Garage and House Build/Remodel Update – 6/14/16

Garage:

  1. My slab is cured and the densifyer has been applied.  really happy with the results – a big thank you to Mr. Mark Flood!!
  2. The ground around my garage slab is all level.  I rented a Skid-Steer this past weekend and played in the dirt.  Hauled 2 yards of excess over to the neighbors yard to fill some voids and I used the skid-steer to pull out 7 small stumps for her.
  3. Got a call from the builder yesterday and the lumber will be onsite today, Framing starts Wednesday, and trusses are delivered on Friday.
  4. Was asked to move the Honey-bucket so that the lumber would have enough room.  Odd, request for my builder to make of the homeowner/customer, but I did it just so there would be no issues with the lumber delivery.
  5. If schedule holds, windows and siding start next Wednesday, and we will be fully in the dry by next Friday.
  6. It looks like I will be installing the windows as I am more particular than the builder about such things.
  7. My son, The Ruminator, will be here for a few weeks and I will get him help me run wire in the garage shell.
  8. My 2-post car lift will be installed by the end of the month

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House:

  1. We are finishing up the paint on the main level.
  2. I need to start putting the 1/4 round trim back down.
  3. Bathroom: there is tile work to finish and a mirror to be hung.
  4. Basement remodel is stalled.  We had the head manager for the plumbing company out on Saturday after we found even more problems with the work that was done and we have told them: “…in light of the previous and continuing issues, incomplete work, existing damage caused by your subcontractors that we will have to have repaired, and that the basement portion of our remodel has been brought a complete stop,  my wife and I do not want a____________ employee, or anyone from a subsidiary company back in our home.  We do not wish to continue dealing with _______.”  We can’t really touch anything until they agree to this.  If they do not, then we can’t do anything as the matter will have to be settled via remediation.

What I Want Thursday – June 9th, 2016

Below are the things that I really want and that are present for me today:

For my interior painting to be 100% done in our house.
For my Garage to be 100% built and finished.
More time with my children and family.
Summer BBQs and cold rosé in the yard.
I want to stick to my diet and workout schedule and not fall off the wagon and back into the cookie/café Mocha/lethargic/big-belly/back-hurting abyss.
For the Attic and basement (mostly the bathroom) to be done.
Letters – written on actual paper – from my kids, friends and family.
8″ joiner/planer, 15″ Bandsaw, New Dust collection system for garage
Christopher Ward Quartz Trident with black rubber strap
For the US Political system not to be dysfunctional and a little/lot less crazy

New Garage Slab Has Been Poured!

The slab is down and the curing has begun. It is not laser flat – 1/8″ – 1/4″ variance in couple spots in the field, but the pad is smooth. I had the apron poured extra thick (8-9″) brush finished and control joints troweled in. I had a sprinkler on it for the 1st 24 hours and soaker hoses and a poly/burlap wrap was applied just after the slab control joints are cut yesterday morning.

I will let is cure for another 5 days and then apply a densifyer (Ashford) on top. Framing will start next Thursday or Friday. I am so exited that I feel like a pimply teen who just scored a playmate as a prom date!

 

 

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Garage Build Update 5/10/16

My slab gets poured next Tuesday. All clear from the City for electric trench and slab forms. There were a few issues that I saw last week that needed to be adjusted: There was a rebar oops in the car lift footings that was a serious new-guy error, but instead of calling my contractor to bitch, if just fixed it. Sometimes you are only as good as your worst employee… I picked some rebar and a couple boxes of chairs, looped ties, and put a 12″OC grid down of 1/2′ rebar 3″ from the dirt in the footing hole on Friday evening after work.

I also lifted the existing rebar over the footing holes up with chairs so that it would all be the same level as the welded wire. Hanging it from the wire would force the wire down to the top of the visqueen, negating the use of the material in a large area. I took the extra chairs I had and added them to the welded wire field. I understand that it gets stomped down when they pour and walk the pour, but the trick for me is to limit the amount that stays down. It was $90.00 worth of material and a couple hours of my time and we can work it out as we move forward with the build. The minor details in the grand scheme.

