AmateurWoodWorker – Page 2 – Greatwall Studios Graphic Design

That End Table episode we’re all talking about.

June 22, 2022June 22, 2022greatwallstudiosLeave a Comment

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.

Just gonna squeak one in here on ya, if’n you don’t mind.

June 20, 2022June 20, 2022greatwallstudiosLeave a Comment

Had a brain wave the other day about building a walnut side table that was hollow, but could accept the floating bottom walnut drawer I had made a few months ago. Make it tall, on thin Hickory legs, do a thicker walnut skirt, and try a tapered edge on the legs. Round it all over, and then see how close i got to my plans. I’ll draw it out first, and then see if i was actually able to pull it off. That should give me a sense of where i am making my mistakes. I also need to finish by June 30th, before 11:00am, as that’s when schools out for the summer. Pushing against a dead line, and following a plan. Could be fun. But i have a report coming late this week, so that’ll cut into my time significantly. Chop chop, quite literally.

So I have cut up four Hickory legs, the last substantial portion of my slabs. I milled and cut up some rough walnut, and have glued up a single four foot long panel, which will be chopped down into my hollow top. I cut two inch strips for skirting too. I need to figure out a jig for careful, and repeatable tapered legs. Dado out my leg slots to hold the skirting on. I’ll keep the legs poking up above it, to tenon into the hollow top. Then it’ll be round overs on round overs, and sanding until my hands go numb. A quick and easy project.

Walnut skirting and the as of yet un tapered Hickory legs. Followed by a four foot long walnut panel glue up. Didn’t skimp on the clamps this time around.

Here’s how my other table build turned out. Doesn’t look too out of place in the basement. Good height for the sofa that’s there anyway.

The Ninja Turtle is progressing. I like the Apoxie Sculpt, a tad sticky though. But fast to work with. I may still end up detailing it out with Super Sculpey, but for now I’m enjoying the process with Apoxie Sculpt. This could potentially sit for months if need be before I come back to it. I’ll focus primarily on the furniture build, as that can warp, buckle and twist if I don’t build it sooner rather than later. Learned that lesson the hard way with my screen door.

Today is domestic duties Monday, so I need to get the second load of laundry in, run the dish washer, vacuum and tidy up a bit today. I’ll need to sort and hang the laundry too. I hear the temperature is on the rise through this week. Going to feel like 40 °C for several days in a row. Yikes. Also need to get rolling on my youngest child’s birthday party later this week. Busy – busy. Ciao Bella!

The Coffee Table Build Episode.

June 18, 2022June 18, 2022greatwallstudiosLeave a Comment

The one that started out being about turning two book matched Hickory slabs into one monolithic water fall edged table, with a fat & chunky Ash leg on the opposite end. Then I pulled the slabs out from storage and the small one was perfect, and the show piece was cracked in three so badly it snapped in my hands. So new idea. A smaller coffee table using one live edge slab as the top, and the broken pieces of the other as the legs. Then I hated the live edge aspect, and cut it down into a more traditional rectangle. Chopped the Ash chunk into four legs, and decided it was a boring blob of a thing. So I cut skirting, and then I thought, what if I use a Dado to inset the skirting on the interior side of all four legs. After that I figured I should add a drawer that was shallow, and use the skirting to hold up and slide the drawer out, rather than metal drawer slides. Much cheaper option too. Then I thought, well the drawer is so shallow I could build a slatted shelf about 6″ up from the bottom of the legs. I looked at my available raw materials and saw I had to go front to back with six slats rather than across the width. I was hoping to make it look and feel longer by running the open slats across the longer axis, but materials dictated I go otherwise. Not angry. My last vestiges of doubt were on just doing a clear coat vs staining with Danish Oil with a Walnut Tint. I don’t like the bleached look of Ash, so tinted stain we go! Now once all of this dries I will clear coat with a Varathane brand Diamond spray finish from a rattle can.

I did my glue up in stages to try to offset my amateur hand cut mortises. The tenons I did on the table saw, so I knew they were as good as I could get those. I hand chiseled out a few other odds and ends, but the bulk was done via circular saw on a track, and my Rigid 4512 Table saw. This was the first time I’ve ever used a bow tie to stop a crack. That took some doing, but I don’t hate the end result. I used a flush cut saw to trim off the bulk of the bow tie that sat proud of the table top. Finessed some other over hanging bits with the flush cut saw as well.

Come the fall, I would like to purchase either one long slab or two matching from the same species and actually try a waterfall edge coffee table. I opted for my electric hand planer, and manual hand planes to finish the top surface. I built a router jig out of angle iron to try to flatten the surface of my slabs, but I haven’t yet built the rails/ Saw horses it is meant to stack on top of. I have it ready for next time.

