It feels good to have a day where you get a lot done. It has been busy enough that it is worth making a list of things completed. The morning was unexpectedly free when Will didn’t wake up feeling well enough to go to soccer practice (the bad night sleep on Thursday catching up with him):
Took fencing and an old barn sink to the Sawyer farm – returning tools I borrowed from them, and getting 4 dozen eggs.
Finished the new stairs to the second floor of the workshop. Pictures to follow when I feel like going out there and taking some
I got rid of some antique windows, random scrap lumber and some old tractor pieces using Craigslist – and all was picked up today.
I removed the original stairs to the second floor of the barn.
The boys and I made a bonfire, and burned most of the wood from the original stairs.
I moved the drill press and bandsaw to the corner where the old stairs had been.
Lots of cleaning and organizing the workshop(but I still have a ways to go).
Picked up Will’s friend, Tyler, for a sleepover – they are outside playing for now.
Moved the water tank to the second floor.
I still have a little ways to go on the workshop, but the end is in sight. I have to clean up the stairs, add a handrail and a railing in the loft. I still have some shelves to build to finish putting away all the tools – I also need to go through my tools and get rid of ones I don’t need (hello Craigslist). After I complete the work inside, I need to install the large window on the south facing wall, and add exterior trim to all the new windows (and replace the rotted trim on the south facing wall). But overall, the renovation has made the workshop much more usable. All of a sudden it feels like I have nothing but space…
I have been making good progress on the workshop. The biggest part of the renovation is a new set of stairs to the second floor. The current stairs are in the front corner and are too steep, too little headroom, and no landing at the top. Originally there was no handrail, but I put one in last year. One of the other problems is there is no way to close off the second floor so I can heat the first floor.
After much thought and planning (if I haven’t mentioned it, I like to discuss projects endlessly before I actually decide what I’m going to do), I decided to put a new staircase in the back corner. To make the stairs a normal angle, I needed to have the stairs turn a corner. Over the past couple of weeks I have built the wall that will hide the stairs, and have started constructing the stairs themselves.
Saw Till and Hand Plane Storage
I am using the new wall as my hand tool storage (and display) area. It is a work in progress – I have to use the workshop as I am building in it, so I have been adding storage as I go. I had been storing my planes on a shelf, but that is a pretty inefficient way to store them. So for this new wall, I built a storage rack for them. the planes are held in place with a clip and magnet. I used laminated pine shelving that I had laying around (it had in a previous life been part of a stereo cabinet). I also built a saw till. Okay, I built two saw tills. The first one didn’t work so well. I took a 10″ wide piece of lumber I had laying around and cut slots in it to store the saws. Unfortunately, I wasn’t thinking and the slots were across the grain. So the fingers between the saws were pretty weak. On try two, I used one of the laminated pine boards and cut the slots going with the grain. This version is much stronger. It holds three back saws and four hand saws. Now I have to get around to sharpening more of the saws.
Cutting the hole for the stairs from above
Over the past couple of weeks I constructed the landing where the stairs will go around the corner. It is framed 2x6s supported by 2x4s. It is mostly level (as well as I could do with the current unlevelness of the barn). The stairs going from the landing up to the second floor will be 46″ wide (it was a good width based on the overhead joists), but the three stairs from the landing down will only be 36″ wide (I had to fit the stairs to end at the support beam, so couldn’t widen the bottom).
After completing the landing, I built the stringers and stairs down to the first floor. It was pretty simple, only 3 stairs down. The top stringers were a little more work, 9 stairs up.
Tonight (with some assistance from Will and Ben) I started cutting the hole in the floor for the stairway. Of course, once I opened up the floor it meant no more kids on the second floor until the stairs are finished – if anyone falls through the hole, hopefully it is one of the cats, and if not a cat, then a dog, and if not a dog then me.
This week I’ll finish cutting the two joists out, and install the stairs. The treads are made from two 2x6s cut to length (and ripped to width). I haven’t decided where to put the light switch for the second floor – either leave it where it is or put it over by the bottom of the stairs. I’ll also need to add a light on the stairs – they are much darker now that they are enclosed.
After the new stairs are built, I’ll tear down the old stairs and cover up the hole from them. Under the stairs will be storage, and a sink (and maybe a urinal – I have a beer/soda machine, power tools, so all I need is a urinal to make it complete). I picked up a 60 gallon water tank on Craigslist that I will use as a water supply. I’ll put the tank on the second floor and let it gravity feed (it would already be on the second floor, but it couldn’t fit up the current stairs).
I also make a good score at a garage sale this weekend. I picked up a new set of chisels (though I may turn them over to Mark at cost – otherwise they are my loaner chisels), a Stanley 4 1/2 smoothing plane in good shape and a Stanley #120 block plane (okay, not the nicest block plane, but it is in pretty good shape compared to my other block planes).
One of the quickest ways to fasten two pieces of wood is to use screws. But not all screws are the same. Years ago I started by using drywall screws from the big box store. They are good for drywall, but that is it. They have very little strength. Currently, I get my screws from McFeely’s. Their square drive screws are much easier to use than normal philips head screws (there is a much more positive connection between the driver and the screw).
I would recommend starting with a #8 flathead screw assortment of whatever finish you like. And currently McFeely’s is having a $1 shipping and handling special (for the continental US only).
Cam Out Torque table for different types of screws (from the McFeely’s FAQ section of their website)
Cutting boards made by the Curtis boys (all three of us).
It has been a while since I’ve written. I would love to pretend it was because I have a crazy exciting life, and I’ve been too busy living it. But sadly, that isn’t the case. I have been busy, but not that exciting.
I spent this month making cutting board after cutting board. My cousin got married two weekends ago, so as a wedding gift, I made him a set of drunken cutting boards, inspired by projects on lumberjocks. They turned out pretty nice (for my first try). Unfortunately I forgot to take pictures of them (I didn’t want to post before the wedding, in the odd chance that he actually reads this blog).
I decided that cutting boards would be a good way to use up the wood cut-offs I have laying around the shop, and a good project to do with the boys. I took all the interesting short pieces of lumber laying around, cut the boards to 18″ long, milled them to the same thickness, and cut them into strips of varying width (1/2″, 1″ and 2″). I then let the boys pick out the strips they wanted to use and they glued up the boards. I made sure that the boards were narrower than 8″ when glued up so we could flatten them quickly on the jointer.
I had enough strips for Will, Ben and Ben’s friend, Anthony, to make boards. I also made two myself (with the remaining wood). One is a little bigger (pictured above), and the second I gave to a friend at work.
I’ll have to write more later about the wedding trip to Bowling Green, KY, visit to Mammoth cave with dad and Barbara, and a stop over in Louisville to see a friend I hadn’t seen in 20 years. I would love to share all the pictures I took on my trip, but the camera stayed on the counter where I forgot it.
It is nice to be home and back working on the workshop. It is making progress. I’ll take more pictures tomorrow night (maybe).
I finished the final two shelves for the bookcase last night. I love the spray finish and spray system. A step that would have taken nearly a week with an oil-based finish can be finished in a couple of hours. When I used a wiping varnish, I had to let the project dry overnight between coats. With the spray finish it takes 15-30 minutes to dry between coats. That means more coats in a single night, and fewer dust particles on the project. The water-based finish also leaves much less of a smell in the house (and no smell on the project after it dries to the touch in 30 minutes).
It will be a nice addition to have book storage in the study. I’m okay with how the bookcase turned out. I can see some of the mistakes I made – I probably should fit the shelves after the carcase is constructed and need a proper shelf-hole jig. But overall it feels pretty sturdy and looks not too bad. Last night I bet Will a quarter he couldn’t find two mistakes in 5 minutes on the project. Of course the first mistake he found was one that I hadn’t noticed before – it is good to find another honest critic in the house. No sense in building projects for the house if I don’t try to make myself a better woodworker from each project.
I also have been making some progress on rearranging the workshop. My first attempt to reorganize failed (having the planer between the jointer and table saw made for a much too long walk around the jointer to feed wood into the planer).
Today we are planning a chore day. I will get some concrete to pour a footing for an additional support post for the workshop, and then work on making a small patio/step in front of the door to the workshop – I have been using the workshop enough that all the grass is dead – it is now a mud pit. I am using some lumber I have left over and the remaining concrete blocks from the patio. So it is a double bonus. I use up some materials I have sitting around and get a new entrance step to the workshop.
Of course I am expecting to get all these projects done and still have time to hand out, maybe paint the new door to the workshop, maybe work on shelves for the workshop. However, I am learning (yes, it does take a long time to learn) and am only planning the two outside projects for today. Anything else will be a bonus.
Workshop wall after reorganizing. I removed a workbench that was only used to store junk - now to build proper storage for that junk)
The cherry bookshelves after a coat of shellac (I did take a shortcut and not finish the bottom)
What a night… there is nothing like listening to a strong wind in an old house. I never cease to be amazed by how much noise the house makes in the wind. The barn is even worse. I don’t really like working in the barn when it is this windy. Luckily I have project work to do inside the house.
