WIP : Tall Storage Unit

[billw]

Well here it is - my first attempt at putting pictures of my work on this site :shock:

A bit of background to this piece. I spotted the picture which inspired me on Fine Woodworking's website in the gallery and immediately got ideas above my station in trying to make a copy of it. At the time I was just coming to the end of my first piece, a shaker style table (see Ironballs' thread on his table, mine's like that except in maple and with "slightly" less talent involved) and needed to decide what to do next.

Being an accountant I actually did the design and measurements in Excel - yes it IS possible 8) - and from there drew up my cutting list.

I've now been working on the project since last autumn, albeit with some VERY slow progress. I do have some photos from the start, but the ones I have got on this thread were all taken on Monday and given my lack of progress it'spossible to see pretty much everything right back to the beginning!

So, here's what I've done to date.

1. The uprights. These are about 1900mm tall and 48x48 square. It was a bit of a challenge getting some walnut in the right size and then praying that it wouldn't warp! Getting them cut to size wasn't the hard bit - it was my absolute insistence that I did all the through mortices by hand. This took me weeks and weeks and weeks but I think it is worth it as the feeling of satisfaction when I tidied up the last one was fantastic.

2. The front and back rails. I've just got these cut to size at the moment, with the through tenons cut and fitted roughly.

3. The side rails. These are fitted in by tenons, the mortice of which cuts into the through tenon, hence they had to be tidied up once fitted to ensure they didn't interfere with the through tenons.

4. The panels. These are essentialyl just 10mm thick panels which fit into a groove on each side (and the rear, but I've not done those yet). They're not bookmatched but I have been relatively lucky in that the 4 pieces I cut all came from a 3" thick board (yes I know, a LOT of waste!) and therefore look, if I say so myself, pretty good now they're glued up in pairs and cut to size.

So, enough of the waffle. The next post is the photos.....

 

[billw]

Picture 1 - side panel 2 components

The sides are relatively simple. The panel (still with glue as it was barely dry) fits into a 6mm deep groove that was done by machine. The two rails fit into the uprights by way of tenon. The through tenons are obvious I guess :wink:

Picture 2 - dry fit of side panel 2

The top is nearest the front of this photo. It seems to fit well together. And yes, that is indeed a knothole bang in the middle of the side panel. I call it a feature

Picture 3 - dry fit again

This shows the panel the right way up. My next task is to finish off the planing and sanding then get it glued up.

Picture 4 - side panel 1

Yes that ugly bugger is indeed me. Note the classy tool carrying device I have. Oh and those are Stanley chisels

This is the first panel which is glued up and pretty much finished. I've had a few troubles with it - the glue holding the panel onto the top and bottom rails didn't hold so the panel moves but luckily it's a fairly tight fit. There's a few imperfections - the through tenon doesn't correctly line up with the bottom rail on one side, it's about 2mm out, and the top rail isn't perfectly level although it's damned hard to spot and it's within my tolerance limit.

 

[billw]

Picture 5 - the first side with the through tenons

So here is one side propped up with the front and back rails. The one at the bottom are all the way through and fit snugly (see photo later) but some some reason the top ones have become a bit tight, and I didn't want to force them through hence why they're not fully fitted.

Picture 6 - top through tenon

The ends will be rounded so I'm not too fussed about the nicks on the end. I am quite pleased that the fit isn't too bad - given I did all the morticing with a slightly blunt 1" chisel and a mallet they're not turned out too bad at all.

Picture 7 - bottom through tenons fully fitted

The bottoms ones fitted all the way through. The top and bottom rails are around 2mm set back from the uprights, and the panel is another 3mm back from the rails. I had originally planned to have the whole frame flush and the panel set back 5mm, but it looked a little bit too plain.

 

[billw]

Picture 8 - the inside of the bottom corner

The back rail has got some tear out at the end and the fit isn't perfect, but it does at least meet with the side rail at the same height, give or take a millimetre!

Picture 9 - close up of bottom through tenons

You can see some of the problems I've had with tear out on this photo - I opted to not get bogged down in trying to remove all the tear out else I'd have been planing and sanding for another 2 years. I know it's clearly not the ideal scenario but I'm going to get it constructed and then spend more time seeing where I can reduce the problems.