It’s not perfect by any way, shape or form, but I’m slowly getting better at whatever I’m playing at. Should look fine at the cottage or in the basement with my first ever coffee table build from years ago.

Table build progression from raw materials to stained end product. Clear coat finish not shown.

Back in the shop for a partial build day.

May 17, 2022May 17, 2022greatwallstudiosLeave a Comment

Yesterday I milled down all of the Cedar trim I would need to fill in the inside portion of my screen door. I cut a 1x6x8ft board down into eight .25 strips, and then trimmed those to be .75 inches wide by 8ft, by .25 inches thick. I pin nailed in the first layer. Now I have to cut up and staple in place the actual mesh material. Another big step forward. Makes me nervous. I have the second layer of trim cut and ready to sandwich in the mesh material. Fingers crossed I don’t screw this up, as I only have so much mesh to work with before I’d have to order & wait for more to arrive.

Once this goes in, I’ll affix the handle, and push plate. Then we are on to hinges, and hanging the heavy thing up in the door frame. Wish me luck! I’m going in.

Busy working on the screen door today.

May 5, 2022May 5, 2022greatwallstudiosLeave a Comment

I have (for me) what I would consider a reasonable dry fit for the outer frame of the screen door. It’ll need a wedge or two to fill gaps, but it holds up, and is somewhat square-ish. So I measured out the tenons and mortise for the center brace, marked them on blue tape, and used a forstner bit to hog out as much of the meat as I could. I used a multitool to cut straight lines through the center so I could hammer out some substantial chunks, and now I’m going at it with a mallet and chisel to clean back to my scores lines. Maybe I’ll try a dry fit of all five pieces today, or maybe not. Once I start to rush, this will collapse in on itself. So slow moving it is.

I have lots of trim I need to mill up to sandwich in the mesh, plus wedges for gaps to make. Then wood filler, sanding, rounding over edges. Glue up and then more sanding, then primer and paint. Plus hinges need to be cut out of one long side, and the door frame where it’ll all hang. Then I have to put the door stop inner frame up so it won’t swing inwards and wedge shut. Hooks, push plate, handles and all sorts of hardware has to be fitted to it too. I can see this going on for another week if I do it correctly. Which would be nice for a change.

Nearly done one full mortise. Needs a touch more clean up.

So in all, a good day today. Sunny and bright weather. I need to eat breakfast soonish though. Then on to illustrations for my book. I have six backgrounds left to go, and then character drawings to populate those backgrounds.

What a busy day it was, yesterday.

May 1, 2022May 1, 2022greatwallstudiosLeave a Comment

Took the kids for a two hour play at the Tree Top Trekking village, which they loved thoroughly, and I was able to participate and enjoy the obstacle course aswell, even masked up. Then we had a big group lunch where they played for another hour or so, all told it was four hours of fun from start to finish.

After a brief rest at home we finally got to meet our newest nephew outside, while masking up to protect the 7 day old newborn. Can’t be too careful! He’s a sleepy cutie pie, who didn’t make a sound. The kids were enthralled by him, though my youngest got bored of the baby lump action and went for an hour long trampoline jump-a-thon to stay busy in the warm and welcome sunshine.

I need to go do a smaller grocery shop in a few minutes, so I’ll cut this short. Much as I predicted, I have done nothing with my illustrated book this weekend. I did build an armature for my next sculpture. I finished off my other bust a day or two ago. Trying to bring the memory back to my hands. I think I’ll either do a ninja turtle in Super Sculpey or a Killer Croc bust. I have several clay ninja turtles, but nothing in ceramics, or polymer clay which you bake to harden. But I’ve never done a DC’s Killer Croc before. Might be fun to try something outside the usual for me.

I have made headway on my screen door build. I put the dado blades on my table saw for the first time, ever. And made the tenons for my three cross braces of the door. It’s a very tight press fit, so I’m shaving them down a touch so it won’t shatter or explode from the stress. I see a lot of wood filler, sanding, additional planing and painting in my future. I had hoped to stain the door, but my prowess with wood is low, so thick primer to cover my various failings it’ll be! Gotta love it. I’m glad I got over my fear of the dado blade set up. Cut like a hot knife through butter. Better than I’d have done with a hand saw or my tiny Skil bandsaw. Which is a glorified scroll saw at this point. Not good for anything more than .5″ thick hard woods. My doors are 2″ thick, and 4″ wide. So the Skil bandsaw isn’t really an option.