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House Status and Plumbing Woes

We are making progress, abet slowly:

  1. My father-in-law came in this weekend and painted our bathroom and the trim.
  2. I have a new granite vanity top installed – one with the facets centered on the sink.
  3. New reproduction 1920’s glass handles are installed in the vanity.  I is not gud counter.  I bad at numbers.  Didn’t have enough – one short.  Store now sold out.  Amazon to the rescue.
  4. The drywall should completely done and sanded as of today.  The new arches are super sexy!
  5. I modified the kitchen knife rack to fit the new ceramic sharpener.  The original was broken by the asshat moving company and Kyocera doesn’t make that size anymore, so I had to drill out its assigned slot.  The replacement knives (also the movers…) are now in as well.
  6. Primer will go on the fresh walls tonight and tomorrow night.
  7. I have patched the hole in the tub surround and am waiting for the thin-set mortar to dry so that I can lay the tile.
  8. The new fireplace insert is in and fantastic.  I will do the new surround and mantel after the floors are refinished and as I am trimming out the Dining room Ceiling
  9. I met with the garage foundation crew on Monday to go over all the details and they start the ground work today.  I am almost giddy with excitement.
  10. My new dutch doors are ready and I will pick them up Friday
  11. The finish carpentry trim-out starts next Monday.
  12.  I learned yesterday afternoon that no plumbing permit was pulled and that we might have to demo the concrete in the basement – the new concrete – and the newly laid supply line so that the county inspector can view the pipes.  I am super unhappy and will update as I know more.
  13. We are now 4 weeks without a shower or bathroom sinks at the house. I have been a decent human being and fairly understanding up to this point with our plumbing company (big company, one of the oldest in Seattle). I am afraid that they have mistaken nice for weak and unwilling to have a confrontation.  That was a miscalculation.  Please refer to the Capone quote concerning kindness…
  14. My wife is still medium chipper and hasn’t threatened to leave me yet over the lack of a shower or all the dust, so that is something.
  15. The lavender out front is in bloom and the bees are back, so not all is lost.

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Productive weekend with Heavy Equipment – The Old Garage is Down!

Super Productive weekend!  The old garage came crashing down at about 9:00am on Saturday.  All it took was a little push with the forklift at the peak of the roof (I rented an extension boom forklift and a jack-hammer to assist with the garage and old slab destruction)  I didn’t take out any fences or cars, but one of our recycling cans took a beating.  Within 3 hours it was all loaded into a debris dumpster that I had dropped Friday morning.

The forklift was a little manky to start and keep running.  I would overload the hydraulics just a touch and instead of straining, it would die and take 3-5 minutes to restart.  The rental company was supposed to bring another one out, but we kept waiting and waiting and just making do as we whittled away at the slab and footing with the jackhammer and forks.  While the garage demo was a breeze, the slab was something else altogether.  It was super tough, full of quarter-sized aggregate, and 6 inches thick.  The footing was +16” deep.  I was impressed – I thought it was just some concrete poured over dirt like our basement slab.  Nope, this stuff was WAY overbuilt for the tiny carriage house.  I could had parked a tank on this thing and it would have been just fine.

With the slab about ¼ split and loaded into a second dumpster, the forklift finally died.  After a couple of calls, the rental company brought me a free 18000lb rated track-hoe with a bucket thumb and a pusher blade!!! That translated into an adult sized Tonka toy for my yard.  It was 5:30 or so by the time the track hoe was off loaded, so after demonstrating that I wouldn’t run it into a power pole, I parked it and work in the house a little.  I try to be a good neighbor and running heavy equipment while it is dinner time in a neighborhood does not endear you to others.

I was up and at it at 8:00 the next morning and the second piece of equipment was so sweet and made the tear out and load go so much faster than I expected! However, it is apparently not a normal occurrence to have a piece of heavy equipment spinning, grunting, working in my little neighborhood.  I one point I looked over and I have 5 neighbors standing in the shade of a neighbor’s garage, drinking beer and watching me demo.  When I took a potty break, one asked me if I could break something to make it more interesting.  Son of a…  They had gathered to watch me wreak havoc and as it did not ensue, were somewhat disappointed in me.

After five hours on the track hoe the garage, the whole slab, footings, three tree stumps, and four posts that were set in concrete were loaded and ready for transport.  All our water lines, fences, and overhead electrical lines were still intact so it was a successful second and final day of garage demo. My back yard is now a flat spot of dirt and is waiting for a new garage slab.

