wouldwurker Posted March 10, 2014 Report Share Posted March 10, 2014 Hi all. Lumber is here from bell forest (beautiful). 220v outlet to be installed this week for the new tablesaw (love the 15% off Powermatic sale!). And, been playing with my new Domino 500 all weekend (in my 15m windows of free time). So I'm thinking the Domino will be a confidence booster for my first build, but had some quick questions. 1. Has anyone tried this guild build with a Domino? 2. I'm guessing with the 500, the big 10mm x 50mm dominos (rows of 2 or 3) will be the main floating tenon joinery - 28mm per board depth. Sturdy enough for this chair? 3. With Mahogany, should I use the wider mortise setting on one of the boards? (manual recommended this for harder woods) 4. And lastly, any potential pitfalls for which to look out? Been scratching my head a bit over the angled tenon in the front leg joinery. Thanks all. Any feedback would be appreciated. I'll be sure to document my build, catastrophic mistakes and all . VJ 1 Quote Link to comment Share on other sites More sharing options...
wouldwurker Posted March 20, 2014 Author Report Share Posted March 20, 2014 Update: Double and triple checked my measurements on the side legs, since I'm not cutting the one-piece tenons. Almost screwed up the angles about 5 different times - thank god for scrap test cuts. So easy to goof up when that mitre gauge comes out. I only get about 30m in the shop per day, if that, but it's good to know I made some progress tonight. Quote Link to comment Share on other sites More sharing options...
..Kev Posted March 20, 2014 Report Share Posted March 20, 2014 Nice progress especially for 30 minutes. Sometimes it takes me that long just to decide what I want to do next! Quote Link to comment Share on other sites More sharing options...
wouldwurker Posted March 22, 2014 Author Report Share Posted March 22, 2014 Update: Side legs curves cut and sanded. Every day, a bit more progress. Plus, a great excuse to buy an oscillating spindle sander (which in my head, I always seem to say with a snagglepuss accent). Tomorrow, I break out the flush trim bit and the turners tape (smash cut to me with a mahogany board taped to my beard). Quote Link to comment Share on other sites More sharing options...
..Kev Posted March 22, 2014 Report Share Posted March 22, 2014 Sweet - You won't regret the purchase! Quote Link to comment Share on other sites More sharing options...
wouldwurker Posted March 26, 2014 Author Report Share Posted March 26, 2014 Second leg copied, and cloud lifts added. Couldn't help but notice that the cloud lift curve was the same size as the flush trim bearing. Is that by design? The 2" flush trim bit is officially my new favorite toy (23000 rpm take your face off toy) Progress....slowly. VJ 1 Quote Link to comment Share on other sites More sharing options...
..Kev Posted March 26, 2014 Report Share Posted March 26, 2014 Those look great! Quote Link to comment Share on other sites More sharing options...
wouldwurker Posted March 27, 2014 Author Report Share Posted March 27, 2014 Side legs complete Feels good to have completed a portion of the project and I had quite a few takeaways. Just in the side legs alone, it was my first time using: - my new tablesaw - mitre gauge angled cuts - mahogany - flush trim bit on my router table. - turners tape - osc spindle sander Learned a lot and am pleased with the result. Quote Link to comment Share on other sites More sharing options...
..Kev Posted March 27, 2014 Report Share Posted March 27, 2014 Pretty good results for learning a bunch of new stuff! Quote Link to comment Share on other sites More sharing options...
EdgewaterWW Posted March 27, 2014 Report Share Posted March 27, 2014 Great start on the Chair. It's always fun to use/have new tools! I'm a turner (90% of the time) and didn't know that Double-Sided tape was talked Turner's Tape. Funny that tuners call it Double-sided Tape and Flat Work Woodworkers call it Turners Tape. haha Learn something new with every post. Quote Link to comment Share on other sites More sharing options...
wouldwurker Posted March 30, 2014 Author Report Share Posted March 30, 2014 Leg Details: Holy %#*^. It worked! I thought the odds were stacked against me... - My router never comes out of the router table - the plunge stops have been disabled - I don't have a 1" bushing - I've never used the router in 'handheld' mode To make up for the lack of bushing, and since I already built the jig, I used a couple 1/8" shims and double stick taped them to the inside of the jig, only touching the plywood (see photo). To my surprise, first try and it worked. I jumped up and down like Tom Hanks in Castaway when he finally creates fire. I CREATED G & G LEG DETAIL!!! (Scrap photo attached) One side rode just a hair deeper, but sanding cleaned it up to make both ends of the taper even. Still, I wonder what the culprit was for that. Maybe my jig isn't completely flat. I still don't understand the bit in the video about the 2nd clamp only grabbing the rail sides to keep the other end of the jig from rising. What am I missing? Seems the jig comes off the table regardless? Also. since I had several hours in the shop today, I knocked out most of the apron. No bandsaw. So I used the tablesaw. Cuts were true, so no need for jointer between cuts. I did however get a bit carried away with the glue....( see messy photo). The angle on my mitre guide would up being about 40 degrees. I'd love to use my planer to clean it up, however I don't trust it enough to not to bite the ends a little....which sucks. It's a nice piece of machinery (12" Makita), but I don't have confidence in it. I'll likely spend some time with the ROS instead. Going to need a shot of courage before routing the detail on the actual legs ( 8 times).....I think I'll go out and buy a 1" bushing first. VJ Quote Link to comment Share on other sites More sharing options...
..Kev Posted March 30, 2014 Report Share Posted March 30, 2014 Great progress! Quote Link to comment Share on other sites More sharing options...