Over the weekend, Susanna and I moved the cherry bookshelves from the workshop to the basement to be finished. I spent a couple of evenings this week sanding the carcase to prepare it for the finish. The plan is to do one coat of shellac and then spray the water-based top coat. Tonight I applied a single coat of shellac. I probably won’t be able to spray the shelves until this weekend.
I have two of the four shelves completely finished. The last two shelves will be finished after I am done with the case. There isn’t enough room in the finishing room to manage the case and shelves at the same time (yes I do need to get rid of things).
I have a couple of clamping squares – they are useful for making sure that corners are perfectly square when I do glue-ups. I have one from Woodpeckers Precision Tools. It is a beautiful piece of machined aluminum:
Woodpeckers clamping square
I love the the tools from Woodpeckers. All the ones I have used are high quality and precise. Not the cheap tools one can get from the local stores.
I have two larger plastic clamping squares from Rockler. They are plastic, and of course don’t have the fine feel of the machined aluminum. However, they are a little larger (and easier to clamp), and work just as well for the projects I have needed them for. They are also a little cheaper:
Clamp-it square from Rockler Woodworking
I only have 3 total clamping squares and have been able to get by with that many. Another 2 would be useful at times. I might recomment starting with a pair of the aluminum ones, on sale now at Woodpeckers. The Woodpeckers tools are made in the USA as well.
It seems in the workshop one either needs one or two clamps at a time for a project, or two shops worth of clamps for a glue-up. Never anything in-between. I’ve had to glue the face frame to the bookshelves in individual pieces because of my limited number of clamps. However, the current arrangement of the workshop makes it nearly impossible to walk all the way around the case when it is on the saw horses. So maybe it is good that I didn’t have enough clamps to attempt a big glue-up at once.
Attaching one side of the face frame to the shelves
The project overall is coming along pretty quickly. It is amazing how quick a project can be done when using sheet goods (can you say no milling of lumber).
On the down side, the top that I glued up isn’t deep enough with the face frame attached. Luckily, I have a spare piece of cherry milled and ready (hey, I do eventually learn – to mill up extra lumber) to cut and glue to the top to get it deep enough. Now if I had more clamps to do the glue-up while the face frame dries. I guess it doesn’t matter – I can’t get to the table saw with the case in it’s current location. And I don’t want to move it with the glue drying…
I was able to finish two of the shelves (build, glue edging on, one coat of shellac, and 2-3 coats of spray varnish). They turned out pretty nice. Cherry is pretty light colored right after finishing. A couple of months exposed to light and hopefully it will turn darker.
Shelves after spray finish (plus a table leaf that had been sitting in the basement for years just waiting for me to finish).
Writing in my blog – a good way to spend filling the time between the glue-up and when I can take the clamps off (and move the shelves). I think it may be time to get more clamps. Maybe a pack of 24-inch clamps from USA Clamp Company. I have 5 clamps made by them, and I love them. Plus they are way cheaper than the bar clamps purchased at most woodworking supply stores.
The bookshelf carcase naked - needs back, face frame, shelves and top...
After assembling the carcase, I started milling and building the rest of the bookshelf. I milled the face frame and shelf fronts from a single 72″ section of cherry. The shelf panels have a 1″ tall piece of 3/4″ thick cherry glued to the plywood. I decided to use a little taller piece of wood than the 3/4″ thick shelf. The wood will be flush on the top, and extend slightly below the shelf. Having a thicker piece of wood will add some rigidity to the shelves so they won’t sag under the weight of books.
Two of the four shelves glued up with a solid cherry edge piece
I glued up the top from two pieces of the cherry. I set it on the top of the shelves and it had a decent overhang and room to cut the board square. However I forgot that the bookcase will have a 3/4″ cherry face frame attached (Duh). Not sure if the top will be big enough. Luckily I have another piece (or two) of cherry milled that I can add to the top panel if needed.
The top panel glued up
The edges to be glued were jointed on the power jointer. However the jointer didn’t leave the best edge for gluing (I think it needs new blades), so I used a hand plane to do the final jointing prior to glue up. The trick is to make sure both edges are perfectly square to the faces (that they aren’t on this panel can be seen by the very slight bow in the panel when I hold a straight edge across it. I’ll have to remember to keep checking the edges with the square when I use the hand planes… I’m hoping that the slight bow in the top will just be a design feature (either to cause water to run off the front and back – if the the convex side is up – or a place to store tennis balls where Tucker can’t get them – if the concave side is up).
