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Posted

With limited weekend entertainment options available, I embarked on another mini-project.

image.png.126279ab0f8f2fda366a82f30654d78d.png

Modelled up a simple design, based on 25mm thick oak veneered ply, mitres and peanut connectors.

 

image.png.0764f2fbd59c9cddd1659d07004e3718.png

Brought the ply sheets into the study to do the set-out of the parts.

 

image.png.e25c183c4f9caf65226139e0b9dc3271.png

image.png.210896c0d2f19ff9eeef41e0737fec5d.png

Cutting on the straight set-out lines, perfect job for the track saw. Curves cut roughly with the jigsaw.

 

image.png.96f451116de2770f44297d48b400d714.png

image.png.d68471fdf2cb9b21b642fc109c229276.png

Knocked templates for the various curves, out of 6mm MDF, and routed with a pattern bit.

 

image.png.244541377b4b653767e53130df75f0e3.png

Flipped the router upside down to create a make-shift router table for routing curves on smaller pieces,

After cutting the Peanuts, chamfering some bevels, adding some round-overs, sanding and dry fitting. It was time to do the glue up.

image.png.40cce8647961342718102d59af2b63cb.png

image.png.acf1151050e314130ec8bb282c5c7e68.png

image.png.e2e7d084c4b227af2dea33dea0122e5d.png

 

Next steps are to is to burl the mitres closed and add finish and rubber feet. Then hopefully it'll hold 2-3 adults ????

Posted
11 hours ago, patches said:

With limited weekend entertainment options available, I embarked on another mini-project.

image.png.126279ab0f8f2fda366a82f30654d78d.png

Modelled up a simple design, based on 25mm thick oak veneered ply, mitres and peanut connectors.

 

image.png.0764f2fbd59c9cddd1659d07004e3718.png

Brought the ply sheets into the study to do the set-out of the parts.

 

image.png.e25c183c4f9caf65226139e0b9dc3271.png

image.png.210896c0d2f19ff9eeef41e0737fec5d.png

Cutting on the straight set-out lines, perfect job for the track saw. Curves cut roughly with the jigsaw.

 

image.png.96f451116de2770f44297d48b400d714.png

image.png.d68471fdf2cb9b21b642fc109c229276.png

Knocked templates for the various curves, out of 6mm MDF, and routed with a pattern bit.

 

image.png.244541377b4b653767e53130df75f0e3.png

Flipped the router upside down to create a make-shift router table for routing curves on smaller pieces,

After cutting the Peanuts, chamfering some bevels, adding some round-overs, sanding and dry fitting. It was time to do the glue up.

image.png.40cce8647961342718102d59af2b63cb.png

image.png.acf1151050e314130ec8bb282c5c7e68.png

image.png.e2e7d084c4b227af2dea33dea0122e5d.png

 

Next steps are to is to burl the mitres closed and add finish and rubber feet. Then hopefully it'll hold 2-3 adults ????

great job Patches!

Consider more bevel on that top, so it looks much slimmer?

Posted
9 hours ago, Capricorn said:

great job Patches!

Consider more bevel on that top, so it looks much slimmer?

Yeah I did initially plan a bigger bevel, perhaps at a shallower angle too, but that would require a specialist router bit.

The bench top is only 350mm wide and, with the base being 300mm. So a 20mm chamfer only leaves a 5mm reveal on the underside. Think I'm currently at 15mm.

I may push it another few mm.

Posted
2 minutes ago, patches said:

Yeah I did initially plan a bigger bevel, perhaps at a shallower angle too, but that would require a specialist router bit.

The bench top is only 350mm wide and, with the base being 300mm. So a 20mm chamfer only leaves a 5mm reveal on the underside. Think I'm currently at 15mm.

I may push it another few mm.

Hand plane?
Maybe a jig that guides the router at the required angle, Lengthwise for the straight bits. Much like flattening sled.
Then finish off with sander/handplane for the corners.

Posted (edited)
19 hours ago, Capricorn said:

great job Patches!

Consider more bevel on that top, so it looks much slimmer?

Yeah, your shins will thank you for that later.....

