Accidental Woodworker

hmm.....

I was leaning towards painting these two frames but maybe not now. They have two coats on them and the poplar isn't white. There is a slight greenish tint to them that I like. A couple of more coats to go before the command decision hammer drops.

Leo's bookshelf

I thought I had made Leo's bookshelf already but if I did I can't find it. The size of the cherry matches the one I made for Miles. There wasn't anything else on the workshop plate so I did this.

I'm going to try and go to Highlands this week to get the cherry for Leo's desk. I'm hoping the weather cooperates because it has been nice for the past few days. Hoping that Mr Murphy doesn't want to shake hands with me.

layout

The ends have some sapwood on them but one has twice the other one. I am positioning that towards the back inside. If they had been about the same I would have put it on the front outside faces.

ready for chopping

Got the dadoes for the shelf knifed and the mortises for the back slats. I was concerned with the mortises because some of the back slats for the desk came out looser than I liked. The goal was to not repeat that with this.

first one

I would guess the first goal is to make it self supporting. The 2nd would be a gap free fit. Achieved both on this one.

first two

Self supporting, clean, tight, and with snug fitting tenons and mortises. Happy face on. Went 4 for 4 on the mortises and 2 for 2 on the dadoes.

hmm......

The mortises are not long enough to get a router to do the depth. I had to do them with just a chisel. It turned out not to be the nightmare movie I had floating around in the brain bucket. Did them by chiseling lightly and then scraping the mortise flat with the same chisel. Check the depth, wash, rinse and repeat until it was a 1/4" down.

dry fit

All the joints were snug and I was able to seat everything with some gentle mallet blows. There is something about doing this - layout, chopping, and fitting that revs my motor. Seeing what I did by hand fitting up as it should is incredibly satisfying no matter how many times I do it. 

small cutout

There wasn't much room for a cutout but I had planned for it. This cutout is about 5/8" at the highest point but it still has 4 small feet.

glued and cooking

Started at 0800 and it was glued up before lunch time. A pretty good AM session IMO. 

first time (dry fit)

I have had these bessey corner clamps for almost 20 years and this is the first time I have ever had a miter close up in it. I had four of them but one crashed and burned during its first free flying lesson many, many moons ago.

sigh

The miter broke way too easily. This is one of the miters I glued up yesterday that was going to be a setting jig that I didn't use. My miters are getting better but what isn't improving is the glue bond. I didn't size this but that doesn't seem to matter. 

glued and cooking

I got a good tight fit on the miter, toe to heel. The experiment is to see how well the glue bond is. You're saying maybe I should try hide glue. I have and the results were the same as with yellow glue. I will find out in the AM how this one turned out.

 accidental woodworker

out of the clamps

Both frames are laying flat on the tablesaw with zero rocking. The 5x7 frame is spoken for and the larger one is in stand by. My wife changed her mind on buying the map but it is ready for whenever.

none worked the best

I used all of these gizmos to screw in the table top clips. The four clips under the drawer guide rails were the worse. I had to use the offset screwdriver to do them. Those four took me a bazillion years to do.

this one took the longest

This one was the most awkward one to do. I just couldn't maintain downward force along with a good grip on the offset screwdriver. Note to self - on Leo's desk screw the top on before I do the drawer guides then unscrew it.

glamour pic #1

This is based on the desk I use everyday. The only quibble I have with mine is that it is too small. But with a bigger desk top I would just have a ton more crappola on it. This should be more than adequate for an eight year old.

glamour pic #2

I really like spindles/slats. Thinking ahead to Leo's desk maybe I should do a wide center slat like I did on the back, on the sides.

glamour pic #3

I am glad now that I got the epoxy filled knot hole facing out. Now that it is done it compares favorably to the epoxy fill knot hole on the desk top. IMO it looks like it is a natural occurrence in the wood. 

final glamour pic

I am going to give Miles the bookshelf along with the desk. If Miles doesn't want to keep it on his desk that is his choice.

hmm......

Too big for the desk, it eats up a wee bit too much real estate. However, after seeing this, a gallery with drawers might work. I am making another cherry desk for Leo but I don't like giving the boys the exact same desk. Thinking now of making a gallery for his desk. Just something a little different between the two.

spline groove

Working on the two new pic frames. Got the spline groove  done on each corner. I used cherry for the splines because I didn't have any poplar.

back frame

Nailed and glued the back frame on. This creates the rabbet for the glass, mat, and pic to sit in. I like having whatever is framed set back toward the rear of the frame. I don't like having the pic up close to the front face of the frame.

chamfer

I hadn't planned on doing a chamfer on the frame but I had to. The small frame fell off the bench and one corner got dinged. The chamfer removed it.

shellac

Thinking of leaving the frames natural to highlight the cherry splines. If I don't like how they look I can paint them. The shellac can be a primer coat for the paint.

accidental woodworker 

 Getting awfully close to the finish line on the desk. The slats are done and I got 4 coats on the base. I'm happy with how it looks with that many too. After dinner tonight I'll get the final coat on. In the AM, first thing, I'll attach the top to the base. I'll be done with it by sunday at the latest (fingers and toes crossed).

done

Got two coats of shellac on the frame. I brought it to the Frame it Shop after lunch today. Don't know when it will be ready but no one is holding a gun to my head on it neither.

shoulda, coulda, woulda, but didn't

I have this miter frame clamping gizmo and I forgot all about it. This could have been used to clamp up my wife's map frame. hmm.... since I am waiting for the base to dry I might as well try this while I'm standing around giving everything my best goofy looks.

hmm......

First thing that shook hands was what a PITA it is to spin the wing nuts down the threaded rod. I was tempted to cut the rods down but I resisted. I don't make the same size frames so that wouldn't advantageous. I got the rods set loosely to the size of the frame I just made.

new frame

My wife mentioned that she was thinking of buying another reproduction map so I'm getting ahead of the curve. Made another frame and shot the miters on the shooting jig. Now I'm running into a storm of hiccups.

