Stouffville, Ontario Canada (647) 962-1997 gwstudios@rogers.com M-F 8:30am - 2:30pm & 8:00pm - 11:00pm

Day: June 22, 2022

Throw Back To: Episode of when I took two plus years to build a screen door.

greatwallstudiosLeave a Comment on Throw Back To: Episode of when I took two plus years to build a screen door.

It all started when I was gifted some Ash boards from the family farm, that were rough sawn, and stored in a shed for twenty plus years. I gladly took them home after sawing the sixteen footers in half by hand, and tossing those heavy suckers in my van.

I planed them for what felt like hours, and then had to man handle them across my jointer. Which took forever to do. This was back when I had my tiny 10″ Ryobi table saw, which kicked on full tilt, and scared me to death. Cutting 2 inch thick ash boards that were 80 plus inches in length took some doing, and set my heart to pounding. I settled on four inch wide boards by roughly eighty inches long, and two inches thick.

I then cut down four cross members, two in Ash, and two in a douglas fir that was pretty heavily knotted. It was at this point that I began to run out of warm season, and all my flat, square milled lumber got shut away in the garage for seven months.

The following spring I dug out my lumber, which was still square and decided to hand cut some mortises for the top and bottom of the door uprights. I first used a circular saw to cut two slices through the end grain about four inches deep. This was super sketchy, and my super old school, under powered Kawasaki circular saw died after a cut & a half – twice. So I finished it off with a Stanley hand saw. You know the old kind that weirdos play with a violin bow to make high pitched whiney muzak. I had to climb up on my work bench in order to get this to work.

I gathered up my chisels and a hammer and got dug in cutting away the channel where the cross members would rest. This would prove a difficult and arduous task. It took several days, and my channel was not straight, nor were they even. I took a file to them, and worked that for a few days too. It was at this point that I started to refinish a rocking chair for my very pregnant sister in law, and that took my whole season.

The following year ( this year 2022) I took some rasps to my channels, and evened them out a fair bit. I then used a brand new Dado blade to cut some even tenons for the cross members. It was an endless cycle of dry fit testing, rasping, filing, and planing until I had a suitable snug fit. Then I measured out my center line, and cut out two mortises for the third, and final center cross member. I hugged it out with a forstner bit, then used a multi tool to cut through the rest, and then hand chiseled it to a clear rectangular hole. It worked quite well. After assembling it all as a dry fit, I noticed my angles were all wonky, and then realized my flat, square lumber, was now bowed, and twisting ever so noticeably. But as I was about to begin sanding I hit the most egregious spots with a hand plane, and sort of made the best of it.

I took the time to glue the frame together. Then in each corner I drilled out a 3/8ths hole and glued some dowels through the joints. Flush cut those, and then did endless rounds up through the grits on every single surface of the door. I stopped to add copious amounts of filler, which meant no more natural wood look, but I was now going to have to paint it all white, to match the house trim.

I used an oil based primer to paint on four coats of pristine paint. Then I cut down some Cedar strips, 16 lengths in all, which would sandwich my screen mesh in place, for the two openings on my screen door. After much cutting and sanding i put the first layer in place. Cutting the mesh material was far simpler than i was imagining it would be. So i put those in place, and pin nailed my last strips on, holding the mesh as tight as i could get it.

It was at this point I placed my hardware on the door. Pilot drilling holes for the handle and a push plate. I also then hand cut in my hinge recesses. Drilled and attached those. Fought with the door for an afternoon to cut in the receiving hinge slots on the house, and hung the door single handedly (do not reccomend). I then added backing trim to stop the door swinging too far inwards and binding. Added a latch, and an extra handle, and Bob’s your uncle. Done like dinner.

I didn’t take any photos while cutting the cross member tenons, but they’re there, and I did them myself.

That End Table episode we’re all talking about.

greatwallstudiosLeave a Comment on That End Table episode we’re all talking about.

This time around I thought I’d go a little bit fancy. Which is, or course, a relative term. To me that meant attempting repeatable tapered Hickory legs. Which required me to build a whole new jig/sled to accomplish exactly that. And would you look at that it worked. I was duly impressed with myself.

Then I cut down my skirting, and added a relief to the underside, which recieved a round over, to soften it up a bit. Followed by setting up the dado blade as fat as it’ll go, and cutting the slots for said skirting, and adding the .75″ long tenons to the end of each leg.

I rounded over all four faces to each leg, and did a test fit of the skirting. Wouldn’t you know, three of the four were spot on, and the first was a touch loose. Not a big deal. I can manage.

The glue up of the three Walnut boards to make one large panel was mostly uneventful. I had to joint a bunch of complementary edges, and RIP off the bark, or ruined portions. Use thirteen clamps to wrestle the twist out of the boards. Scrape the excess glue off, and then move through a series of hand planers, and my Bosch electric hand planer to even out the end product. I also took my card scraper for a spin to get a better starting surface once I complete the structural elements and begin the sanding process.

I saw a tutorial somewhere that said for tighter outside edges on a mitered box, you should over shoot 45°, for something like 44.8°. But my table saw doesn’t do that, perhaps a higher priced Cabinet saw would, but mine does not. So a straight 45 it was. Praying for no slips or binding against the fence. We will only know during the glue up.

I used a 1″ forstner bit to hog out the bulk of my mortises. I had intended to chisel out the rest, but I cracked an edge, so had to pause to blow glue into it, and reclamp it. Switched over to a coping saw to save any undue stress on the base piece of Walnut.

I will progress through, 60 / 80 / 100/ 120/ 150 / 220 / 320 grits with an random oribtal sander. Then after I glue up and I need to do touch ups, the very top most surface with get a hand sanding at 400 grit.

After assembly of the hollow top, I will cut in eight (8) splines on all four corners, to add some visual interest. Then round it all over to look a bit cleaner. The tenons of the legs are through & throughs on the base. So a pocket of colour should be seen when you get up close to it. Not finished yet, but you get the gist of it.

Fan-tabulous wet bulb Wed-Nes-Day!

greatwallstudiosLeave a Comment on Fan-tabulous wet bulb Wed-Nes-Day!

Going to be a hot, wet & humid day on the books today. A real damp in the wool, sweater of a day. Dribbles and rivulets of stinky stuff down your back, collecting in your socks kind of a day. Have mercy!

Looks as though I’ll be working on my end table today, which is cool. I sorted out a tapered jig yesterday, which allowed me to safely make repeatable cuts on the table saw. Which is nice! Going to do some more structural building today. I like the idea of keeping everything in pieces for sanding, and then doing the glue up in stages to try to correct for any errors I’ve made. It’s not fast, but it yields better end results. A Win-win for yours truly.

After I get through this Walnut end table, I’m going to go on hiatus until September, as I’ll have the kids around, and my report building schedule will pick up a bit. Doesn’t look as though it’ll be peak 2018 numbers, but better than last year, if I’m lucky.

My random post from before is still getting random likes from people/bots that didn’t read it. Which is weird. Lots of Crypto Bro types, or bots from those sorts of people. But as they say, it’s doing numbers. Just not authentic human engagement. But it’s doing numbers!