" thick strips. They were cut to proper length and using glue & brads installed on the door casing. As soon as Debra gets the door moldings painted I will be installing that. She has the baseboards painted and ready to install, but I have to wait till the door molding is installed.
In the mean time, I will clean my shop area up and get ready for the next steps.
On another note, Friday, May 30, 2008 is our 17th wedding anniversary. Seems only yesterday that we were installing a new deck on the house in Chattanooga and took part of a day to go get married. Tried to get Debra to make our celebratory trip to Loews today, but she didn't want to get out in the rain. We're going out tonight to celebrate since I have to work closing shift on Friday evening. We have reservations at the Marriott 360 Grille. This should be an event to remember since we've not been to the tower since the Marriott took it over.
More later.
I had to mill several 1/4 x 3/4 strips to flush out the door frames. Since the original walls were of 1/4" paneling, all of the door casings had been installed to flush to it. After I installed the 1/2" Sheetrock this would have left a 1/4" gap between the door casing and the door molding. So, to the table saw I went.
I picked up a piece of 3/4" S4S clear pine at the HD last week just for this purpose. I ran both edges across the jointer several times to true up the edges. I then started ripping 5/16" strips off the edges. Then these 5/16" strips were run through the thickness planner and milled down to identical 1/4" thick strips. They were cut to proper length and using glue & brads installed on the door casing. As soon as Debra gets the door moldings painted I will be installing that. She has the baseboards painted and ready to install, but I have to wait till the door molding is installed.
In the mean time, I will clean my shop area up and get ready for the next steps.
On another note, Friday, May 30, 2008 is our 17th wedding anniversary. Seems only yesterday that we were installing a new deck on the house in Chattanooga and took part of a day to go get married. Tried to get Debra to make our celebratory trip to Loews today, but she didn't want to get out in the rain. We're going out tonight to celebrate since I have to work closing shift on Friday evening. We have reservations at the Marriott 360 Grille. This should be an event to remember since we've not been to the tower since the Marriott took it over.
More later.
Wednesday, May 21, 2008
Dispatch #9 Den Remodel Project - Update
Yesterday we completed a couple of punch list items such as deciding on the molding required to trim the edge of the den wall where it abuts the breakfast bar area. We settled on a 1-1/4" shoe molding to make the transition.
The laying of the laminate wood flooring was began also yesterday. I got about of third of it down and had to stop until I got the door frame from the den to the hallway cut off. I tried out my Rotozip with the flush cut attachment for the first time on this task. It worked great. Wouldn't quite cut all the way through the thickest part of the frame, but that was easy enough to chip out with a chisel.
Have to go back to work today, from 7 till 3, so won't get to work on the flooring until late this afternoon.
Continued to work on the flooring when I got home this evening. Got about four more runs installed. Had to take my recip saw and cut some more wood from the door jams so that the flooring would slide all the way underneath it.
The laying of the laminate wood flooring was began also yesterday. I got about of third of it down and had to stop until I got the door frame from the den to the hallway cut off. I tried out my Rotozip with the flush cut attachment for the first time on this task. It worked great. Wouldn't quite cut all the way through the thickest part of the frame, but that was easy enough to chip out with a chisel.
Have to go back to work today, from 7 till 3, so won't get to work on the flooring until late this afternoon.
Continued to work on the flooring when I got home this evening. Got about four more runs installed. Had to take my recip saw and cut some more wood from the door jams so that the flooring would slide all the way underneath it.
Tuesday, May 20, 2008
Dispatch #8 Den Remodel Project - Update
Crown molding has been installed and caulked. Still have to touch up some nail holes and seams but it is looking good. Started yesterday planning for laying the hardwood floor. The transistion strips between the tile and the hardwood are going to be a PIA (pain in the ass). They are designed to be held in place by a plastic channel that is attached to the floor and in which the wood strip snaps down into. Not a very good design for floors that are not dead level flat. I'm going to modify them and use countersunk trim screws to hold them down. I'll then use oak plugs to cover up the screw heads. I thought about using my air nailer to install them but don't think they will stay in place with just the nails. The strip is going to get a lot of traffic across it so it can't be popping up everytime you happen to step on it.