There is going to be a bit of a learning curve on how to use this type of clamping setup. I fiddled and faddled with it for almost 30 minutes and nada. I couldn't get the frame to square up. This set up is not self squaring as far as I can see. It has to be square to what is being clamped up and each corner tightened individually but in unison. I got a wee bit frustrated with it.

not aligned

This was the 3rd time I tried to dry clamp this frame and failed. So far one corner has been off on the toe to heel. One a brighter note this was the best I did so far. I kind of figured out after this about getting the clamp frame kind of square before tightening it down. 

I gave up on trying to get the clamp frame work. The frame came together dry almost perfectly. So it should have clamped up without any hiccups. I even set the clamp frame by measuring the diagonals to be the same. That worked but I still couldn't get one corner's heels and toes to align.  

I'll try this again because I refuse to let it win. I bought four 1/4-20 slip nuts from McMaster-Carr (~$12 each) and I should have them monday or tuesday. Slip nuts will definitely speed up getting the nuts on/off the threaded rods. 

hmm......

Clamped up without so much as a whimper in the Sears Craftman clamps. This 2nd one looked better then the first one I did yesterday - all the miters were tight and gap free on both sides.

my band clamp

This clamp can be fussy but I was able to clamp it and get all the miters closed up. It has the same problem I had with the threaded rod clamp but this one was easier to get and keep the miters aligned toe to heel. 

This frame came from the off cuts from the frame above. It is big enough for a 5x7 pic. 

helping hand

This clamp tends to pull up on one corner - one closest to hand screw. Placing a heavy thing on it flattens it and keeps it that way while it cooks.

getting there

I put the moving blanket on the workbench to keep the base clean. I had noticed that my dirty workbench top was getting on the legs. Should have done this before I first put it on the bench.

oh....

I didn't think this all the way through. The intent was to put a spline across the miter face. My spatial thinking said this would work. I was wrong and I blame the spatial hiccup. This is going to be a jig for positioning the table top. This is part one and part two will be two pieces of plywood that will set the offset between the base and the outside edge of the top. 

ready for the last coat of shellac

One more on the bottom of the legs and then the legs and rails. Happy face on. The base looks good and the slats don't look any different the rest of the base.

accidental woodworker 

ready

The frame has been sanded smooth, front and back, and it ready for paint. It is laying dead flat on the workbench - no rocking at any corner.

needed

The spray shellac is working fine. It is laying down smooth and drip free on the slats. However, the aerosol spray lingers like a fog in the shop. The fan does a good job of airing out the shop in just a couple of minutes. Glad for that because is it sill only in the middle 40's F/7C outside. 

4 coats

I should be done with the slats today. The can says it dries in minutes which I assumed was 4-5. It stayed tacky for almost 20 minutes and not dry to the touch for almost an hour. I got time but I'm getting impatience waiting until I can apply the next coat.

missed it

Glue squeeze out and it isn't the only spot I missed. I started applying shellac to the base because I didn't want to leave the shop. The shellac made it pop, because without it the glue blended in with the cherry. I removed it here and 2 other spots with a chisel.

the base

There aren't any glaring differences between the spray shellac and the batch I mixed. There is only one coat on the base, 5 on the slats, but they look the same. 

2nd coat

On the first coat I tried to paint the whole frame. That kind of worked and kind of didn't. The biggest headache was holding the frame to lay the paint down. Decided it wasn't worth it and I only put a 2nd coat on the back of the frame. After dinner I'll put a 2nd coat on the front and that should do it. 

2nd can of shellac

Got my answer on how much shellac per can before it is empty. I got four coats on the slats from one can. Noticed that the weight of the can went down after each spraying and it was as light as a feather after the 4th coat.

Getting real close to getting a check mark in the done column with this desk. I should be done with it next week hopefully. Won't be too soon and I'll have to motor up to Highlands to get cherry for Leo's desk. 

accidental woodworker 

hmm.......

To my eye it looks like a design element of the desk. (the little doo hickey things on the underside of top rail against the legs). It hides the end grain of the front rail from being seen. Note to self - on Leo's desk make all the top rails the same width .

happy face on

Out of the clamps and all is fine in Disneyland. All the miters are tight heel to toe on this side. On the opposite side it is the same except one miter is a 1/2 of a frog hair open at the top. Overall happy with the outcome and the frame withstood me scraping the miters on both sides.

)(&@%)Q&@*_Q

Made the first batch of splines too small. Only one might have been usable but it had zero wiggle room. Made a new batch oversized more than I allowed on the first ones.

not my fault

I know this spline was loose because I checked it dry. When I applied glue it froze about 1/8" shy of bottoming out. Glued in a shim from each side to close up the hole. Clamped all the splines and set it aside to cook.

PITA

Got the rails and legs sanded and ready for paint without any hiccups. However, the slats are proving to be a massive PITA. I had planed all of them before gluing them to the rails and now after the first sanding with 120 all kinds of ugly tear out are popping up to shake hands.

I worked on resolving that until the dinner bell rang. Got one side and the back done but left side still needed attention. I dealt with that after I filled the pie hole.

better

Got  6 spray coats on the test piece and it matches the top pretty good. Even the depth of the finish looks about the same. It looks like 6 spray coats on the slats will do the job. 

prepping the frame

Used the #3 to smooth and flush the miters. I am keeping the frame as is. No chamfers or any other molding edge detail. The map is a formal document and the frame will match it.

back rabbet frame

Glue and nailed 3 sides first. Then I fitted the last one to it. Filled in the nail holes with putty. I'll be painting it black in the AM - not milk paint but a latex black paint.

hmm.....

First spray coat on the slats. I did that so I could if any spots of tear out were missed. Cherry is a pretty wood with a finish applied. I will spray on 6 coats before I brush shellac on the rest of the base.

accidental woodworker 

sigh

I kind of thought this might go south on me. The saw blade had slipped so the slot mortises and the tenons were different lengths. Being brain dead, I glued it up anyways and hoped for the best. Well boys and girls, it bit me on the arse and drew blood.

new frame

I am going miter this frame. I didn't feel like digging into the saw blade height hiccup. Besides I have to master making mitered frames in spite of how much I dislike miters.

hmm......