After playing in the yard for most of the day, Stamps-With-Foot and I went into Seattle and bought all the paint (Benjamin Moore only thank you very much) for the house interior and new fixtures and lights for the main floor bathroom and the laundry room sink.  I then cut and installed the new bathroom vanity on the main floor and did a little electrical work in the basement. It was then shower and night-night time, because I have a regular J-O-B to go to every morning.

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House Remodel Status – 4/12/16

Things are moving along with the house and garage, abet very slowly.

  1. I cut the dying vine maple out of the back yard.  Its loss made both my wife and I sad – we loved that tree.  Part of it I saved for fire wood and part I gave to a local bowl turned I know so he could make beautiful stuff out of the sections that were free of rot.
  2. The new 1″ water supply line is in.
  3. Our basement slab was cut for the new basement bathroom and drains
  4. Concrete floor re-poured.
  5. I have demo’ed part of the basement ceiling, the front bedroom closet and a huge spot in the dining room for the plumbing company to run PexA supply lines and vent pipe.
  6. Plumbing rough-in is going on today and we may have a functioning toilet and kitchen sink by 5:00pm tonight – maybe…
  7. We haven’t had water for a week and have been staying in an air B&B, which has gotten old and expensive.
  8. Basement bathroom framing is going in tomorrow.
  9. The new 1st floor bathroom vanity is done and in place, but the holes in the granite top for one of the facets are cut wrong – it has made me a little crazy…
  10. I have cleared all the stuff out of the way in the back yard and am ready for dumpster deliveries.  I am taking the old garage out this coming weekend.
  11. The attic is ready for new floor joists, but still waiting on the engineer’s report to decide what is going in and options for the space.  We had wanted a Master Suite up there, but are not sure if it can be done at this point.
  12. Our fireplace insert goes in tomorrow and the new fireplace tools are already there.
  13. The three windows for the garage and two for the house are on order and should be here next week.  I just have to find a place to store them.

Some pictures of the current status and the latest progress:

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I haven’t had a day off in about three weeks – working my day job, making calls to contractors and supply companies at lunch and on the way to work/home, and working at the house at night and on weekends.  I have to work all this week getting ready for the garage demo and all weekend tearing it down.  It is all starting to take it toll on me.  I’ll get an evening off from remodel this week to attend my new advanced throwing (pottery) class, and will have a two evenings off next week while the drywall goes in, but will be back at it painting the entire weekend of the 23rd and every evening the rest of the week after.

My wife said a little something a few days ago that resonates: “Life is a journey an not the destination, but remodeling is all about the destination.  The journey sucks!” I swear if I had to make this decision again, I would have sold the house and bought a McMansion in Maple Valley or an updated mid-century rambler Bellevue and just moved right in in.  I have remodeled many homes in the past, but this one and the size/scope are both out of hand and way too ambitious for someone who has a day job.  When all is said and done, I do not want to touch a thing in or on the house for YEARS and would like to just enjoy home for a while, sit in the back yard and drink rosé in the summer sun with my wife.

 

A small personal note:

I don’t normally get super personal here, but this is a happy day and I am going to share.

1. We have been dealing with an insurance company who is in charge of covering a loss that happened during our move back to the States. We have had a claim that is almost 8 weeks old, moving slowly through their “process”. It is not for a small amount of money. I got a note today (after badgering them for two weeks with facts, data, and common sense) that they were going to send us an interim payment for 1/5 of the total claim while they continue to work through it all. I was happily shocked as they have up to this point been rife with fuckery.

2. We are are in the process of refinancing our house and taking a little equity cash out so that all of the unexpected repairs that have come up during the remodel don’t all continue to flow directly out of my now shallow pocket. I got a call that we have the green light to start the closing process, which means I will have a finished house and new garage/shop by summer.

3. I do not currently have ass cancer. I have been privately dealing with that real possibility for a couple of weeks and went to see a specialist/surgeon today. Apparently, I am fine and my plumbing is all good. I almost broke down and sobbed like a little bitch when I got the news.

Overall, it has been a very good day.