Very nice work. I know you were complaining about lumber shortages, is that sorted now? How much material wastage is there on something like that?

Edited by Steven Knoetze (sk27)
Posted (edited)
On 11/2/2021 at 8:06 AM, Capricorn said:

Hand plane?
Maybe a jig that guides the router at the required angle, Lengthwise for the straight bits. Much like flattening sled.
Then finish off with sander/handplane for the corners.

Ummm... I don't know how to admit this, but despite my apparent addition to arming my weeked-warrior self with all manner of tools, a hand-plane has yet to find its way into my garage ???? hahaha

It's not that I'm anti them, I'm just more easily distracted by things that go whirrr and buzzz, hahaha. But yeah, at the very least I have a block plane and jack plane on my procurement list.

@carrera4s undoubtedly has some sage advice on handplane essentials uses etc.

Also, having almost no handplane experience (apart from as a kid when my father told me never to store them sole down, which I believe is now a myth), how well do they perform on ply? I have heard that planes and end-grain don't always like each other and every alternate layer of the play would be end-grain.

As for angling the router, by little Makita trim router has an angled base, but I fear I would either stuff it up relying solely on that, or the creation of a fool-proof jig would be so time consuming I may as well but a dedicated bit like this:

image.png.5e6e3087e456fcd760186a9f003829c7.png

 Another option (if I didn't have the rounded corners) would be a simple table saw jig to safely cut boards in the vertical. Chris Salamone does this faily often. Something like this.

Table Saw Tricks For Making Vertical Cuts | Woodsmith

Something to try on the next one!

 

14 hours ago, Steven Knoetze (sk27) said:

Yeah, your shins will thank you for that later.....

Very nice work. I know you were complaining about lumber shortages, is that sorted now? How much material wastage is there on something like that?

Thanks!

As for timber shortages, they're still an issue, but it's mostly construction lumber. This project was made from off-the-shelf "decorative" ply. The kinda stuff the big hardware stores sell for people to attach make shelves out of or attach some table legs to.

As for wastage, it wasn't too bad. I uses 2 sheets of 2200L x 600W x 25 thick oak veneered ply (@ $80 each). I laid out the cutting in AutoCAD first and got the top on 1 sheet with some usable-sized off-cuts and all base pieces out of the other sheet.

image.png.30b9d7ad1ae36b9d1e2a6ca7f71df5e9.png

So $160 (excluding fasteners, finish and time) for a 1800mm long bench, is not too bad... provided it doesn't fall apart, haha!

Edited by patches
Posted

It's been a long time since I posted any of my projects here, but this one was special to me and the people it went to.

I volunteered to make an urn for friends recently deceased dad. Pai to kids Mr. Machado to all of us around him, a gentlemen and life long mariner. In 1986 when his wife passed away he constructed an urn from teak and for her with hearwood inlay. 

I decided to do the reverse of that with a Yellowwood with Imbuia inlay as a contrasting effect. Everything handmade except for the inlay groove which I used my palmrouter for...

Splitting the raw plank and glueing up the panels for the top and bottom

IMG_8060.JPG

IMG_8062.JPG

Posted
14 hours ago, patches said:

Ummm... I don't know how to admit this, but despite my apparent addition to arming my weeked-warrior self with all manner of tools, a hand-plane has yet to find its way into my garage ???? hahaha

It's not that I'm anti them, I'm just more easily distracted by things that go whirrr and buzzz, hahaha. But yeah, at the very least I have a block plane and jack plane on my procurement list.

@carrera4s undoubtedly has some sage advice on handplane essentials uses etc.

Also, having almost no handplane experience (apart from as a kid when my father told me never to store them sole down, which I believe is now a myth), how well do they perform on ply? I have heard that planes and end-grain don't always like each other and every alternate layer of the play would be end-grain.

As for angling the router, by little Makita trim router has an angled base, but I fear I would either stuff it up relying solely on that, or the creation of a fool-proof jig would be so time consuming I may as well but a dedicated bit like this:

image.png.5e6e3087e456fcd760186a9f003829c7.png

 Another option (if I didn't have the rounded corners) would be a simple table saw jig to safely cut boards in the vertical. Chris Salamone does this faily often. Something like this.