The mitering was going fine. No hiccups other than a little see sawing with getting the sides to be the same length. I allowed a 1/4" of wiggle room on the overall length to plane the miters.

encouraging

Planing done and the frame dry fitted with all corners closed up.

no expletives said

Dry fitted the frame with my Sears miter clamps. No hiccups and all the corners look good. Three are dead tight and one has a bit of a gap at the toe. Other than that I'm happy with how well the clamp up yet.

survived

Of course with glue applied all the miters tried to out do each other with slipping and sliding in/out and up/down. I got it done without the urge to give it free flying lessons. Added the extra clamps to pull the miters together tight from heel to toe. I will let this cook in the clamps until the AM.

fixed and ready to go home

Happy with the paint job but it isn't completely done. I wasn't going to paint the drawer unit on the top. However, I noticed that there were a few dings with some white showing. But there is a color difference between the drawer unit and the dresser. I have time to paint it to match the dresser.

so far, so good

The three rails I glued back in place appear to be secure for now. I have manhandled this quite bit since I glued it and nada. When I first shipped this down to North Carolina, one of the rails popped loose putting it in the car. I tried to replicate that stress/strain and the rails have behaved. Fingers crossed that it stays that way this time.

back rabbet stock

These are off cuts from making the first frame. I'll add them after the 2nd frame is done and splines are installed in the miters. 

came last night

I don't have any experience using spray shellac. I am not sure how many cans I will need to do the slats. I'll be finding out later this week.

hmm.....

The top has 6 coats on it and it looks good but I'll be adding a few more. For now this is good enough to set aside as is while I sand the base.

left drawer

At the end of pushing it in the drawer stuck a little. I was still able to push it fully but there was a bit of hesitation I didn't like. I planed the top a couple of times and that cured it. Easily pushes in fully without any binding or hesitation.

done

Both drawers are done, well almost done. I'll have to put a couple of coats on the top of the left drawer before it is a 100%.

I like

IMO I think the oil bronze pulls look good. I thought of using brass but nixed it after seeing a knob on the cherry. The almost black color of the pulls matches the black gun pockets perfectly.

hmm......

I was on the fence about doing a small chamfer on the outside edges of the legs, specifically just these edges. There is a ding on the back left leg edge that was driving this decision. A chamfer would hide it and wouldn't look out of place. Putting chamfers on the other 3 edges is doable but not as easy. Plenty of time to kill some brain cells thinking on it.

sigh

The bottom of the front rail bottom is visible from the side. It looks unsightly IMO although I doubt anyone other than me would notice/pay attention to it. 

the fix

I'm going to glue a small block on the bottom of the side rails at the front and back. Don't need it at the back but it balances it.

the top

The top has a shine that I like but it also has a depth to the finish. It will live here until it comes time to marry it to the base.

I hate sanding

I am using 3 grits to sand the base - 120, 180, and 240. After starting I had to add the Stanley #112 and a card scraper. One of the back legs had minor tear out on squirrely grain that the sandpaper did nada on. The #112 and card scraper removed it. 

hmm......

3 coats of the spray shellac. I can see a difference between the two. I'll spray on 3 more and see how it looks than.

hmm......

I thought I was done but one more leg wanted to shake hands with me. With the flashlight and the pencil I high lighted several problem spots on the legs. The #112 wasn't working well and neither was the card scraper. Sanded it first with 80 grit and that took three attempts before they disappeared. 

Followed the 80 grit with the other three and they were history. Smooth leg with no tear out anywhere on it. Went dead in the water here because of the blocks I had clamped. It restricted how I could position the base for sanding. I'll pick it back up in the AM session.

ugly looking

I shoulda, woulda, coulda, but didn't clean up the glue squeeze out when I clamped it. Out of the clamps and I removed the glue squeeze out with a carbide scraper and it torn out chunks of wood along with the squeeze out. It is tedious work but I'm making slow progress using a chisel as a scraper to clean up the damage.

accidental woodworker 

underside

Three coats and I'm calling this part done. Three coats is sufficient for the underside IMO.

topside

No evidence of the indentation but the chamfer and the end grain needs a touch up. Sanded them with my sticks from 100 up to 220 grit. After that I was read to apply the shellac. Spent the rest of the AM session applying said shellac on the top and the drawers.

new pic frame

My wife bought a reproduction of a 1689 map of the Plymouth Colony. I was asked to make a frame for it and this is it. 1/2" poplar frame that I use bridle joints to join the corners.

glued and cooking

I'll let this cook until tomorrow. I'll bring it to Maria after I get it painted.

4 coats

This batch of shellac is super blonde and I can see a difference in this compared to my last batch which was blonde. This is a lot clearer without a hint of a yellow/orange tint. 

my OCD was in overdrive

I had to replace the left drawer tilt rail. Super glad that I didn't use glue on this.

hmm......

The pine drawer tilt rails are strong enough for this purpose but I am concerned about the poplar wearing against the pine. There is over an 1/8" of clearance between the tilt rail and the top of the drawer. I'm going to glue a 16th inch thick cherry strip to the underside of the tilt rail. Cherry should wear better than the pine would.

done (almost)

Wear strips glued and cooking. I had tested the wear strip clearance and the drawer slid in/out smoothly still. It knocked down the slight tilt the drawer I had to almost nothing. 

much better

Better fit with no gap this time. Installed it the same way as the original, no glue and one screw.

hmm.......

I'll let this cook until the AM to ensure a good bond. It is only a glue connection, no nails or screws to help out.