Debra continues to work on the french doors. She has them fairly well sanded and was working on the edge next to the glass yesterday. Next step will be to start applying a couple coats of Kilz primer and then the final semi-gloss white enamel.
Debra continues to work on the french doors. She has them fairly well sanded and was working on the edge next to the glass yesterday. Next step will be to start applying a couple coats of Kilz primer and then the final semi-gloss white enamel.
Thursday, May 8, 2008
Dispatch #7 Den Remodel Project - Update
Work is progressing on the den remodel project. The sheetrock is finished, two coats of primer and the first coat of paint was applied tonight. 
The crown molding has been painted and is ready to install as soon as the final coat of paint is applied.
Won't be able to work any more on the den until next Monday. We are heading out to Nashville this weekend to visit my sister.
The crown molding has been painted and is ready to install as soon as the final coat of paint is applied.
Won't be able to work any more on the den until next Monday. We are heading out to Nashville this weekend to visit my sister.
Tuesday, May 6, 2008
Dispatch #6 Safety Switch on Table Saw
Got the new safety switch in yesterday from Grizzly. Installed it today. Had to fabricate a couple of brackets from some 1/8" x 1-1/4" flat stock I had on hand. Picked up a deep plastic conduit box and mounted the switch in it. It works great and in case of an emergency I can bump it with my knee and it'll shut the saw down. I tried it a few times and it works great. A excellent upgrade to my table saw.
This the location of the new switch
The new switch from the left side showing the rear mounting detail.
And from the right side
This the location of the new switch
The new switch from the left side showing the rear mounting detail.
And from the right side
Monday, May 5, 2008
Dispatch #5 Delta Table Saw Mobile Base Fix
Recently purchased a Bessy Fence for my 10" Delta Contractor table saw. After I installed it, it created another problem as to what to put under the extension wing table legs. I purchased a 20 ft lenght of 1" x 2" 14 ga tubing and a 20 ft pc of 3/16" x 3" flat bar. Cut it to my design lengths using a Ryobi 14" metal chop saw. Then welded it with my 115 volt wire feed welder. Got some splatter on it and the some of the welds look like pigeon poop but over all it came out well.
I designed the mobile base addition to mirror the existing Delta base and since it was so long I designed in a flexible tail end assembly so that it could flex with out getting hung if I need to roll it out of the garage. My garage floor has a slight elevation change from the driveway to prevent water from flowing into the the garage during heavy rains. It works great but has always caused a problem getting the table saw in and out.
I plan to build a cabinet that will set between the table saw base and the extension wing legs to hold my extra saw blades, dado blades and my cutoff sled.
This was the problem:
The process of solving the problem
Frame welded and laid out
Details of wheel well brackets
The finished solution
I designed the mobile base addition to mirror the existing Delta base and since it was so long I designed in a flexible tail end assembly so that it could flex with out getting hung if I need to roll it out of the garage. My garage floor has a slight elevation change from the driveway to prevent water from flowing into the the garage during heavy rains. It works great but has always caused a problem getting the table saw in and out.
I plan to build a cabinet that will set between the table saw base and the extension wing legs to hold my extra saw blades, dado blades and my cutoff sled.
This was the problem:
The process of solving the problem
Frame welded and laid out
Details of wheel well brackets
The finished solution
Dispatch #4 Monday, May 5, 2008
Went today and purchased the crown molding and baseboard for the den. Got the wrong crown and had to take it back when I went to work and exchange it for the right molding.
When I got home this evening, UPS had dropped a couple of goodie packages off for me. I got the top for the stage one part of my dust collector (DC) for the workshop. It is the black top on the garbage can. This allows larger pieces to drop into the can before going into the DC.
I also received the jig from Rockler to drill the holes for the European Hinges that I plan to install on the cabinets I'll be building.
Worked from 3:30 pm till 9:30pm at the HD BORG.
All in all a good day.
Wednesday, February 20, 2008
Dispatch #3 The Den Remodeling Project
We began on the den in early February. We moved all the furniture except the big TV cabinet into other parts of the house. (The sofa is in the kitchen right now). I ripped down all of the old 1980's plywood paneling and exposed the studs. We ripped up the old original to the house carpet and disposed of it.