What I Want Thursday – Febuary 2016 Edition

Below are the things that I really want and that are present for me today:

More time with my children and family.
I want to stick to my diet and workout schedule and not fall off the wagon and back into the cookie/café Mocha/lethargic/big-belly/back-hurting abyss.
For the house remodel to be done
For my Garage build to be 100% and my new lift and tools installed and waiting for me.
Growler or two from West Seattle Brewing Co.
Letters – written on actual paper – from my kids.
A longboard skateboard
I could stand a new Kindle
A handsome tweed vest – or two
Brown Redwing Engineer’s boots
Huge antique pattern lathe found in a barn or a PM4224 with all the add-ons.
A pair of 1/2 round and a pair of Snipe Bill molding planes
A 1.75 – 3Hp SawStop Table Saw
One fine compound sliding miter saw
>8″ joiner/planer
A Grizzly G0752 Benchtop Lathe and G0801 Vertical Mill

If you want to hear God laugh, tell him what your plans are…

As mentioned a few weeks ago, we hit a snag on the garage build. Super frustrating. There is some stuff in the house that takes precident – they just have to happen and happen right now. Thankfully, we are in a place to take care of it, but my dream shop has been pushed a couple of months. That hasn’t stopped me from getting everything prepped though. I have completely cleared out my current GROP and moved all the innards into storage for the duration of our build/re-build. A few things like ladders and yard tools are left, but after giving away an entire trailer load of scrap lumber and plywood it is all open space. It hurts a little that the cleanest my garage shop has ever been is right before I tear it down to built a new one…

The other day, I had to do a little fiberglass repair on the Jeep top and swap out my floor-mounted headlight dimmer switch. Not super a fun/sexy mod, but taking the door off made it easy – ish. I will not be bright-lighting folks for my entire commute anymore. It was nice to have a dry spot to work during a Seattle winter. Also, this was the only time in 6+ years that a vehicle had been in it.

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We had to start the house remodel before the garage and start in the rear bedroom (NW corner of the house). The interior walls had to come out to repair an issue(s). After we take care of the repairs, a new arch will lead into the kitchen, there will be a 4′ French door with a 12″ balcony looking out into the back yard, and we will have wainscoting up to 68″ and a coffered ceiling in what was the back bedroom and what will be the new dining room. Here are some shots before the full wall removal, some replacement studs and new headers.

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The basement stairs are also in need of replacement and will be taken out and rebuilt next week. The new HVAC will go in the week after. It has been and will continue to be a test of our resolve and patience.

Another one has left the nest…

I sold my midi lathe last week. It was the last one of 3 and I am now lathe-less. It made me more than a little sad. We made such cool shiznit together, but I am making room for the new shop build where I will have a huge 3HP gap-bed pattern lathe with +26″ swing ad huge bed.  I won’t have a place to turn and have zero room left in storage.  It was time to let it go to a good home and get many more years of use.  That is a better life for a lathe then sitting is a dark storage room surrounded by boxes and plastic containers. It still makes me sad to both see it go and to not have another yet.

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Mid-month Update – Jan 2016

We have a LOT going on around La Maison du Talley and I have had 12 texts and e-mails about different stuff, so here is an overall update:

  1. We have our garage permit!!  I did a victory dance when our contractor sent me the mail.
  2. Building is on hold for a bit though as we have an issue inside the house that has to be dealt with before ANYTHING else.  Looks like it will not be cheap, but it has to happen right now.
  3. The old garage will be clear as of tomorrow and ready for demo, but that has to wait on the house as well.  Dammit!
  4. Still don’t have an HVAC contractor for the house – 2 that can’t do the work until summer, one that won’t send a written quote, one in the running, one contractor that sent me a quote that is for almost the same amount as the entire garage build & double the next closest bid, and another that I am on the fence about – mixed reviews, but good pricing.
  5. We finally had the new hot tub cover delivered and it is fantastic: light, ridged, perfect color…  Stamps-With-Foot is stoked.
  6. Finished the movie (shot with a GoPro) about our cross country jeep trip, but YouTube blocked the audio because I used a snip-it of Hendrix’s Voodoo Chile, which is uber verboten.  I will edit it for sound this weekend – maybe some rockin’ blues and re-post with links.
  7. Sticking to my workout schedule and wrist is 90%+ healed from the break.  My gym has hung heavy bags and I want to start smackin’ them, but will wait for wrist to heal 100%.
  8. Still chubby 🙁
  9. Jeep is running great.  Front window seal is leaking a touch and need to unstick the odometer.  She will be getting an oil change and fluid check this weekend.
  10. The puppies/monsters are good, but they long for the Toulousian sunshine.
  11. I made three more bowls in pottery class and have decided to make matching food and water bowls for the puppies as my first project.
  12. My J-O-B is great.
  13. Really happy to be back in Seattle.
  14. Our furniture won’t be here until February.  Customs issues…
  15. Nana is good, her Seahawks are good. She wrangled 90 days of free HBO from Comcast, so she is happy.
  16. Stamps-With-Foot is happy to be going back to work.
  17. Looking forward to Date Night with my wife tonight at an awesome hole-in-wall Greek place in West Seattle.