Got the spray shellac from Amazon so I can't put it off anymore. I will be done with the applying shellac to the top by tomorrow. The next batter is sanding the base which I ain't looking forward to.

accidental woodworker

couldn't wait

Went back to the shop after dinner to check on the dent. It had been a couple of hours since I steamed it and it looked good. It was flush - I couldn't feel it at all with my finger tips. Happy with that but I could still see the outline of it. 

twenty minutes later

Scraped and sanded the indentation outline until it disappeared. I wiped down the area with alcohol and 99.9% of it was gone. One small spot could be seen in raking light but I stopped here. Made a command decision that this was good enough.

surprise

UPS delivered the drawer pulls at 2034 on saturday. I can't recall ever getting a saturday deliver from Lee Valley. The pulls are smaller than what I thought they would be. The under grabbie space is adequate - my fat fingers fit - so it will definitely work for Miles/Leo.

checking the indentation in the AM

The work I did on it after dinner last night still looked good in the AM. Even the small spot I saw in raking light was hard to find this AM. The final check mark will be what will happen once shellac goes on.

hmm.....

Wiped the area where the indentation was first with alcohol. Nothing popped out with the alcohol. I then wiped down the entire top with alcohol  to see if there were any other holidays.

fingertip test

Ran my fingertips all over the top to feel for any rough spots. I had sanded the top after wetting it with water and I found a couple of raised rough areas. The indentation was no where to be seen. I think I'm finally done with the top.

template

The screw holes on the pulls are on 3 1/4" centers. Which means the holes are 1 11/16" on either side of the center line. Used this to transfer the screw holes to the drawer front with a center punch.

Editing update. While proofing the blog I saw that I had lost a 1/3 of the blog post. It was going nutso trying to save it and it went south into the black hole. Stercus acidit. This is the second time in the past couple of weeks that this has happened. Another annoying quirk to deal with?

Recap of what blogger shitcanned on me - got 3 coats of shellac on the drawers except for the fronts. Three coats of shellac are on the bottom of the top. Mixed a fresh batch of clear shellac that I'll use for the rest of the desk. 

To help with applying shellac on the slats I bought 3 cans of spray shellac from Amazon and I'll have them today. From past experience, applying any type of finish on slats is difficult and time consuming. It is maddening trying to keep drips and runs from happening. I'll brush shellac on all the drawer fronts, rails, and legs.

accidental woodworker

flushed

The epoxy planes easy and clean but it is kind like planing cherry. I'm not going nutso on cleaning the bottom at all. It is flat and straight in all directions and that is all that really matters. 

hmm.....

I'm going to install a couple of anti drawer tippy things. I have them on my desk and I'll put them on Miles. The drawer tips downward a little and it is a wee bit floppy so this will cure that. However, I can't put them centered on the drawer because I have table top clips in the way. Instead I'll position about 1/3 of the way in from the drawer edge.

reinforcing the top rail

Found a bunch of #12 two inch screws for the rail screw job. I had ordered some #8 by 2 1/2" screws but now I think they would have been too small for this.

Yankee screw driver

I was surprised by how well this screwdriver handled the #12 screws. I had no hiccups driving them 99.9% of the way and no headaches locking it and driving them flush. I like using these Yankee drivers - I have 4 of them - for driving screws. Unlike using a cordless drill, it is almost impossible to over drive or strip the head of a screw with them.

underside of the top rail

I only put one screw in the center divider along with one each at each end. Feel a lot better about the table top clips not failing due to the rail going south.

checking

Since I had the base on the top, I checked that my overhang  was consistent all the way around. I checked each and every position for the table top clips. One to make sure that they fit and two, that I would be able to screw them down. The drawer guide assembly wasn't interfering with any of them. 

boring work

Routed a 45° chamfer all the way around and now I'm sanding the end grain smooth with the sanding sticks starting with 100 grit.

cherry ain't easy

The 100 and later 120 grit sanding sticks were making poor progress on smoothing the end grain. Decided to try a card scraper and it worked. I was not expecting it to work as well as it did on end grain. In spite of it working much better than the sanding stick, it still took a lot of time and calories to smooth the end grain.

sigh

Sanded the top starting with 100 and ending with 200. This spot has a couple of indentations that came from ?????? I tried to scrape them away but nada. I thought I was  done with the top but it ain't so boys and girls.

test piece

I am using 3/4 pine for the drawer tilt thing (drawer tilt rail?). I cut a slot centered on each end for a #0 biscuit. Did a test piece to make sure I figured out how far down from the top of the rail the mating biscuit slot had to be. Got it on the first try.

done

The biscuit is just to hold the rail in place. I drove one screw in at each end to secure it. No glue, just an one inch #6 screw and a #0 biscuit.

hmm......

underside of the top

Sanded the underside with 100 grit and stopped there. Branded and initialed it. This has a check mark in the done column.

better pic

I didn't notice this after I was done sanding so it happened between then and when it shook hands with me. Tried sanding it with 220 and nada. Plan #2 is try steaming it out with my shop iron.

done

Continue to be impressed with the paint job with the smooth finish roller. I think I'm done, I didn't see any holidays .

drawers

No streaks from a paint brush and it looks pebbled now but after it dries it will be as smooth as a state zero sea.

Steamed the hiccup on the top and it didn't go smoothly. I accidentally spilled water on the top so I had to flood and wet the entire top. I'll be sanding it again in the AM but I think I managed to get the indentation raised. I'll find out in the AM how well that went.

Didn't get any pics of the initial fiasco but I was optimistic about how the iron did steaming the indentation. 

accidental woodworker 

fitting the drawers....

The left side drawer in/out guides are square to the front. However, the right side ain't so boys and girls. On the flip side of the coin, the guides are parallel front to back. I pried off the right guide and used the drawer to set it again. Sure glad I only nailed them.

almost

This was the fit of the left drawer after planing the top and bottom edges flush all the way around.

done

Fitting the left drawer was painless. I had to go back and trim the sides twice before the drawer slid in/out effortlessly. No binding or hesitation pushing it in or pulling it out.

done

Both drawers work the same. I didn't go nutso trying to get a piston fit - I care more about how smoothly the drawers work in/out.

right hand drawer

Dry clamped the drawer guide and then I fitted the drawer. I got the left drawer in/out guides screwed down. No glue, just screws, so anyone coming behind me can effect any necessary repairs/replacements.

super glue

Decided not to nail the drawer guides first before screwing them. Instead I put a couple of dabs of super glue at each end. Clamped them lightly to help the super glue cook and set quicker.

drawer stops

I glued the stops in place and let them set for an hour. After that I added two screws to each of them.

hmm......

Both the drawer fronts are slightly proud of the front rail. I marked them with a pencil and planed them within a frog hair of being flush.

done

The right hand drawer guide is screwed off and nothing shifted. The drawer still slid in/out easily and without any hiccups.

hmm.....

There isn't much left to do on the desk. I put stops at the front so the drawer can't inadvertently be pulled out and play the bounce test with Mr Floor. All that is left to do is finish the top, attach it, sand endlessly, and slap on 5-7 coats of shellac.

speaking of the top

I like the overall look of this desk. It is clean and simple. Glad that I didn't go for a bank of vertical drawers on the right side. The tedious part of applying the finish is just around the corner.

one more hump

I doubt that this would be noticed but I expended the calories and flattened it. It took me less than an hour to do that. Used 3 hand planes, the Stanley #80 & #112, and finally my random orbit sander with grits from 100 to 220 to finish the top.

passed with flying colors

Wiped down the top with alcohol and nothing popped out. No plane tracks, chatter marks, rough squirrely grain showed up.

choices

A 45 chamfer or a table top thumbnail, which one wins the Kewpie doll? I really liked the thumbnail profile a lot but in the end I'll be using the 45 bit. The round over of the thumbnail bit doesn't fit in with the overall look of the desk. The overall look of the desk is rectilinear with squared off edges galore.

hmm......

The divider gave up the ship. Four of the corner blocks let loose. Glued it back together and let cook in situ.

pull out stop

No need to go nutso on this. Unless someone goes Cro magnon, it should last as long as the desk does.

hmm.......

The top of the front rail flexes a lot. Too much to ignore. The top of the rail will be under the strain of holding the top down to it and it needs some help. I am thinking of putting a couple of 2 1/2" screws into the center divider and the two ends to stiffen it up. 

hmm.....

This is the underside of the top and I thought I had filled this in already. All I had done was to stuff the knot hole with cherry shavings.

done

Filled it in with epoxy. I didn't bother to dye it black because it is the underside. This will keep bits of the knot from loosening and falling out down the line.

accidental woodworker 

first one

The fit looks good - it is snug and gap free even though it is seated less than a 1/3 of the way in.

2nd one

Fit was just as good and it continued on with the 3rd and 4th ones.

hmm.....

I didn't think the drawer would fit at all. Disappointed in the half blinds at the front. After they were fully seated gaps stood up and shook hands with me. Sigh.

plowing grooves

On the dry fit of the drawers I checked that the bottom edges lined up flush. This way the groove would align all around.

left hand drawer

I used prefinished plywood (one face only) for the drawer bottoms. It was left over from the bookcase I made a few months back. I could only get one corner of the left drawer to fit in the opening.

glued and cooking

Needed some help with the back dovetails - this drawer had loose fitting back dovetails. I didn't want the back clamps to pull the drawer out of square so I clamped the front ones. They were snug and didn't need any clamp pressure.

1st coat

I'm impressed with this first coat. It covered every sin with nothing showing. I'm optimistic that one coat will do it but it will be getting at least two. One of the rails didn't cooperate and the paint didn't cover well and will need a second coat.

from Wally World

The only spot on the dresser I used a paint brush was the legs. Everything else I used this roller. I have always been a brush man but that changed today. The paint job from the roller was heads above the brush work. The roller work is dead smooth and the brush work on the legs is no where as smooth. I was skeptical about this 'smooth' finish but I'm impressed the results. 

filling the groove ends

In order to bury this groove in a pin socket I would have had to sacrifice drawer depth and I didn't do that. I'm able to contain my OCD and fill in the holes.

gap filling stock

Took some heavy shavings with the 5 1/2 until I made some thick enough to fill the gaps in the tails/pins. 

it worked

I wasn't sure that the shaving would survive being pushed into the gap but it did. I used this on all the gaps I filled.

one done, one more

Found a thin piece of cherry to fill in the half pin gaps at the top and bottom. I used a hammer to thin the cherry until it fit the gap.

still cooking

I am going to wait until the AM before fitting the drawers. I didn't want to risk planing them now and blowing out the joinery. 

came 3 days early

Jefferson is my 2nd favorite president. I have a book about Monticello and the gadgets he has I find fascinating. This desk was the 18th century equivalent of a tablet. Looking forward to reading it - it also has plans to make one.

I ordered 4 drawer pulls - oil rubbed bronze - because I like how they look against the cherry.  Ordered them two days ago and they shipped today. I doubt that I'll get them before monday of next week at the earliest. 

accidental woodworker 

hmm.....

The glue up healed well and was just slightly proud. A few strokes with 120 grit and it was flush and smooth.

one down and one to go

Tails done on the first drawer. The plan is to do one drawer, one step each, before moving on to the next one.

lost the previous one

Searched for it but nada. This is needed to set the height of the stock in the vise correctly.

hmm......

The spacer top is flush with the top of the outboard thing a ma bob behind it. Makes transferring the tails onto the pin boards level and easy.

should swell with glue

Back of the first drawer dry fitted. Went together off the saw.

hmm.....

The back left corner is loose as in it ain't snug. I initially put it together the wrong way. That way it was snug but when I put the corner together in the right orientation, it was loose. There is no way glue will swell this one. I'll be filling in the tails/pins with veneer.

2nd drawer

Found the problem mismatch on the first drawer. I had labeled the bottom of the sides wrong. They were correct for the long sides but not for the back. Caught that before I did the dry fit on the 2nd drawer.

prepped

There are two more steps before the drawers get a check mark in the done column. I have to chop the pin sockets in the drawer front and plow the groove for the drawer bottom. There isn't much more that needs to be done to complete the desk.

pin sockets

This was the last thing I got done today on the drawers. I don't over saw my half blinds, I think that is sloppy workmanship. A wee bit harder hammering the card scraper in cherry vice pine.

Had to go the VA in the AM and I'm glad I did. My wife is coming to West Roxbury with me for the CT biopsy on the 22nd. The procedure takes ~30 minutes but I have to spend 5-7 hours in recovery to ensure I don't get a collapsed lung. Anyways, I made a reservation for the shuttle and that is what I'm glad for. There wasn't one for me, unexpected, but the coordinator saved a seat for me and my wife. 

accidental woodworker 

clamps off

There weren't any stresses in the desk - as the clamps came off nothing groaned or shifted. Sawed off the dowels and flushed them with a chisel.

hmm.......

The back drawer rail is 5/16" off the front drawer rail. I hadn't thought about this when I made the front rail wider to accommodate a bigger drawer - depth wise. It took a few to wrap my head around how to deal with difference. Sometimes my spatial visualization ain't too good.

test piece

I think I resolved what had to be done at the rear drawer rail to make it level with the front drawer rail. A 5/16" tongue on the back of the drawer in/out guide was the trick. The test piece lap was too deep but it put me on the right road.

depth setting jig

My 18" combo square worked just as well as this would have had I not broke it.

drawer in/out guides

Glued the guides and set them aside to cook. After lunch I added 3 screws to them because I didn't want to rely solely on glue.

front drawer rail

No glue for this, just 5 screws. If need be any repairs/replacement will be easy.

didn't want to break this out

The back drawer rail install didn't go smoothly. Initially I had screwed one end and the rail had shifted downward. Unscrewed the rail and filled in the errant screw hole. I then nailed the rail flush with the back top rail. Part of the problem was there wasn't any where to apply a clamp. The nails were sufficient to hold the rail flush so I could screw it off.

in/out guides

Since I had the nail gut out, I nailed the guides with one nail at the front and back. After I make the drawers and fit them, I'll add a screw at the front and back to each one.

drawers

The plan was to start the drawers in the AM. I stopped working on the desk here and turned my attention to Leo's dresser.

no paint today

Got the dresser and all the drawers sanded and ready for paint. However, I blew off a big chip on the front of the dresser. I glued that back on and once it has set I'll have to do some putty work. One part of the blow off went MIA.

hmm......

Made a test groove for the plywood I plan to use for the bottom of the drawers. This fit is not snug but it isn't sloppy loose either.

done

Got the depth and inset from edge dialed in. I was going to use drawer slips but I am now plowing grooves for the plywood in the front and sides.

 Laid out the tails on both drawers and set up my Moxon vise. I'll start on the half blind dovetailing in the AM.

accidental woodworker 

hmm......

My set up thing-a-bob is several frog hairs short. I thought I would definitely need it for the back rail to set the bottom drawer guide rail.

the fix

I glued a thin piece of cherry to the guide to build up the depth of it. Planed it until it was dead nuts but all for nothing. I broke the jig rendering it into kindling. 

center drawer guide

I'm not crazy about the width of the maple at 5 1/2" wide but it will work. Thinking that I will use only screws to assemble it, no glue. I'm pretty sure that I used glue and nails on the drawer guides on my desk.

before I broke it

With the guide in place and the bottom drawer guide rail butted against it, the top of it was flush with the bottom of the drawer opening.

hmm......

Upcoming hiccup to resolve. The front drawer rail is 5 1/2" wide and the back one is a little more than 5". The in/out guides will be sitting atop the front and back drawer guide rails. I will have to half lap the in/out guides on the back drawer guide rail.

nope

There isn't enough room to drill the Miller dowels in at 90°. I won't be drilling them at at an angle. Instead I'll drill them at 90° from the outside. 

cooking

Hiccup free glue up of the base. Happy that clamping pulled the twist out of the left side that was twisted. The base isn't rocking nor does it look like it is twisted. The diagonals on the top were less then a 16th off.

maybe

The dust panel is proud on the left side. I'll find out if it will be a hiccup when I install the drawer.

needs a paint touch up

All the drawers fitted, easily pulling in/out without any hiccups. I went to Benjamin Moore paint store and they had a record of the paint I bought for the dresser in june of 2024 - Smoke Gray. The important thing is that drawers slide in/out and the rails I glued are rock solid now.

top drawer unit

This is good to go. No dings or 'white' spots on it anywhere. I'll screw it back down to the top after the painting is done.

haul from the paint store

Dresser paint, 4-0 steel wool, and two empty quart cans for shellac.

paint prep

Sanded the drawers and the dresser first with 220 and followed that with a card scraper. Filled in the dings, etc with wood putty. Tomorrow I'll sand those spots and paint it. Hopeful that it will only be one coat but I don't think it will be so. 

Miller Dowels

This was it for today. I'll have to cool my heels and let things cook until the AM.

accidental woodworker 

dust panels

Happy with the rails. They are secure, tight, and appeared to be glued good this time. One sharp rap with a mallet and the rails just giggled at me. However, the dust panels didn't fit - they were about a 16th too wide.

dust panels

One panel I was able to drop into rabbets. The other didn't have rabbets. When I made the rails I brain farted and put the rabbets facing down rather than up on two of the rails. The panels aren't structural so I was able to glue the 2nd one in place along with nails.

been a while

Been a couple of months since I last posted a blurry pic. This one is for the center divider. I flushed it with 80 grit sandpaper. I will have to slap on at least one coat of paint to cover this and a few others spots.

leveled

This is the epoxy filled in knot hole after 99% of it has been leveled. No pin holes from bubbles so far. You have to be careful with the pigment because even dry, it will stain the wood. Like an idiot I mixed the epoxy and stain on this board. Note to self, don't do that again.

cute

Went to Lowes and bought a 4 foot length of 1/2" maple for drawer runners. Saw these miniature 5 gal pails on the way in and bought two of them. Food safe too. Absolute no idea why I bought them because I don't need them.