First off was the electrical modifications. I added several wall plugs that would be accessible to our furniture arrangement and install cable TV boxes in two locations. Previously the cable TV was routed up through a hole in the floor. Near the entry to the den from the foyer, the builder had put the switch for the overhead lights on the right hand side that wound up behind the bi-fold door and the overhead fan switch on the left hand side. Really a PIA (pain in the ass). I moved the light switch wiring over to the left hand side of the door and added additional wire for a new switch to control the spot lights to be installed later. This made for a 3 gang box. The newly installed recessed lighting got a illuminated sliding dimmer switch, the spotlights got a standard sliding dimmer and the fan got a standard paddle type wall switch.
At the French door going to the sun room, the builder had put the sun room overhead lights & exterior flood lights on the right hand side and the ceiling fan switch on the left hand side of the door. I moved the wiring for the fan over to the right hand side and replaced the two gang box with a 3 gang box.
First off was the electrical modifications. I added several wall plugs that would be accessible to our furniture arrangement and install cable TV boxes in two locations. Previously the cable TV was routed up through a hole in the floor. Near the entry to the den from the foyer, the builder had put the switch for the overhead lights on the right hand side that wound up behind the bi-fold door and the overhead fan switch on the left hand side. Really a PIA (pain in the ass). I moved the light switch wiring over to the left hand side of the door and added additional wire for a new switch to control the spot lights to be installed later. This made for a 3 gang box. The newly installed recessed lighting got a illuminated sliding dimmer switch, the spotlights got a standard sliding dimmer and the fan got a standard paddle type wall switch.
At the French door going to the sun room, the builder had put the sun room overhead lights & exterior flood lights on the right hand side and the ceiling fan switch on the left hand side of the door. I moved the wiring for the fan over to the right hand side and replaced the two gang box with a 3 gang box.
Tuesday, February 19, 2008
Dispatch #2 Victory Declared
On this date we declared "Victory" on the kitchen remodel project. While there is still a small punch list of things to be done, most can not be done until it is tied into the den remodeling project. Below are a the completed project pictures.
Thursday, January 17, 2008
Dispatch #1 Home Remodeling Project Aug thru Dec 2007
I'm playing catchup on entering pictures and information to this blog:
Last year marked the beginning of my home remodeling project. I decided to start in the kitchen and get that part out of the way. Here is a picture of the kitchen looking from the den.
This shows the cabinet that was installed over the breakfast bar. There was only about 24" of clearance between the counter top and the bottom of the cabinet. When you were in the kitchen you felt that you were isolated from the den. To see into the den you had to bend over the cabinet and be careful not to hit your head. Unfortunately, I failed to start taking picture until I was well into the project.
Here is one of the first pictures I took of the remodel project.
As you can see, I have removed the cornice board around the top of the cabinet. The original was plywood that had been wallpapered. It looked like crap. I framed the top in and after rewiring the under cabinet lights so that the wiring was behind the cornice board I covered the area with 1/4" sheet rock.
This gave a much smoother appearance to the top of the cabinet area.
We also installed a new LG Dishwasher:
Here is the before and after pictures of the original windows over the sink and the replacement windows:
As we came into Jan of 08, things begin to take shape and come together. The following are some pictures of the finished kitchen sections:
New recessed lighting was installed along with new counter tops.
Last year marked the beginning of my home remodeling project. I decided to start in the kitchen and get that part out of the way. Here is a picture of the kitchen looking from the den.
This shows the cabinet that was installed over the breakfast bar. There was only about 24" of clearance between the counter top and the bottom of the cabinet. When you were in the kitchen you felt that you were isolated from the den. To see into the den you had to bend over the cabinet and be careful not to hit your head. Unfortunately, I failed to start taking picture until I was well into the project.
Here is one of the first pictures I took of the remodel project.
As you can see, I have removed the cornice board around the top of the cabinet. The original was plywood that had been wallpapered. It looked like crap. I framed the top in and after rewiring the under cabinet lights so that the wiring was behind the cornice board I covered the area with 1/4" sheet rock.
This gave a much smoother appearance to the top of the cabinet area.
We also installed a new LG Dishwasher:
Here is the before and after pictures of the original windows over the sink and the replacement windows:
As we came into Jan of 08, things begin to take shape and come together. The following are some pictures of the finished kitchen sections:
New recessed lighting was installed along with new counter tops.
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