Picture 10 - through tenon

The top and bottom of the through tenons should line up perfectly with the top and bottom of the side rail. I say "should".....

Picture 11 - exploded view of corner

This shows how the side rails fit into the uprights - the mortice goes right the way through to meet the through mortice. You can also see the groove routed to fit the side panel into.

 

[Chems]

I'm not getting any pictures?

 

[billw]

What this piece has taught me.

1. Tear out is a pain! I've had huge problems with it and it's become a bit of a frustration. I fully appreciate that the tools I'm using aren't the best you can buy, which isn't helping. I won't go so far as blaming the machines for doing it - but those damned students probable blunt them all :wink:

2. Getting measurements perfect is an art as well as a science. Even when I checked and double-checked and cross-checked the position of the mortices against each upright that it related to, they were still slightly out. The main problem was the top and bottom experienced some differences. For the sides I made a couple of jigs which I clamped to the side of the mortice when cleaning them out to try and help get them all level, which seems to have worked.

What is left to do.....

1. Glue up the second side panel
2. Make the rear panel
3. Tidy up the front and back rails
4. Make the top panel
5. Glue up the rest of the carcass
6. Make pegs for through tenons
7. Fit pegs for through tenons
8. Put the stops in for the floor panel to rest on
9. Make and fit floor panel
10. Make doors *
11. Fit doors
12. Make and fit shelves
13. Apply finish
14. Weep with joy
15. Realise tears have caused finish to run and ruin entire piece

*whilst this is one step, it's actually a bit more complex.... the main door frames are walnut, the central panels are spalted beech, the top and bottom smaller panels are holly, and the decorative details and handles are ebony. They're going to take a while

 

[billw]

I'm not getting any pictures?

:? Try going directly to http://www.wignall.org/images and they should all be listed there.

 

[Ironballs]

I can see your pics Bill and remember, it's a glory hole, not a knot hole :wink:

 

[Chems]

I tried everything they weren't showing. They are now. Looks great! Thats a very complex piece you are attempting and looks like its going to come out really well.

 

[OPJ]

Looking good so far. I do like that book-matched panel; that knot couldn't have appeared in a better place! :wink: When you chopped the mortises, did you remove most of the waste with a smaller diameter drill bit first? It would save a LOT of work! If you're making a through mortise, you should also drill from both sides to prevent breakout. Your results do look good though.

 

[billw]

Looking good so far. I do like that book-matched panel; that knot couldn't have appeared in a better place! :wink: When you chopped the mortises, did you remove most of the waste with a smaller diameter drill bit first? It would save a LOT of work! If you're making a through mortise, you should also drill from both sides to prevent breakout. Your results do look good though.

Thanks 8) As for the through mortices, every last cut on all 8 of them was by hand :shock:

 

[maltrout512]

Well looking good. Breakout is a problem, but to limit it a waste piece of wood under the mortice will help there. Sharp tools and fine cuts on the tenons help a little there. Anyway as said looks good.

 

[John. B]

Well I'm impressed! :lol: I'm not a keen furniture maker.
I turn therefore I am. I particularly like the bookmatching sides.
If only I could do as well.

John. B

 

[Lord Nibbo]

I can't see nuffin either.

 

[DaveL]

Bill,

Is your domain newly setup?
I get a DNS lookup error, it might not have propagated everywhere yet.

 

[Steve Maskery]

Nothing here either
S

 

[billw]

OK do they appear now?

 

[DaveL]

OK do they appear now?

For me they do.
Nice work, worth the wait, well done. 8)

 

[9fingers]

Bill,

Is your domain newly setup?
I get a DNS lookup error, it might not have propagated everywhere yet.

I get the same DNS error too Dave.
Strange as the domain seems to have been set up in April 2000?

Still I can see the pictures on the forum and I note they are hosted somewhere else.

Ah! the mysteries of the interweb!!
Bob

 

[Digit]

Looks as though we are in for some stiff competion chaps! :lol:

Roy.