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

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"

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:

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.

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.

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.

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