Llama Posted March 30, 2014 Report Share Posted March 30, 2014 Nice work! Quote Link to comment Share on other sites More sharing options...
wouldwurker Posted March 31, 2014 Author Report Share Posted March 31, 2014 Is it a chair yet? Tis a fine barn, lad, but tis no chair. Bit the bullet and went with my modified jig, to accommodate my lack of a 1" bushing. I fixed some of the inconsistency by sanding the top of the jig flush. For the record the modification was as follows: 2 shims 7/32" thick by 3/4 wide by (the length of the jig hole) - double stick taped on each inner side. My taper shim was also 7/32" thick. Total router bit depth measurement was 11/16" ( no plunge, just started it on the high end). Give me a 1/8" cut that tapered about 4 inches to flat. Routed all 8 leg details, which was easily the most stressful part of this build yet. Put the apron through the planer too...came out beautiful. My fears were for not. Using the domino for the joinery (this week) has given me the luxury of not committing to a any certain side of the legs just yet. It's nice to be able to dry fit with double stick tape and clamps to see what I like best. Modifying the jig to fit my equipment was the most fulfilling part of this build yet. 1 Quote Link to comment Share on other sites More sharing options...
..Kev Posted March 31, 2014 Report Share Posted March 31, 2014 I like the jig! Nicely done! Quote Link to comment Share on other sites More sharing options...
wouldwurker Posted April 5, 2014 Author Report Share Posted April 5, 2014 Back slats done! (but for the notch) My front and back brace boards were pretty warped. Bell Forest's customer service took care of me. In the meantime, I skipped ahead to the back slats. Little by little... Quote Link to comment Share on other sites More sharing options...
wouldwurker Posted April 16, 2014 Author Report Share Posted April 16, 2014 We have joinery! After making about 5000 test mortises with the Domino, I finally put the rubber to the road with the front and side legs. The 17 degree angled cutoff scrap pieces from the side legs were perfect for making my test cuts. Used the 10x50 tenons for the side leg/front leg joinery. 3 total, with a 2 domino thickness spacing in between. Pencil guide lines used for all cuts. Retracted the dog paddles on the domino, as they really get in the way. The mortise depth in the plan calls for 1 1/8 inches. With the 10x50 domino tenon, I get just shy of 1 inch penetration with ~3mm of expansion room on each end of the floating tenon. Hopefully, there's no major loss in structural integrity. I'm no engineer, but my assumption would be that the 3 tenons are applying upward force to six different (strong) surface areas, equally disbursed within the legs. Coupled with the joinery in the rest of the design, it should support my 150lb frame just fine! For the record, I used the "tight fit" setting for all three (six) mortises. More photos on next post. Quote Link to comment Share on other sites More sharing options...
wouldwurker Posted April 16, 2014 Author Report Share Posted April 16, 2014 Part 2 of 2 Quote Link to comment Share on other sites More sharing options...
..Kev Posted April 16, 2014 Report Share Posted April 16, 2014 Great progress! Really looking nice! Quote Link to comment Share on other sites More sharing options...
wouldwurker Posted April 19, 2014 Author Report Share Posted April 19, 2014 Apron joinery complete. Since the plan called for a 3/8" mortise for the apron, I used the tiny 4 x 10mm dominos. Lined up 4 in a row. If the plans didn't also call for the 2" screws, I likely would have used 2 rows of 4 in each apron side, but this should work just fine. Lined up the back slats just for fun. Starting to look like a chair! Quote Link to comment Share on other sites More sharing options...
..Kev Posted April 19, 2014 Report Share Posted April 19, 2014 Nice! Really starting to come together! Awesome progress! Quote Link to comment Share on other sites More sharing options...
wouldwurker Posted April 21, 2014 Author Report Share Posted April 21, 2014 Question: Starting the upper back brace/arms and it looks like the half lap is pretty necessary - I don't think I could get away with domino joinery there. Can a (lot) of passes suffice on the router table with a 1/2" bit for the half lap. Or will I run the risk of small 'ruffles' (can't think of a better term) because of so many passes? Thanks - it essentially determines whether I need to purchase a dado stack. Of course, if the upcoming Morris chair requires a dado-stack....maybe it's time to buy one anyway. Thanks all. --VJ Quote Link to comment Share on other sites More sharing options...
wouldwurker Posted June 15, 2014 Author Report Share Posted June 15, 2014 Lower back brace complete Took some time off of this project to work on a few others. Happy to be back to it. The bevel was a challenge, because I don't have a bandsaw. I did come up with a solution, however, using my table mounted jigsaw. With a thin scrap board double stick taped to the edge, and some test cuts, I could run the tilted piece across the table to achieve the desired angle (see pic) It made me happy to come up with a solution - I'm learning that adaptability is a big part of woodworking, but also quite a fulfilling aspect. Lots of time measuring and marking lines to get the dominos just right, but they came out great. Used 10x50's. (Pic attached). Time for the arms and upper back brace. Here we go. 1 Quote Link to comment Share on other sites More sharing options...
..Kev Posted June 15, 2014 Report Share Posted June 15, 2014 It has been a while for this one, nice to see you back on it! Quote Link to comment Share on other sites More sharing options...
wouldwurker Posted June 19, 2014 Author Report Share Posted June 19, 2014 Half laps complete - and check out my attention to grain selection on the arms. ...um...on the bottom of the arms... Arggggggggh Ah well. Quote Link to comment Share on other sites More sharing options...
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