chefmagnus@grics.net Posted October 17, 2014 Report Share Posted October 17, 2014 I got some help from an engineer friend who put my Sketchup design into a cadd program. We found that the stress on the inner rails was with in 5% the break tolerances of most plywoods. So we changed the dado to mortises for each of the decking boards and gained a lot of strength. He also helped put some textures onto the faces and get my tenons made. I hope that no one finds flaws in my design so I can proceed with making it this weekend. Chef Quote Link to comment Share on other sites More sharing options...
wtnhighlander Posted October 17, 2014 Report Share Posted October 17, 2014 Looks nice to me. And so does the saw! Quote Link to comment Share on other sites More sharing options...
Beechwood Chip Posted October 17, 2014 Report Share Posted October 17, 2014 I'm concerned about those side pieces that attach to the castors. Are those plywood or solid wood? If they are solid wood, I'm worried about them splitting at the curve. Quote Link to comment Share on other sites More sharing options...
chefmagnus@grics.net Posted October 17, 2014 Author Report Share Posted October 17, 2014 The side rails are each made from four layers of laminated plywood. I am going to use a sheet of recovered plywood to make the sides. I got it from a dumpster. It looks like it had been used as a door because it has hinges on one side and a hole drilled into the other. It doesn't have any signs of water exposure. I broke it down with my poor man's track saw this morning into the rough sizes needed to make each of the lamination parts. I am going to cut all of my mortises while everything is still square. I have a spiral cutting bit with edge guide on router that I was going to make the mortises with and square the end up with hollow chisel mortiser. Do you think that it would be ok to glue up the two inner parts then make the mortises through the 1-1/2" resulting piece so the mortises are true to each other. Tired from dialysis and can't think about how to do it right now... Chef Quote Link to comment Share on other sites More sharing options...
Beechwood Chip Posted October 17, 2014 Report Share Posted October 17, 2014 I think that's a good plan. Plywood won't have the grain problem that solid wood would have in that design. Quote Link to comment Share on other sites More sharing options...
chefmagnus@grics.net Posted October 18, 2014 Author Report Share Posted October 18, 2014 I scored a couple of sheets of new plywood at Lowe's this morning. I found a sheet of Baltic Birch 2 sided sanded with a 3" bit missing from a corner and a sheet of one side sanded maple that was miss a Dutch man so it had a hole through it. I saw the department manager and asked he could make me a deal on both. He said $30 and I offered $25. He said ok. I got them cut into 4'x4' squares and loaded into van. I have plywood for another project, plywood for my bandsaw longboat, and still have my recovered sheet of plywood to use as assembly table on a pair of saw horses. Quote Link to comment Share on other sites More sharing options...
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