Getting a new garage in 2016!!!

Woohoo!!  It looks like we are a go for a new garage and some needed updates to our heat, plumbing, and wiring at the house.  I am meeting our builder this weekend and passing him a check (two checks actually, one is for the City of Seattle permit office…) and I will have a real garage and wood-shop by spring.  I will have room for a big lathe, cabinet saws, wood storage , my joiners workbench, room to assemble projects/furniture, a real dust collection system, and all my planes/saws/chisels/hand tools on one side.  On the other side of the shop will be a mini-machine/fabrication shop with a two post lift, lathe, end mill, welder, mobile paint booth, and work table…

I cannot tell you how stoked I am!  Seriously, I am all giddy about it.  I plan to make cool stuff, descend into super-nerdy, and will be voiding the shit out of warranties!

Here are the prelim drawings that are being submitted and a lay out of the shop floor.

Garage floor 3 Garage Floor 1 copy Garage floor 2 copy

Update:

Drawings sent to the city. Cross your fingers and pray with me that Planning is having a good day/week/month and these babies get a stamp.

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Wood Lathe for sale in Cornebarrieu – SOLD

The move is ON!  we have two weeks until the packers and movers get here and Stamps-With-Foot and I spent the morning and part of the afternoon going through stuff and listing stuff for sale  the largest of which is my lathe.  It hurts me a little to see it go, but I know that a huge old gap-bed lathe waits patiently for me in Seattle.

Below is the add that my wife is posting on the local English-speaking forums here in the Toulouse area:

FAR TOOL TBF 1000 Wood Lathe for sale in Cornebarrieu: 

FAR Lathe_Main

I bought this lathe brand new from a local shop 18 months ago.   Since it came unassembled, I reinforced the standard steel base with additional shelving, cross-braces to remove any possible flex.  I then sheathed three sides for extra rigidity and added a strong bottom platform for ballast.  I have turned everything from honey dippers, to bowls (large, small, & huge), stools from tree trunks, stair balusters, platters, furniture feet, tiny wooden and acrylic ornaments, lids, etc.  It has been a great lathe and has NO PROBLEMS or “small issues.”  The bearing are true and tight and there is ZERO rust on the ways/bed.  This lathe is in perfect shape and the only reason I am parting with it is because we are moving back to the US and the power there will not work with the lathe’s 240/50Hz motor. 

 Here are the details and specs as well as a couple of links to shops that sell it:

  • Cast iron variable speed lathe features a 360 degree swivel headstock.
  • Solid cast iron headstock and lathe bed construction.
  • Extra bed extension for outboard turning.
  • Speed is fully variable between 450 – 2100 rpm.
  • Weighs ~120 kilos
  • 300mm width capacity over bed and 900mm between centers.
  • Have turned 600mm platters with headstock swiveled 90 degrees
  • 550W enclosed fan-cooled motor
  • hollow self-ejecting tailstock with #2MT
  • Cast iron offset tool rest and extension arm
  • Head Stock has MT2 Taper and 25.4mm (1:8TPI threading – industry standard for lathes this size – easy to find chucks and accessories
  • Includes reinforced/enclosed steel base, added powerstrip for lights and hand sanders, a 4-prong drive centre, bowl/platter faceplate, live tail center, 4 wrenches, knockout-bar, shop-made stead rest.

It will be perfect for your garage or shop or for your partner’s Christmas present since it is ready to work and you just have to plug it is.  I paid 520 Euros for this lathe 18 months ago and it currently lists for 550 – 745 Euro depending on the shop. I am asking 375 Euro.  Please give me a call if you have any questions and the lathe is available for demo if you would like.

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UPDATE:

I sold the lathe to a nice English gent, who got a smoking deal. I helped him take it all apart and put it in his car. The rear springs were seriously loaded, but he looked happy as he pulled out of our drive.