Table Saw Tricks For Making Vertical Cuts | Woodsmith

Something to try on the next one!

 

Thanks!

As for timber shortages, they're still an issue, but it's mostly construction lumber. This project was made from off-the-shelf "decorative" ply. The kinda stuff the big hardware stores sell for people to attach make shelves out of or attach some table legs to.

As for wastage, it wasn't too bad. I uses 2 sheets of 2200L x 600W x 25 thick oak veneered ply (@ $80 each). I laid out the cutting in AutoCAD first and got the top on 1 sheet with some usable-sized off-cuts and all base pieces out of the other sheet.

image.png.30b9d7ad1ae36b9d1e2a6ca7f71df5e9.png

So $160 (excluding fasteners, finish and time) for a 1800mm long bench, is not too bad... provided it doesn't fall apart, haha!

 

Nicely done Patches!

Jip, a jack plane and a block plane is a good start.  But you need a solid bench, else your bench will just shake around... My "Festool"  MFTC was way too rickety when I tried using a hand plane on it.  And also too high.

Yes, they do not like plywood that much, but you will just have to sharpen a bit sooner than normal. 

Posted (edited)
On 11/3/2021 at 11:33 PM, carrera4s said:

 

Nicely done Patches!

Jip, a jack plane and a block plane is a good start.  But you need a solid bench, else your bench will just shake around... My "Festool"  MFTC was way too rickety when I tried using a hand plane on it.  And also too high.

Yes, they do not like plywood that much, but you will just have to sharpen a bit sooner than normal. 

Yeah, the portable little Bora Centipede bench I have does not like lateral movement at all. Even sanding and routing have it shifting slightly.

I did recently come into possession of an older Festool MFT (funny story in and of itself which I will share below), although the MFT will be a step up from the Bora, I have heard they are pretty shifty.

Whilst it won't quite be a roubo and nearly not as elegant as your creations, I do plan on building the MFT into more of a workstation/cart to store systainers, shop vac, etc below. Something like this, but with my own take on the functionality based on my tools and needs.

Multi-Function Mobile Cart For Festool MFT - The Wood Whisperer

Folding up the spindly legs with stop blocks under MFT to prevent shifting, and getting some decent stopping for the base (maybe more of the Rockler type wheels that lift up, as opposed to locking casters).

I thought of making it a height that allows for the MFT to be half propped off the side if one needs more workspace. The lower section should offer a more comfortable height for hand-tool operations.

Expandable (Triple Wide) Mobile Compact MFT3 Cart

I've heard the rough guideline for benches is something like:

Handtools: level with knuckles/mid fingers, when standing with arms at side

Powertools: level with wrists, when standing with arms at side

I also plan to get a new MFT top CNC'd out of Valchromat (fancy colourful MDF), as the one on my MFT has seen better days and the dog holes are a little loose.

I'm working on a design that allows for angles from 0-100deg  (from either side of the bench) in 1 degree increments by either angling the rail in 5 degree increments (magenta holes), finer tuning by angling work piece from 1-4deg (cyan holes) or super fine tuning by using the slots and a locking type dog.

image.png.2063bdc690a4968c9c69285625897ba8.png

 

So, as for how I came into an MFT by mistake...

There was an MFT 1080 (bench only) on $1 reserve auction. I often add things like that to my watch-list, out of curiosity. I barely ever buy. Anyway, the app sends a notification 5min before the auction closes. I was on the "thinking-seat" when the notification came through, and somehow between trying to unlock my phone by pin code because the face recognition was having hick-ups, then the face recognition kicking in and me accidentally clicking on the "BID" for the app and raised the previous bid by the min ($5), I suddenly found myself winning the auction. (true story, not just the one I tell my wife).

Bids are legally binding and cannot be retracted without the seller's involvement. For the next 5min I was sweating bullets, hoping the other bidders would come to the party and beat me. To my dismay they did not, and I left the think-tank with a slightly sick feeling.

Anyway, over the next day or so I looked for opportunities to turn my buyers-remorse into excitement, and I think my mishap was actually a blessing in disguise ????

Edited by patches

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