wizer
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- 3 Mar 2005
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Well after MikeG's recent comments, I thought I'd better do something other than buy tools.
I wasn't going to take WIP pics on this but after the disasterwith the handle, I thought I'd give it a go. The progress starts half way through, after the box was completed. It was dovetailed on the Leigh Jig.
So after the handles cracked I decided to re-make rather than repair. First I planed up some ash:
15mm will do:
Then mark the handles onto the ash using the template. The template was printed from the SU plan on a plotter then stuck to some 18mm MDF, bandsawn and then cleaned up with bobbin sander, spokes, and sand paper.
The bottom angle was cut on the SCMS.
I then roughed out the shape on the bandsaw. I mean rough too, I need to really practice my bandsaw skills
I then stuck the template to the ash using double sided tape, making sure there was an even amount of material all around to remove. This is the first time I have template routed since my finger incident, I was a little nervous, but I was armed with a bit more knowledge this time. Although I didn't use a guard, I used paddles and steered well clear of endgrain.
This meant that I had to do some work on the ends of the handles.
Not a problem on the bobbin sander.
A bit of final finenessing was called for and I reached for the Boggs spoke shaves. I love these things. I had to stop myself from going to far with them.
Oh, forgot to say earlier that the 2 handles where stuck together with double sided tape, so when finished shaping, both where identical.
Then I grabbed the LV LAS to clean up the faces and remove any sticky stuff left by the tape.
I decided to drill and plug the handle to the box, so I went on to mark out and drill the holes.
I then marked out for the round mortice.
Then set the depth for the 24mm forstner bit and drill away
Lovely
Then the dowel was trimmed to size on the TS
I then set the dowel on top of the vice so that I could turn it.
and then used the palm sander to taper the end slightly
Check for length
After all this was done I thought it was best to get a finish on it before fixing the handles to the box. I couldn't make my mind up on a finish, in the end I went for Danish Oil, but it darkened the ash more than I liked.
It then occurred to me that I had to fit the plugs, so the handles needed to be fitted to complete the finishing. I clamped the handles to the box and then screwed. The dowel went into the mortice without any problems and was a nice snug fit without the need for glue.
Look Ma, No Cracks
I cut some plug in some scrap ash, glued them in and trimmed back using a Lidl pullsaw
Sand flush
Then I remembered that Osmo Poly X existed, I'd used it on my work bench and was impressed with the finish and ease of use. So I ordered some from Rutlands. I applied it with a foam brush, left for about 10-20mins and rubbed off with a cloth.
A couple of coats later and we have the finished article.
Wow, didn't realise I'd taken so many pics. If you're still awake...
I like the finished result. Ok, so you can buy these for a fraction of what it cost me in time and money. But I enjoyed it and learned a lot.
Now, can I get back to buying tools please?? :lol:
I wasn't going to take WIP pics on this but after the disasterwith the handle, I thought I'd give it a go. The progress starts half way through, after the box was completed. It was dovetailed on the Leigh Jig.
So after the handles cracked I decided to re-make rather than repair. First I planed up some ash:
15mm will do:
Then mark the handles onto the ash using the template. The template was printed from the SU plan on a plotter then stuck to some 18mm MDF, bandsawn and then cleaned up with bobbin sander, spokes, and sand paper.
The bottom angle was cut on the SCMS.
I then roughed out the shape on the bandsaw. I mean rough too, I need to really practice my bandsaw skills
I then stuck the template to the ash using double sided tape, making sure there was an even amount of material all around to remove. This is the first time I have template routed since my finger incident, I was a little nervous, but I was armed with a bit more knowledge this time. Although I didn't use a guard, I used paddles and steered well clear of endgrain.
This meant that I had to do some work on the ends of the handles.
Not a problem on the bobbin sander.
A bit of final finenessing was called for and I reached for the Boggs spoke shaves. I love these things. I had to stop myself from going to far with them.
Oh, forgot to say earlier that the 2 handles where stuck together with double sided tape, so when finished shaping, both where identical.
Then I grabbed the LV LAS to clean up the faces and remove any sticky stuff left by the tape.
I decided to drill and plug the handle to the box, so I went on to mark out and drill the holes.
I then marked out for the round mortice.
Then set the depth for the 24mm forstner bit and drill away
Lovely
Then the dowel was trimmed to size on the TS
I then set the dowel on top of the vice so that I could turn it.
and then used the palm sander to taper the end slightly
Check for length
After all this was done I thought it was best to get a finish on it before fixing the handles to the box. I couldn't make my mind up on a finish, in the end I went for Danish Oil, but it darkened the ash more than I liked.
It then occurred to me that I had to fit the plugs, so the handles needed to be fitted to complete the finishing. I clamped the handles to the box and then screwed. The dowel went into the mortice without any problems and was a nice snug fit without the need for glue.
Look Ma, No Cracks
I cut some plug in some scrap ash, glued them in and trimmed back using a Lidl pullsaw
Sand flush
Then I remembered that Osmo Poly X existed, I'd used it on my work bench and was impressed with the finish and ease of use. So I ordered some from Rutlands. I applied it with a foam brush, left for about 10-20mins and rubbed off with a cloth.
A couple of coats later and we have the finished article.
Wow, didn't realise I'd taken so many pics. If you're still awake...
I like the finished result. Ok, so you can buy these for a fraction of what it cost me in time and money. But I enjoyed it and learned a lot.
Now, can I get back to buying tools please?? :lol:
