Popular Post MisterDrow Posted January 1, 2017 Popular Post Report Share Posted January 1, 2017 So I finally got this project going today. Laying out the rough lengths on the rails and stiles and adjusting for knots and figure in this 6/4 rustic alder. Got everything cut to rough length. Ran everything through my table saw with a sled to get a nice jointed edge. Running 88" 6/4 boards through the table saw was slightly nerve wracking but I took my time and only took off a tiny bit each pass. Worked well in the end. Then took everything down to thickness. This stuff was remarkably flat, which made this step a lot easier. Again... I really need a dust collection system for this planer. After getting everything down to thickness, I cut everything to width. Rails and stiles are 5" wide and 1 3/8" thick. That's it for today. Tomorrow I'll cut these to final length and start the mortises and tenons to get the frame assembled. Then I'll work on the 4/4 pieces for the panels inside. Hoping to have this thing all assembled and glued up by the end of the day tomorrow. 3 Quote Link to comment Share on other sites More sharing options...
Woodenskye Posted January 1, 2017 Report Share Posted January 1, 2017 Looks like you're off to a good start. 1 Quote Link to comment Share on other sites More sharing options...
MisterDrow Posted January 1, 2017 Author Report Share Posted January 1, 2017 I almost canceled our plans for game night with friends tonight because I was enjoying myself so much. I've got all day tomorrow though and it'll be nice to spend the evening with friends. Quote Link to comment Share on other sites More sharing options...
mat60 Posted January 1, 2017 Report Share Posted January 1, 2017 Nice start man. Look forward to seeing more tomorrow. 1 Quote Link to comment Share on other sites More sharing options...
Coop Posted January 1, 2017 Report Share Posted January 1, 2017 That ts will sound a lot louder tomorrow ! Enjoy tonight! 2 Quote Link to comment Share on other sites More sharing options...
Unknown craftsman Posted January 1, 2017 Report Share Posted January 1, 2017 Looks like a great start,and some killer looking Alder. Aj 1 Quote Link to comment Share on other sites More sharing options...
Ronn W Posted January 1, 2017 Report Share Posted January 1, 2017 I have a fondness for nice alder and I am very fond of your wood. 1 Quote Link to comment Share on other sites More sharing options...
Popular Post MisterDrow Posted January 1, 2017 Author Popular Post Report Share Posted January 1, 2017 I am very fond of your wood. That's what she said. (Apparently I'm 12) 4 Quote Link to comment Share on other sites More sharing options...
Popular Post MisterDrow Posted January 2, 2017 Author Popular Post Report Share Posted January 2, 2017 Got some shop time earlier today, though not as much as I wanted so I'll be out there again tonight. Fired up some woodworking music: Marked everything out for the mortises in the stiles Got it all lined up... the feeling of potentially screwing up such a large project piece wasn't the most fun here... A minor alignment issue on one end at the start but all in all it went well! First official routed mortise! More to come after tonight's session. 4 Quote Link to comment Share on other sites More sharing options...
MisterDrow Posted January 2, 2017 Author Report Share Posted January 2, 2017 2 hours ago, Lester Burnham said: That mortise is dead-on, elf. When you set that up, did you clamp some stops on there to make sure you don't go past the mark or just free hand it? I usually use a forstner bit for the ends of the mortise when I can. I "drilled" the ends first with the router and then routed out the middle somewhat freehand but using my mortise jig I made. No stops. Though I think I'll use stops for the rest of them to save my nerves. Also, impressed you recognized the 'elf' reference in my username @Lester Burnham (unless you've mentioned it before and I forgot... which is entirely possible). Fellow nerds unite! 1 Quote Link to comment Share on other sites More sharing options...
MisterDrow Posted January 5, 2017 Author Report Share Posted January 5, 2017 I did. I told you, in another thread, that Drizzt is one of my favorite characters. Morrowind, Oblivion, and Skyrim, I roll a dark elf named Drizzt every single time. That's right! I forgot about that! First tenon fit and done last night. I really need to reconfigure my tenoning jig to fit my new fence. This one took way more finessing than I like to get to fit. Still, for a first tenon, I'll take it. 2 Quote Link to comment Share on other sites More sharing options...
MisterDrow Posted January 8, 2017 Author Report Share Posted January 8, 2017 Man... this is way more slow going than I wanted it to be. Of course it doesn't help that we've had the worst winter storm in 20 years here in the past week. Here was the starting temp in the garage today. After turning on my heater it got up to about 45 with 45% humidity. Felt quite nice after it being below zero so much here. Obligatory woodworking music pic... Anubis Gate is a progressive band... sort of a modern Rush, if you will... but harder rock. Didn't get a pic of marking out all of the rest of the tenons. A couple of the mortises were slightly longer than the original measurements, two of them were slightly off center. This made cutting the tenons a little more time consuming as I had to adjust things for each one. It is what it is, though. Modified my old tenoning jig to cut them. Hand cut the tenons to width... took care to stay to the outside of my marks. A little tight but not a bad fit in terms of thickness. Just need to round them all off and make sure each fits properly before glue-up. And here's all three rails with the tenons cut and ready for final fitting. Turning in for the night to have some drinks and snacks with the wife while we watch a movie. Hopefully I'll have the frame all glued up tomorrow and rabbeted for the panels. 2 Quote Link to comment Share on other sites More sharing options...
shaneymack Posted January 8, 2017 Report Share Posted January 8, 2017 Just caught up on this one. Its looking great ! I'll be following along. Sent from my SM-N910W8 using Tapatalk 1 Quote Link to comment Share on other sites More sharing options...
Pondhockey Posted January 8, 2017 Report Share Posted January 8, 2017 Wow, that's pretty fancy for a barn door! 1 Quote Link to comment Share on other sites More sharing options...
MisterDrow Posted January 8, 2017 Author Report Share Posted January 8, 2017 Wow, that's pretty fancy for a barn door! Yeah, probably a bit of overkill but I want it to be nice and to last a long time. It's also an opportunity for me to learn and practice some skills. 1 Quote Link to comment Share on other sites More sharing options...
MisterDrow Posted January 15, 2017 Author Report Share Posted January 15, 2017 Well, last night was stressful. Dry fitted the frame, had to make a few adjustments to the tenons, but it came out okay. Then I applied glue to the tenons and started putting it all together... that's where things went wrong. Some of the joints that fit nice and tight before all of a sudden didn't want to close up. I was able to pull some of them tight with clamps but ended up with a couple gaps I just couldn't close. Having already applied glue (which had begun to set because I messed with it so long) there wasn't much I could do at that point. I ended up with a gap on one of them that's slightly smaller than 1/16". I'm wondering if I can cut some thin strips of wood and glue them in to fill the gap and try to hide the mistake. Honestly, I'm just sick over this. Any advice? Quote Link to comment Share on other sites More sharing options...
MisterDrow Posted January 15, 2017 Author Report Share Posted January 15, 2017 Man, that's a tough one. I'm sure someone on here can give you some advice. When I was putting a bed together last year, I had the same thing happen but I was able to persuade the joint by placing a board one the side of it and blasting the hell out of it with a small sledge hammer. Are your tenons exactly the same length as the mortise depth? Maybe there was too much glue and it had no way to get out of the way of the tenon? I think my shoulder might not have been fully square on one side of the tenon. On closer inspection the other side of that is together and flat, no problem. This is the back of the door so I'll figure out some fix for it but at least it won't be seen all of the time. I'm cutting the panels today and will rabbet the back of the frame with my router for the panel to sit in. Going back, I wish I'd have gone with my initial idea to cut a groove for them to sit inside the frame but I'm here now so I'll make the best of it. The panels will only be attached at the top and bottom of each with a single Brad in the center of the board. They'll be connected to each other via tongue and groove without glue so they can expand as necessary. Quote Link to comment Share on other sites More sharing options...
wtnhighlander Posted January 15, 2017 Report Share Posted January 15, 2017 You might turn that little gap into a "shadow line feature", by using a V-groove router bit to make a small chamfer around the inside frame edges, including right across each joint. 2 Quote Link to comment Share on other sites More sharing options...
