mat60 Posted April 28, 2018 Report Share Posted April 28, 2018 Looks like PNT but. I don't see no HF clamps there. Quote Link to comment Share on other sites More sharing options...
curlyoak Posted April 29, 2018 Report Share Posted April 29, 2018 The general public has no idea of the work involved and the time it takes to properly make the joints. If you tell them the hours required just to complete the arch, they can't see it. I see it and I appreciate the effort and time it takes to do it right... 2 Quote Link to comment Share on other sites More sharing options...
RichardA Posted April 29, 2018 Report Share Posted April 29, 2018 I saw it live, and I appreciate what Steve and Rick do. It's very complicated and they master it. 1 Quote Link to comment Share on other sites More sharing options...
curlyoak Posted April 29, 2018 Report Share Posted April 29, 2018 Is Rick a co worker? employee? Quote Link to comment Share on other sites More sharing options...
wdwerker Posted April 30, 2018 Author Report Share Posted April 30, 2018 ??? PNT ??? I used a hodgepodge of clamps because length & handles kept running into each other. I've got a few things from HF but clamps ain't one of em. Northern Tool has a small selection of Bessey "F" clamps & the auto adjust toggle clamps for just under $19 each. Best price I've seen them at. Every shop should have a pair of those Bessey toggle clamps, awesome on all sorts of jigs ! Rick is an old friend and former neighbor that helps out from time to time. The time envolved caught me off guarg on this one. Should have bought a finger joint bit in hindsight. Luckily the big arch gets backed up by the plywood the big TV mounts too so those 4 joints won't get flexed after its mounted. The small arches only have 2 joints. Quote Link to comment Share on other sites More sharing options...
curlyoak Posted April 30, 2018 Report Share Posted April 30, 2018 Steve, if the project takes more time than originally thought, does that cost you or is it time and materials? I know my limitations but when I go to new never done before I always go over...The hardest thing for me is calculating time required... Quote Link to comment Share on other sites More sharing options...
wdwerker Posted April 30, 2018 Author Report Share Posted April 30, 2018 If it takes longer I make less. But if it goes smoothly, faster = profit ! Quote Link to comment Share on other sites More sharing options...
Popular Post wdwerker Posted May 15, 2018 Author Popular Post Report Share Posted May 15, 2018 Finally got back on the big arch. Pattern routed the blank to final shape then sanded both edges smooth. Routed the molding on both sides and had to do plenty of freehand climb cutting with tightly clinched cheeks. A 7' wide curved part is not an easy thing to route, the grain direction keeps changing. A few sections had some tearout from the pattern routing but I was able to get them out when I cut the molding. Then I clamped the sanded part to a jig to trim the ends and rip the top of the curve off. A few dominos let us dry fit the arch. We clamped it to the side of the table so it was held firmly to receive a vigorous sanding to remove a ridge left after routing. The inside of the triangles made by the arch gets moldings. I spent the day today cutting & fitting 10 degree miters and sanding the cuts until they fit, that's 5 degrees each side. A 3/8" thick molding with a 5 degree mitered end means the cut is about 2" long. The side cuts of 67 1/2 and 22 1/2 were a breeze in comparison. Dripping sweat I got frustrated fitting the last long miter so pictures will have to wait till tomorrow. 5 Quote Link to comment Share on other sites More sharing options...
Coop Posted May 15, 2018 Report Share Posted May 15, 2018 Amazing work Steve. Quote Link to comment Share on other sites More sharing options...
Chet Posted May 15, 2018 Report Share Posted May 15, 2018 Alway see stuff in your journals that you don't see in the average hobbyist builds. 1 Quote Link to comment Share on other sites More sharing options...
RichardA Posted May 15, 2018 Report Share Posted May 15, 2018 Keep bringing us that work, we all learn from your labor. 1 Quote Link to comment Share on other sites More sharing options...
curlyoak Posted May 15, 2018 Report Share Posted May 15, 2018 I learn a lot from you Steve. Thank you! I wonder with your good vision and experience did you anticipate all of these necessary and exotic efforts to complete this task? And then to calculate how long it will take. It is one very special thing to complete the task you are on. But on top of that to determine the steps involved and predicting how much time you will take in my eyes may be harder than the actual project, as tough a challenge that it is. Do you ever ask the client for time and material for these kind of projects? I am enjoying this project. Thanks. 1 Quote Link to comment Share on other sites More sharing options...
wtnhighlander Posted May 15, 2018 Report Share Posted May 15, 2018 Patience must be kwy for that sort of work! Quote Link to comment Share on other sites More sharing options...
wdwerker Posted May 15, 2018 Author Report Share Posted May 15, 2018 I had a totally different approach in mind when I quoted the job. Then I figured out it wouldn't work. The little details are eating up the budget but it's about time to knock out the big casework and go after the finishing. Thanks for the kind words ! I will take pictures of the long sharp pointed miter process today. I had to figure it out 20+ years ago to wrap exposed roof trusses in a skylight shaft. 1/4 Mahogany ply and a cap molding I set up and made seemed like a good idea until cutting this joint was a reality. 2 Quote Link to comment Share on other sites More sharing options...