wee bit of a panic

Got the bottom of the slats in with no hiccups but I couldn't say that for the tops. The dry fit went off without a hitch but with glue in the equation I couldn't solve it. Had a devil of a time getting the first three slats started. After several frantic minutes I got them going and then slats 10,11, and 14 had a major hissy fit. They finally fell into place. What took me 3 minutes to do dry, took me almost ten with glue applied.

sigh

Put the center stile in upside down. The cathedrals point down. I brain farted and put it in the bottom rail with a the labeled top facing up when it should have been facing down.

dry fitted

I didn't glue the base up here. I wanted to leave it dry because I was going to dry fit the drawer guide assembly. Wasn't sure if I could do it with the base glued and cooked.

sizing the top

I barely had to saw more than a 1/8" off either end. Not something I had any confidence in sawing with a handsaw.

happy face on

The overhang on all four sides was dead on. 

sigh

Couldn't find the slat I used to make the dutchman for the missing part of one of the legs. Could have sworn I saved it. 

table clip slots

I didn't brain fart on the table clips. I got all four inside edges done correctly.

ta da

Found the dutchman. I'll get it installed after I glue the base up. Until then I'll keep it here on the base.

Didn't get any time in the PM session. On a trip out to the recycling bins, I tripped and did the bounce test on the back door stoop. I slammed into the cobblestones and ripped a pound of flesh off both my knees. I'm sure that I'll be feeling it in the AM.

accidental woodworker 

hmm.......

I don't remember it, but I can see how I did the drawer guides for my desk. I kept it simple and easy. I'll be replicating it for Miles's desk and Leo's later on.

center drawer divider

I've been using this desk for years (10 or more?) and the drawers still work flawlessly. the guides (red oak) show almost no wear at all. No worn drawer bottom grooves at all but I won't be using red oak on either for the grandson's desks.

Miller dowels

I pinned the sides with Miller dowels on the inside faces. The dowels worked perfectly as they were a 16th less than the width of the legs. The back I might have to do the doweling from the outside face. I'll deal with that when I glue the desk together.

table top clips

I am going to attach the top to the base with these clips. I chopped the mortises for them with a 1/8" chisel. Three each on both sides.

back top rail

Put five in the back rail - I didn't think 3 would be sufficient.

filled in

The actual hole is smaller than what you see here. It got larger when I hit the epoxy with a heat gun to pop the bubbles in it. If I don't like it after it has set up I'll move on to plan B which is a dutchman.

hmm.....

Wasn't sure if I was going to do the table top clip mortises in the front rail. I was a little gun shy after screwing up the back but I bit the bullet. If I did them wrong it would be easy to whack them out correctly. As a bonus the errant mortises will be hidden with the drawer guide rail.

hmm........

Whacked out a jig to help with setting the front drawer guide rail. The top edge of it will be flush with the bottom of the drawer opening. This simple jig will ensure it is even across between the legs.

fingers crossed

Scraped the ends of the rails and the housings as best I could. Glued and installed the rails again. They will cook at least until the AM and maybe longer.

top rail

I didn't have any problems getting the top rail and the center divider out. The dovetail detail was on the thin side and a small splinter stayed behind from the bottom of the divider. Scraped what I could and glued it again.

sigh

The ends of the rails seated flush and snug. The center divider was a PITA. I tried frantically for several minutes but I couldn't get it flush. The screw holes for the drawer guides lined up but the center divider is proud of the rails. After the glue has set I'll see what I can do to flush it. 

drawer set up

There is a bottom bearer on the front and one on the rear. The drawer guide will be screwed to it. Underneath it will be a board that drawer will ride in/out on.

center divider

This is an idea of what the whole thing will look like. The white wood is maple which should wear well as the drawer will be moving in/out over it. I don't have enough of it to do all three so I'll be making a Lowes run tomorrow. 

accidental woodworker 

 Went to the shop this AM with one goal in mind. That goal was to get all the slats installed on the back rails. Spoiler alert - made my goal with 12 minutes to go before the quitting bell rang.

hmm......

Split the outside face chopping a couple of mortises. I let them cook while I chopped the mortises on the other rail.

almost done

It would seem that my calibrated eyeballing needs a reset. Two of the mortises were not deep enough. Fixed them and made them a few frog hairs deeper than 3/8".

done

Got the wide center rail fitted into the top rail. The next batter in the rotation is slat #1.

planer snipe gone

Three of the legs had some snipe and I planed it off. This was the 3rd and last one to be done. All of the snipe was placed on the outside faces.

yikes

How did this happen? Missing a big chunk at the top of the mortise. It won't effect the rail tenon to mortise connection. However, I will fill in the missing chunk and I'll probably use epoxy due to the shape and location.

fitted

I will do this after I glue up the desk.

sigh

I would have bet a lung that I had double, triple checked this but something wandered out into La La Land. I really wanted this to face the inside but it ain't so boys and girls. I'll be filling this in with epoxy and black pigment dye.

it was almost lunch time

Went dead in the water here. I needed to dry fit/clamp the base so I could measure for the length of the back rail slats. I had planed both of the back rail edges so I knew they wouldn't be the same length as the side ones. It took 6 shavings to clean/smooth the top rail edge and 5 on the bottom one. I had to give this rail at least an hour to cook before unclamping it.

5 extras for any oops

Picked through the remaining slats and got lucky. I was able to get 16 slats that had straight vertical grain. The center wide rail has cathedral grain.

this is finally toast

Been well over a week since I mixed this batch and I can say it is now toast. It is still liquid and there was a lot of settling at the bottom. It was mixing in but it smelled like a sewer hole.

hmm.......

Clamped it enough to get a measurement for the back rail slats. They were a 1/8" less than the side rails.

the back bottom rail

Checked the depth of all the mortises and 3 were too shallow. I didn't want this surprise to shake hands with me when it was being glued up.

hmm......