I will most likely need to mill up more thin strips to line the inside panels of the screen doors, so I can sandwich the stapled on mesh material. So I have a fair few steps left to go. Plus I still need to drill and chisel out the mortise for the center cross brace. But the tenons are shorter, so I don’t have as much to dig out, hopefully. I’m definitely going to need to pin the top and bottom braces in place with dowels to not have to rely solely on the press fit and glue holding. I have a handle, push plate, and hook latch to add after it’s all sanded & painted. Plus I’ll be cutting in the hinge plates to the side of the door, and the frame at the back out the house. Maybe a router jig would be better for that? Not too sure. I have weather stripping for the door to butt up against so it won’t swing inwards and get wedged in place. Good lord I hope this all works out. I’ve put a lot of time and effort into this door these last few years! Bah! At least at this point I’m spending time and not money on the project. Happy Lazy Sunday to you all.

One fine day… Saturday.

April 23, 2022greatwallstudiosLeave a Comment

Another week in the can, with a few brand spanking new physical wood projects to show for it. Fantastic! I love when things come together. Now if I could just focus that drive into my children’s book, I’d be all set to go. I’m trying to have fun with drawing again, and I have a lot to do, so it could take some time. I’m resisting going to the computer first, because I always wanted to illustrate a book by hand, and what better thing to do that with, than my own? Right?. So I will keep trying. It’s not like I have a publisher or editor waiting for my work, it being a hobby and all, so I should try to keep it light. But on the other hand it means something to me, so I want to put a lot of effort into it. Tough balancing act.

I managed to get a fair chunk further on my old fisherman bust sculpture, which is great news. Nothing boosts morale like some solid wins under the belt. Been a tad out of practice with sculpting lately as well. Have to build up my finger sensitivity and 3d spacial awareness. Takes a different kind of thinking to build out primary shapes and build a life like form. Hard to describe it, except you know very easily when it’s wrong. Lots of adding, subtracting, and pushing clay around to get the volume and shapes correct. Playing around with it in my palm until I’m happy with it. Same goes for drawings too. Could be a bit of a wait until I get it all where I want it to be. Should be all the better for it.

I originally wanted to edge the drive way and front lawn along the curb, but it is to rain for ten hours today, so that’ll be a tomorrow thing. Though we have a children’s birthday party to attend (masked, obviously). Which will eat up my morning. But if the suns out after lunch I can get some minor lawn care done. Perhaps tackle the lawn mower maintenance too. Who knows!

Things I’ve built recently. A 4ft long bench, a smaller 2ft Cedar toy box, an Ash cutting board plank, a 3ft Pine toy box, and a Walnut tray with floating inset plywood panel. It was a productive week in the shop. None of it is heirloom quality mind you. No fancy joinery. Just butt joints, miters and glue and Pin/Brad nails. Quick and easy. Plus various grits of sandpaper. I also busted out the palm router to round over edges, and my plunge router to add details to the large Pine toy box that now lives behind a couch under a windowsill.

Ugly bench made from scrap pressure treated wood.

So that was my week. With any luck in the next few weeks we will see the weather start to get warmer, and then the kids and I will start to walk to and from school every day. It really helps to tone down the hyperactivity when they have to walk everywhere. We do have to be prepared to leave 15 minutes earlier than normal, but if we don’t need boots, snowpants, scarves, hats, gloves, neck rings and toques, maybe we can manage it? Maybe?!?

Returning to my Children’s Book.

April 20, 2022greatwallstudiosLeave a Comment

Now that I most likely have all of Book Two completed, also known as 41 Chapters of The Ghost of the Dirty Starling, I may actually bother to rewrite my childrens story, and begin to illustrate it myself. Of course I might end up writing an epilogue to my interconnected space serial, which opens it up for more exploration, but we’ll see about that. I seem to need a break from it for now. That happened last time as well. I am astounded by authors who are able to create fresh new worlds and pump out glorious novel after glorious novel, year after year. My hat is off to you lot. That hurts my brain to think about. My childrens book is simple and short and features only two characters. I’ll need to come up with an appropriate look for them. One was based on our former dog, now he’s been dead for nearly a full calendar year. I hope that doesn’t make me weepy thinking about him. Hard to say.

The other major question is; do I bust out the pencils and ink, or draw it in illustrator? I could draw it up by hand, scan it and colour it in Photoshop. That would work pretty well for me. I think the simpler I keep it the more likely I am to follow through with it. Hell I wrote 50,000 extra words of a second novella rather than tackle it from December through April, so that might tell you how I feel about starting drawing/inking again.

I have a bust in the works in my office in Chavant soft. I hate the soft Clay’s. So sticky. Plus it deforms too easily as I handle the piece while I work it. Nothing like working hours on a nose or ear, to mash it the next day because you grabbed it with warm hands and forgot to watch out. I tend to use Hard wax/oil Clay’s to avoid just that scenario. Or I use Sculpey Firm and bake as I go, to avoid it too.