RichardA Posted May 15, 2018 Report Share Posted May 15, 2018 Yikes! Quote Link to comment Share on other sites More sharing options...
Popular Post wdwerker Posted May 16, 2018 Author Popular Post Report Share Posted May 16, 2018 So I cut the skylight trim on the mitersaw using a 90 degree jig. I set this picture up just to demonstrate . I copy the angle with a Tee Bevel, protractor , whatever then bisect it. For the small trim I rough cut on the bandsaw and sand to the line. Inevitably it takes a little fine tuning by eyeball. Usually trial and error on a scrap then copy the best result onto a longer piece. I use a scrap to back up thin trim & keep it square to the table. Both sides of the joint had to be cut, free hand grinding a long angle on that piece of curved trim was another butt clenching move. Both sides of the arch top as well as upper & lower corners on each side of the arch. This shot shows the angle on the curved trim. The fits not perfect but after several coats of primer & paint and being 9 ft in the air it will appear perfect. The joints on the bottom edge will be much more visible. A thin bead of glue and a few micropins will hold all this trim in place. 4 Quote Link to comment Share on other sites More sharing options...
mat60 Posted May 16, 2018 Report Share Posted May 16, 2018 You do great work Steve. Quote Link to comment Share on other sites More sharing options...
Coop Posted May 16, 2018 Report Share Posted May 16, 2018 Just the thought process scares the begibers (sp?) out of me. Mods, see how I toned that down 2 Quote Link to comment Share on other sites More sharing options...
Popular Post wdwerker Posted May 16, 2018 Author Popular Post Report Share Posted May 16, 2018 As I started this build I felt a bit overwhelmed. Slowed down, broke it into steps and focused on one step at a time. Feeling much better know. I hope the rest of this build starts moving quicker. The arched tops inside the bookcases will be fun & fairly straight forward. 3 Quote Link to comment Share on other sites More sharing options...
Chet Posted May 16, 2018 Report Share Posted May 16, 2018 40 minutes ago, wdwerker said: fairly straight forward. Steve's experience allows him to say this. Every time I think something is going to be straight forward it ends up a two day adventure. 1 1 Quote Link to comment Share on other sites More sharing options...
Popular Post wdwerker Posted May 18, 2018 Author Popular Post Report Share Posted May 18, 2018 Got started on the curved inside tops for the bookcases today. Basically building a frame to fit inside the case and wrapping the underside with wiggle wood. Sawed out the curve and sanded to the line. Then used that to pattern route the rest of the parts. Used clamps everywhere possible and routed the clear section at each end. Shifted the clamps and routed the rest of the arch. Using a large bearing over bit to pattern route takes some focus and caution. Damn near cut the cord once today. Now there is just a few more pieces to route and it's on to the wiggle wood. 6 Quote Link to comment Share on other sites More sharing options...
wdwerker Posted May 18, 2018 Author Report Share Posted May 18, 2018 Got the arch frame assembled and skinned the inside with wiggle wood (Italian poplar 3/8 bending ply) . Glue & nails plus clamps wherever possible. Knocked this one together and hauled it out of there to beat the traffic. Already have all the parts cut for the second one. That can wait till Monday for assembly. I've got a date with a redhead to get ready for. 1 Quote Link to comment Share on other sites More sharing options...
RichardA Posted May 18, 2018 Report Share Posted May 18, 2018 26 minutes ago, wdwerker said: Got the arch frame assembled and skinned the inside with wiggle wood (Italian poplar 3/8 bending ply) . Glue & nails plus clamps wherever possible. Knocked this one together and hauled it out of there to beat the traffic. Already have all the parts cut for the second one. That can wait till Monday for assembly. I've got a date with a redhead to get ready for. Got to get that chain mail underwear in place, right? 1 1 Quote Link to comment Share on other sites More sharing options...
wdwerker Posted May 18, 2018 Author Report Share Posted May 18, 2018 80 + temps & high humidity = sweat which leads to rust ! Quote Link to comment Share on other sites More sharing options...
Popular Post Coop Posted May 19, 2018 Popular Post Report Share Posted May 19, 2018 2 hours ago, wdwerker said: That can wait till Monday for assembly. I've got a date with a redhead to get ready for. And I quote you in these: ”Sign and date it” & ”Without pics, it didn’t happen” 2 2 Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.