Should have thought of this when I did the side rail slats. Ganged and clamped 8 slats at once and planed a chamfer on the four edges. A bit of a PITA but it did work. The slats slipped by some while planing and the first 2-3 on the plane lead in did not develop the chamfer like the others. I had to go back and give them special attention.

sigh

I shouldn't be griping about this but gaps make me go postal and nutso at the same time. These 4 gaps -slats 1 to 3 and 6- I'll fill in with cherry veneer when I glue them up. Not that bad considering I had to chop 70 mortises.

looks good

Sneak peek on the dry fit with all the slats fitted and shaking hands.

side view

Thinking about chopping four more mortises to decrease the space on the sides. I'll have to see how difficult it will be to layout them out to match the others.

sneak peek with the top on

This will be a good student desk for Miles (Leo will get one too). Initially I was going to put 2 vertical drawers on the right side but nixed it. I don't have that feature on mine and I don't miss it nor do I feel a need for it.

another head scratcher

The top of the desk is square within less than a 16th. The bottom is out square almost a 1/2". I thought the legs at the front not having a bottom rail was the cause. Not so, the measurement between the legs at the bottom of the top rail and bottom of the legs was dead on the same. Could be twisted but the desk isn't rocking at all. I'll play this some more in the AM. Killed the lights and headed topside here.

accidental woodworker

maintenance pit stop

These are still sharp but they needed a touch up to chop these remaining mortises. Cherry is harder than pine and wears the chisels down quicker.

hmm......

The chisel blade is too short to be used in the LN honing guide. With it in the guide, it is over an inch short of reaching the 25° angle setting.

nope

I surely thought that this guide would work but it ain't so boys and girls. The chisel blade isn't that thick and the screw hold down is a more than a 1/4" from touching it.

nope again

Same problem with this one as I had with the LN guide. The chisel blade is too short to reach the 25° angle setting.

didn't want to

Had to sharpen the 1/4" chisel by hand. It had a small chip at the toe and it wasn't square. Started on the 120 grit runway to remove the chip, square the edge, and raise a burr. The bevel doesn't have the same consistent shine as the bevels on the other two chisels. It is sharp and ready to chop regardless.

one down, one more to go

Got this one done just before quitting time. I had expected to get both done today but it didn't happen. Feeling a wee bit out sorts. No aches or fever, just a blah feeling. That translated into a lowered work output.

3 down, 14 to go

I was able to whack out 3 on the last rail before the quitting bell rang.

hmm......

Noticed a hump there when I slid the mallet across the bench. I think the last time I planed the bench was about 6-7 years ago. It is due for a clean up plane job.

hmm......

The jack wasn't cleaning up much. I got just as much new wood peeking out with the #80. I'll finish this up in the AM.

accidental woodworker

ready to go

Changed my mind on the installation of the slats. I'm going to do the two sides first, get them glued and cooked, while I work on the back slats.

last one

Last slat fitted in the last mortise for the bottom rail. Wash, rinse, and repeat for the  top rail.

first dry fit

The only hairy part of this is fitting the slats into both rails. It wasn't that bad and there wasn't even the smallest hint anything would get flying lessons. I had to do this one more time (for each side) when I glued it up.

hmm.......

Before I installed the slats I had dry fitted the rails again and checked the diagonals to get the measurements. Dry fitted again with the slats and the diagonals were off over a 1/4". It took a wee bit of effort with a 4 foot clamp pulling the long diagonal before I got them to agree with what I had without the slats.

2nd side slat installation

First step was to plane a chamfer on all four edges. After that I took two shavings off all edges and progressed from that until the slat fit snugly.

2 dry fitted sides

Looking at the two sides dry fitted, I think I should have gone with two more slats. The gap between the legs and the outside slats is almost 4".

glued and cooking

Got both sides glued and I'll let them cook until tomorrow. Survived both glue ups without any hiccups.

left turn

Changed my mind on using walnut for the center wide slat on the back rails. I sawed off a length to get the slat from. I don't have enough cherry in my stash to make another desk so being miserly with it doesn't matter. I'll use the rest of this board to make the slats for Leo's desk.

2" wide slat stock

The plan was to get the 2" slat from board where the knot was. It doesn't go through all the way through the board.

made a story pole

There are 17 slats on the back rails. One 2" wide (actually 1 7/8") centered R/L and 16 3/4" wide slats. The gap between the last slat and the leg is around 2 1/2" wide. Made a story pole to transfer the layout from one rail to the other.

success

I double, triple checked myself on this layout a bazillion times. I got it right this time or at least I think it was right the four times I checked myself. I'll chop these mortises starting in the AM.

accidental woodworker

almost

Got all the mortises chopped for the slats. Slats are cleaned and smoothed on all four edges. They will be individually fitted to their specific mortise. I'll do all three sets of them at one time.

dead nuts

Both diagonals said hello with 37 7/16". The other side came in with the exact diagonals. 

numbered

I numbered the bottom of each of the nine slats and the inside wall of the top/bottom rail mortises. I resisted the urge to get the slats installed on this but I'll wait.

sigh

Another brain fart. I started the mortises on the wrong edge, again. I didn't want to flip it and do the mortises on the top. These mortises would be visible on the underside of the rail - it is the bottom one. You would have to flip the desk over or get on the floor to look at them. 

I was able to flip it 180 and switch which tenon went into the legs. No haunches to worry about as there are none on the bottom rails. I had to take a few shavings on one of the tenons to get it to fit - it was too snug.

the correction

I did have to plane a bevel on the opposite face so the two rails will have space in the mortises where they meet.

I have one more rail to chop mortises in and the sides will be done. I am making a change to the back slats. I'm going to put one 2" wide slat centered on the rail L/R. I am leaning towards using walnut for it. I really don't want to use any of the cherry stash I have left to get one slat from. 

Didn't get a PM session today. My PCP called and said there was a cancellation and I was able to get my echocardiogram done at 1400. I had a student from the local community college do it. She did pretty good with most of it and had to hand it off to the tech for one portion of the test. It took a wee bit longer than having a tech do it but we all have to learn how. No problem with that because when you're retired time isn't a big deal, at least not with me.

accidental woodworker