Today I build myself an Ash cutting board. I wanted to test out my 45 degree cutting jig, and see how the saw stacked up against 8/4 barn dried Ash. It burns, is what it does. My planer doesn’t care much for hard woods either. My new electric hand planer from Bosch was amazing though, so kudos to them on a find product. I also practiced my trim routing of round over edges. Cut in some 45 degree hand holds, and a through & through finger hole, about 2 inches in diameter. Then used my propane torch to burn the top surface and bring out the grain. Looks interesting. Sanded to 220 grit, and finished with a butcher block prep oil. Not great, but not awful. Works as a cutting surface.

About 24 inches long, 1.75 inches thick, and nearly 11 inches wide. Had a huge crack down one corner, which I cut off, as I don’t have epoxy to fill in the rather large gap. I chose to cut that corner off instead. It’s pretty heavy. I have it resting on a cookie drying rack as the oil penetrates the wood. Nice quick project.

A Cedar Toy Box: Just because I can.

April 15, 2022greatwallstudiosLeave a Comment

While I am waiting on parts to a report I decided to build my kids a cedar toy box, lined with burgundy felt, to store their new horde of LOL Dolls, and OMG Queen Surprise fashion dolls and their myriad accessories. I once again used only materials I had on hand, which meant I could built a 2ft long, 10 inch high box that was 7 inches wide along the sides. The base is made from half inch plywood, and I used spray adhesive to cover the top/bottom of the precision cut plywood base to stop marring our floors, and to cushion the blow from dropped toys into the box itself. I had thought about using box joints, or lap joints, or even miters. But in the end, to save time (as I’m waiting on parts to a project) I did butt joints, glue and Brad nails to lock it all in place. I sanded only to 100 grit, to removed the graying outer surface on the cedar boards, and to round off all the edges and corners. It’s functional, and currently resides under a window, behind the couch.

2ft W x 10″H x 7″ D. Lined with 2mm burgundy felt to cushion dropped toys, and save my old floors.

I need to take Wednesdays bench build down to the orchard at the farm, but my uncle in law has Covid, and I don’t want to bother them while they recuperate.

Holiday Friday today, so need to find things for the kids to do to not drive us crazy. We are also on baby watch for my SIL’s second child. Due date was yesterday, and she’s gone over. Now we wait for the good news, and potentially in a few days, see the new baby from afar! Weee!

Today’s Task: Build a rustic bench for the orchard.

April 13, 2022April 13, 2022greatwallstudiosLeave a Comment

Starting off with pressure treated wood, as it will sit out in the open for the foreseeable future, directly on grass, in mixed sunshine and shade. Doesn’t need to be a beautiful work of art, but should be sturdy enough for two adults or four squirmy kids at once.

I’m thinking a 36 to 48″ wide top, that’s at least 11 inches deep, and 2 inches thick. Four struts of about a foot in length/height, also 2 inches thick. And then braces cut at a forty five degree angle to support legs and top. Counter sunk holes and 3 or 4″ wood screws to pull it all together. Also means I can replace parts as they saturate or rot out over time.

Do I split the top bench to help water pour off, or leave it as one big plank? Decisions, decisions. I’m not going to lie, I think it’ll be ugly, but functional. To dress it up, I could round over all edges with the router. I could paint it? But it is pressure treated, so maybe no paint. Do I use mortise and tenon joinery or skip that to get it done sooner rather than later. We’ll see how busy the say gets before I decide.

**Due to work requirements I went for 3 inch wood screws and 45 degree braces only, no mortise or tenon joinery. I used pressure treated that I had on hand, but some of it had a twist, some had cups, and some were just ugly. So no beauty pageants, but it is sturdy as all get out, and should last a few seasons left out in the elements 24/7 – 365. And that’s all that matters. Plus I got it done in an hour or so, which is even better.

Ugly as sin bench, viewed from upside down.

Yesterday I even managed to finish my 45 Degree cross cut sled for my HP Trunk building operation. Nice to have a parallel surface to work off of, and a place to keep your hands safely away from the blade. Plus the sled means I can reliable make repeatable cuts without having to measure each time I make a cut. Or end up have to shave every piece down until I have too little left for what I was aiming for.

I have a couple of minor leather projects I’d like to do, mainly upgrading my shop apron, and adding some more functionality to it. Make getting it on and off easier, and keeping the shoulders where they need to be. Displacing the weight of the tools more evenly, and adding some quick connectors for tying it on me. If I had the money lying around I’d get one of those split legged Savage Industry aprons, but I don’t have $100 USD burning a hole in my pocket at the moment. Plus whatever the shipping is from San Fransisco to Ontario, Canada.

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