MisterDrow Posted January 15, 2017 Author Report Share Posted January 15, 2017 You might turn that little gap into a "shadow line feature", by using a V-groove router bit to make a small chamfer around the inside frame edges, including right across each joint. Oh, that's brilliant. I really like that idea. Guess it's time to buy a v-groove bit! Quote Link to comment Share on other sites More sharing options...
Popular Post MisterDrow Posted February 15, 2017 Author Popular Post Report Share Posted February 15, 2017 Wow... it's been a busy month. Unfortunately, not busy in terms of woodworking. My oldest is on a robotics team and we spent the last month prepping for the state tournament that happened this past weekend. They finished 12th out of 25 teams, which isn't too shabby for a second year team that lost half of its members midway through the build season. Super fun experience and I'm very proud of these kids. That all being said, I'm looking forward to wrapping up some projects over the next couple of weeks and preparing for some upcoming ones. I'll be updating this project and the walnut/poplar desk project and getting them wrapped up. Got some new toys for my shop to play with, too... can't wait! 4 Quote Link to comment Share on other sites More sharing options...
wdwerker Posted February 15, 2017 Report Share Posted February 15, 2017 Just remember a sliding barn door isn't subject to very much stress. I would cut a sliver to glue into that crack and move on. Progress is looking pretty good so far ! 1 Quote Link to comment Share on other sites More sharing options...
BonPacific Posted February 15, 2017 Report Share Posted February 15, 2017 The few times I've tried to fill a gap with a sliver of wood, I've always ended up calling more attention to the patch than the gap would have. Essentially going from 1 gap to two smaller lines. 1 Quote Link to comment Share on other sites More sharing options...
Popular Post Marmotjr Posted February 16, 2017 Popular Post Report Share Posted February 16, 2017 On 1/4/2017 at 5:42 PM, Lester Burnham said: I roll a dark elf named Drizzt every single time. Where I'm from, that'll get you kicked in the shins every time. That's one of my "off limits' names. 3 Quote Link to comment Share on other sites More sharing options...
MisterDrow Posted June 15, 2017 Author Report Share Posted June 15, 2017 This project has been the bane of my existence... and it's my own fault for doing things out of order and rushing a few things. This was supposed to be a Christmas gift for my wife... that's a huge sore spot in our house right now. A few months ago I got a fancy new tongue and groove bit set for my router Router the panels for assembly... really wishing I had done this in a table rather than by hand. What a pain. Not sure where the pic of the groove cuts went that I did after this but whatever... you guys know what they look like. So, back to the awful issue of the frame. I don't know why I thought it would be easier to assemble the frame, cut a rabbet for the panels, and put them in afterwards. Chalk it up to inexperience, I guess. I made a mess of things trying to cut the rabbet and got so discouraged that I couched the project for months now. That and remember the issue of ill-fitting tenons? Ugh. So, yeah... finally decided what to do. I'm going to take a circular saw and cut the frame apart at the joints. I'll lose a tiny bit of length in doing so but I need to fix this properly. I'm going to cut the rabbets properly (I'd just go get more alder and re-cut them with panel grooves but my supplier is out right now and isn't sure when they are getting more in) and then cut mortises in each piece for loose-tenon joinery instead. That should make up for the loss of tenon length in the rails and still provide strength. I'll then reassemble the frame and put the panels in. I'll need to cut some trim pieces to make the tops and bottoms of each panel look decent but that's better than nothing at this point and that part will be on the back-side of the door and not seen from the main view side of it in the house. I'll document how it all goes and share it with you all here. This project was very far out of my comfort zone and I've learned a lot... the hard way. Sometimes that's how it goes, though. I definitely won't make the same mistakes on future projects. Quote Link to comment Share on other sites More sharing options...
Brendon_t Posted June 16, 2017 Report Share Posted June 16, 2017 That sounds like a whole lot of work, to keep from a sub sixteenth Gap on the back of a door. Quote Link to comment Share on other sites More sharing options...
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