September 25, 2008
One of my favorite features of the top, is actually technically a defect — a quarter-sized knot hole. While both my wife and I agreed that it added “character” to the top, I couldn’t simply leave it as it was; it was large enough to swallow up small objects whole and naturally not very stable.
A large knot
After some searching, I found a few references to folks filling holes like this using “Pour on” epoxy, of the type you might use to encase small chatchkis in a bar top.
A Slow Leak
On the first pour, I found myself constantly “topping off” the depression. I would fill the knot, level it off and a couple minutes later, most of it had been absorbed into the knot. By the time it cured 24 hours later, there was only a thin layer of epoxy, coating, but not filling the knot hole.
Puzzled, I decided to simply pour again. This time it filled just fine. The next day, while moving the piece, I discovered the cause: the knot hole went clear through the board and the epoxy
Pour on epoxy
was leaking out the bottom! With the first coat effectively plugging the hole, the second coat filled it nicely and easily sanded flush (something I was a bit concerned about). The effect is exactly what I had hoped for.
My Favorite Finish
I spent quite a bit of time sanding this piece — and it still probably wasn’t enough. For the finish, I had purchased a wipe-on, “low sheen” Tung Oil-based finish. The first coat on the drawers resulting in less than spectacular results. Though each row was was made from a single board, a couple adjacent drawers were a noticeably different shade. This prompted a second, more vigorous round of hand sanding (and a few choice words). This time, they took the finish much more consistently. A week later I had built up 5 coats on all parts and was ready to attach the top and call this project “done.”
Amateur
After reading
Dick Cain’s forum thread about “
Photographing Your Work” (PDF from
Wood Carving Illustrated), and feeling duly shamed about my previous
point-and-click-using-built-in flash-against-any-old-background photo sessions, I decided to step it up a notch. Unfortunately, I don’t really own any
real photographic equipment and can’t afford to start yet another incredibly expensive hobby at the moment.
So my first attempt fell rather far from the intended mark. I may take another crack at it later in the week — perhaps using a cleaner and less wrinkled backdrop and a couple more lights if I can find someone to lend me any! If the new pics are any good I’ll update this post.
In the meantime, here’s my (rather humbling) attempt at perfeshunal fotogerphy.
3/4 View of Completed Dresser
I thought I’d put some pics of the new baby’s older siblings on top…in theater we called this “dressing the set”…
Drawer detail
September 8, 2008
I love my “new” drum sander.
I purchased the used machine for the purpose of sanding shop-cut veneers and inlay woods. However, with a 23-1/2″ capacity, it is capable of so much more. I first cut my teeth with this thing on the side panels. Now it was time to glue up the top — and I was really looking forward to seeing what it could do with the 21″ x 64″ x 1″ thick part.
Joining the top
I started by rough cutting and gluing up two 5/4 boards. Jointing an edge on these long, tall boards was a challenge on my 6-1/8″ Ridgid jointer’s 45″ table. One of the boards had a 1/4″ bow that simply couldn’t be removed on the short table, so I pin nailed it to a sacrificial scrap of 3/8″ plywood and ran it through the table saw.
It’s a “feature”
I had hand-selected three 5/4 cherry boards, nearly 80″ long for the top from Owl Hardwoods. The first one I chose was beautiful and featured numerous streaks/pitch pockets that I just love the look of in cherry furniture. Unfortunately I was unable to find a similarly figured board in the pile. The other two I selected were nice, but didn’t match the beauty of the first…I figured I’d sort it all out in the shop. Well…the time had come and my dilemma was that the beautiful piece was a poor match for either of the others, and the other two, while a better match for each other didn’t match the beauty of the first. After much consternation, and a determination that I simply couldn’t afford to go back to the lot to find its perfect mate, borrowing a term from software development, I decided that the mismatch should be a feature, not a bug.
I recall reading somewhere (maybe from David Marks?) that in a situation like this you should highlight the flaw…which has me now considering doing a simple inlay along the length of the joint. Perhaps in walnut and echoing the “cloud lift” (double, mirrored) from the front and side bottom apron? Or even something more “organic” (a river runs through it?).
Any opinions on that?
Dead Flat
Once the glue dried, I scraped and then planed the joint relatively flat and prepared to see how well the old Grizzly would handle the large piece. It took a bit of work just to place the machine in the room with >6′ of clearance on either side in my small shop…but in the end, I found the space. Since I was using nearly the full capacity of the sander, I was very nervous that it’d track a bit too far to either side and somehow ruin either the piece or the machine or both. While I did manage to brush up against the duct tape on one pass — resulting in the need to stop and re-secure the paper, I didn’t experience any significant issues. The front roller’s 100 grit paper loaded up enough to require replacement part way through the process, and I did notice some loading that I was unable to completely clean up on the edges, but overall this was an extremely satisfying experience with no burns or noticeable snipe and resulted in an absolutely dead flat top! Awesome!
My only issue was with the dust collection — for smaller pieces like the side panels, the collection was absolutely sufficient. However, with this piece, while there weren’t great clouds of dust or anything like that, I did wind up with a thin film of dust covering all of the shop surfaces. Prior to this, per a fellow LumberJock’s recommendation, I had replaced the flexible hose that came with the sander with rigid PVC. I’m sure this helped, but it still couldn’t quite keep up.
After sanding, I routed a bevel around the bottom edge with a plunge router.
Winding down the build phase
Finally, I installed some small stop blocks on the dust panels behind the drawer fronts to prevent them from recessing too far into the carcass and some “tip blocks” at the top corners so the drawers won’t dip significantly when fully extended.
Next up: Inlaying the top(?) and then sanding, sanding, sanding and more sanding!
September 5, 2008
Labor Day weekend my wife took the kids up to the family cabin for a couple days. I spent most of this time in the shop working on the drawers. For this dresser I had designed the drawers with large through dovetails. Since I don’t own a decent dovetailing jig that allows for custom size and spacing, I was going to have to do these by hand. Since I haven’t done many projects with hand-cut visible dovetails, I figured I’d better take my time with these. To make things a bit faster and more accurate, I used the bandsaw with the table tilted to 10 degrees to start the pins and the router table to hog out the majority of the waste. I’m not sure how much faster it is vs. a hammer and chisel, but it was certainly more accurate than I would be solely by hand and saves a bit of wear and tear on the chisel blades — I wasn’t keen on spending my rather limited shop time sharpening chisels!
That said, I do truly enjoy working with sharp chisels as I am here cleaning up the pins:
The pins completed on one drawer front:
Marking out the tails with an X-acto knife:
I’m very pleased with the end result. This is a dry fit of one of the drawers…
I used a simple dado to attach the drawer backs.
I had originally planned to use sliding dovetail drawer slides, but they fit so well, I decided to simply add guides on either side and a block at the top to keep it from dipping. Here’s the chest with the completed drawers:
Next up is the top. After that, sanding, sanding and more sanding.
