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An oak window seat Part 2

Installation day for the oak window seat.  This one starts out pretty standard with building a platform on the floor and covering it with mdf for a base.  Ive then built a small "wall" with 2x4s and applied the face that I made up and prestained in the shop.  Scribing is a critical skill here, because you want everything as tight as possible to the walls. Even though this house is only 3 years old, the walls are not totally square.

Categories: 2, an, oak, part, seat, window

Flag Corps flag holder

Ive put some temporary end bracing on the unit until the glue dries on the mortise and tenon joints...

Categories: corps, flag, holder

Getting the Big Walnut Table Together

We got the whole claro walnut table together for the first time today .... Theres other stuff going on in the shop but Ill have to write about that later . Were off to see Iris DeMent in Middlebury in a couple of minutes ... click the photos to enlarge them ...
Heres the process ... We made jig for routing for half the base, routed inside that and then flipped it to complete the pocket ... The slab was too big and heavy to get upstairs to the cnc ... Anyway, it was dusty, but fine and the base is incredibly rigid ...
All bolted down to flip over ...
Flipped over .... with one of the ladderbacks from a November post that were finally getting around to making ...
With some people for scale .... Its a big one .....

Categories: big, getting, table, the, together, walnut

banjo 4 10 pot half fretless

well, you probably know what this is ... another banjo by will ... #4. curly maple, ebony, and brass this time ... half fretless. kind of a neat concept that allows the player to slide notes on the upper part of the fretboard where the frets are further apart, but yet play accurately up high on the neck. click the photos to enlarge them ...
heres a link to a 40 second you tube concert here ... a short improv of mole in the ground ...im told #4 has a nice sustain compared to the others. ok ... i can hear that.
being the fourth banjo, it required new new techniques and new and more accurate jigs and processes like the ebony backstrap and the adjustable 3 degree compound angle drilling jig for the dowel stick hole that was based on this jig we made for drilling long turnings on the lathe .... slick
next time, he says hell add a push block to the back of the jig so he can drill the hole using the tail stock crank, but this time he just pushed it slowly against the bit.
will cut the stopped fretboard slots (a nice clean feeling edge, but without the fussy banding on banjo #2 )(scroll down) on the cnc using a mini mini .026 diameter router bit. for the decimally challenged out there, that is 2/3rds of a 32nd of an inch. a pretty small router bit ... get em from mcmaster carr or stew mac i think. ...
the fretboard binding on banjo 2 .. getting that fifth string tuner curve was a trial as i recall
and then, to secure the brass, he used a variation of a nifty trick we read about on a greene and greene details forum where the hall brothers applied ebony edge details with slotted brass screws and then filed off the slotted parts, leaving tapered smooth tipped pins ... i think he also used a little epoxy or something for insurance .. its a very cool detail in person ..
the whole deal
close up of the fretless part with the stainless steel pins
pot shot ... ha ha
and the back view with the ebony details
nice curly cherry and nice detail on the hardware and dowel stick ... i particularly like the brass wire armrest ... the ebony split line is a cool detail ... and i think the finish is 6 or 7 coats of tru-oil, a gun stock finish ... seeders instruments, wills new website has recently received two orders for complete banjos and one for a reproduction neck for an existing older pot ... the boy is off and running ...

in case you missed them
banjo #1 is here
banjo #3 is here

Categories: 10, 4, banjo, fretless, half, pot

Petersburg MI continuing on with the bookcase

Here are some new pictures of the project. Ive finished out the bookcase rough-in, and Ill be moving on to the arched valences next, and then the fluted trim!
This week Ill be doing more staining in the shop, since I have some valence measurements now!
Also, the tile guy was in this week and finished the tile around and below the fireplace.

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Design Experiment Small Improvised Box

After cleaning up the caulking irons, I just couldnt put them back in the ammo box they came in. I had a vague idea that an airtight box, while certainly keeping moist air out, would also trap moisture in with the irons and would probably not be the best home for them. That seems like a good, practical idea - but of course there was more to it. I just didnt like the ammo box - not for these irons. It didnt make me happy. This might sound familiar...

Anyway, I needed to design and build a box for the caulking irons and this seemed like a good excuse to try an experiment. Ive noticed that many pieces built by old timers have a certain "funky" element to them. They dont seem to follow any "rules" of design, and they sometimes flat out break them. But they have character in spades and are wonderful, unique pieces. Often times it seems that there was a material influence on the final form. Maybe they used what was on hand - a thrifty use of offcuts. Sometimes they arent successful - the piece feels heavy or clunky - but sometimes it is successful, and the piece has a wonderful, funky, organic, improvised quality (and I mean improvised in a good way - like a jazz solo - not like a shoddy cover up...).


For this project/experiment, I decided to restrict the materials I could use, design as I went, and see what happened to the final product. I could only use scrap, or left-over wood and hardware. This was going to be a quick box - no worries about perfect surfaces etc.

Heres what I ended up using:

Wood:
Some pine shelves I took out of a cheapo CD cabinet I resurrected from Salvation Army
A piece of mahogany left over from the wood stove fence project
A chunk of 1x2 that was formally a sticker for a wood pile
3" hunk of 3/8" dowel
1 bamboo skewer

Hardware/fasteners:
Cheapo piano hinge from aforementioned cheapo CD cabinet
Screws from the wheel of homeless fasteners
Nails - aluminum tacks! From - well, I dont know where these came from...


The tools to be stored set some dimensions and the material available set others. The caulking wheel was 16" long. I only had two pieces of the pine shelving longer than that. Since I needed the two sides and the top and bottom to be 16"+ I had to get four out of two. One piece I ripped down the middle. This became the two long sides of the box. To hold all the irons the box needed to be wider, so I resawed the second piece and ended up with two thin (approx. 5/16") pieces for the top and the bottom. The ends I made from one of the shorter shelf pieces.

My original idea was to use wooden pins as hinges, so I made two cleats for the top that would overlap the ends of the box and provide me with a location for the pins. After making those from part of the 1x2, I couldnt work out the details of the pins/hinges, so I scrapped that idea and cut a chunk of piano hinge. Then I found the tacks, and used those to fasten the hinge to the back and the top. The front edge of the lid looked funny, so I ripped a strip of mahogany and glued that across the front edge, overlapping the ends of the cleats. Better, but now the base looked odd. More ripping of mahogany strips and I attached a mitered base to the box. Not too bad, but the box still looked top heavy.


I ignored that "problem" and moved on to the handle. I did find an old metal handle, but attaching it to the thin top would have required adding a strip of wood under the lid. I avoided that by sawing and carving a wooden handle and screwing up through the lid into the handle. Not only did that solve the practical challenge of how to attach a handle, it somehow solved the top heavy aesthetic problem as well (at least to my eyes). Unintentionally, the handle came out with an "Asian" flavor, and paired with the top being wider than the base, it gave the whole box a quasi pagoda nature. Weird.


To keep the lid from just opening when I pick it up by the handle, I made two locking pins from the dowel and the bamboo skewer. Then, to avoid losing them, I made two holes in the top edges of the ends to hold the pins. This also has the bonus feature of propping the lid open so it is obvious that it is not locked.


Two coats of bright red milk paint pulled the whole thing together and hid the different woods used. I followed the paint with my own mixture of mineral oil and beeswax.


I think this experiment was successful. The box is functional and has a pleasing design in a funky, improvised, unique way that keeps drawing my attention back to it. Much more enjoyable than the ammo box.


Heres the tool kit for this project:

Categories: box, design, experiment, improvised, small