Obsessing Over a Possible House Remodel & Letting My OCD Shine Bright

We are currently going through a make/buy decision concerning our house in Seattle.  Meaning, do we spend $200-$250K plus, months of time, and lots of sweat equity on updating our house, adding a garage/shop and dining room, and refitting the basement into an apartment for my mom.  Or, do we spend $5K getting the house ready to sell and find another house that has what  we want already done and complete.  Do we keep the house as a rental and build an entirely new one…?  We have met with our estate agent, a builder, a draftsman, an architect, a landscape company, a second builder, and now a third builder in our quest, but really are not any closer to making a decision.  As said before, Stamps-With-Foot and I are going over it all and trying to decide what is best for our finances, future possible family expansion, and quality of life.

I drew our lot and house just after we moved in and have spent more than a few hours modeling all our crap – to scale – and seeing how it would all fit in the possible expansion of our existing house with the new garage build.  Part of this on-going decision process is looking at all the possibilities and modifying the existing drawings into a “someday-maybe state”.  I have a touch of OCD…  If I am working on something or especially in the planning stages, I will drill WAY DOWN into the project.  Evidenced by the below images and the included timeline.

I have modeled sewing machines, yard tools, bikes, my 1986 Jeep, my wife’s Subaru WRX, hand tools, bikes, , machine tools, trees, bushes, furniture, lathes, saws, wiring diagrams, rugs, even our puppies… all to scale…  I may have a problem.

Overview copy

House elev copy

Main Floor copy

Basement ADU copy

Attic Master Suite copy

Garage Over View copy

Garage Interior Detail copy

Shop Interior copy

Attic Interior copy

Garage Garden Shed copy

Wiring detail copy

Time Line copy

Tooling Detail copy

Brodie Detail copy

Sand Box copy

Some small projects around the house

I have been swamped with work and travel for the last couple of months, so my shop time has been very limited. I have mostly been puttering around with my workbench, getting the last bits and bobbles done before calling it done and I have spent the off hour here and there on the lathe and doing stuff around the house:

  1. I had to fix a dishwasher leak and do some painting in the kitchen – still hate plumbing
  2. We did some re-arranging, so I had to fill some nail holes and then make new ones.
  3. Glued a cutting board back together after it split – craptastic glue didn’t hold, so it is back in the to-fix pile and will get some dowels this time
  4. Made a pot lid handle out of some scrap cherry.
  5. Tackled the jungle that was once my yard – twice
  6. Sharpened the lawnmower blade
  7. Turned the compost
  8. I bought a sheet of plywood and built a DVD shelf and a 8′ bookshelf for the lending library we run.
  9. There was been an oak log in my shop for months so I cut it in half and made a couple of stools for my office.
  10. Our puppies play a game called “run away from Mommy” when she takes them out, so I built two small fences to keep them in the back yard and away from the front gate.

I have do a few things in the shop just for organization and am working on a couple of little projects:

  1. We got a huge free wardrobe that I put in the GROP to organize non-tool/shop related items like climbing gear and life jackets
  2. My battery operated tools need a home, so I put together an organization center for them that mounts on the French cleat board
  3. I hung up my 6 heavy panel clamps to get them out of the way
  4. Made a Lathe chuck and tail-stock tool organizer for the French cleat organizer
  5. With a bonus from my J-O-B, I bought a few more molding planes, but they arrived in sad shape. I spent 6+ hours one Saturday cleaning, sharpening and fixing them.
  6. Started work on a blanket chest rebuild: cut here, snip there, new runners and new feet. Will get new milk paint finish when complete.
  7. Working on a copyist lectern rebuild. I made the base, pillar and other bits from some scrap beech left over from the bench build.
  8. Built a wooded top for the puppy Kennel so it blends better with the furniture in the Living Room.
  9. Putting together a 6-board chest for molding plane storage.  Will get re-purposed forged hardware and a Barn Red milk paint finish.

Matt Talley - Projects 2015_06 Matt Talley - Projects 2015_11 IMG_3410 Oak stool 23-2015 (2) Matt Talley - Projects 2015_24 Matt Talley - Projects 2015_22 Matt Talley - Projects 2015_23 Matt Talley - Projects 2015_25 Matt Talley - Projects 2015_17 Matt Talley - Projects 2015_18 Matt Talley _ Drill Organizer _ 2015

My workbench is DONE!!

I am about a month late in posting this – life and my J-O-B got in the way – but the Cornebarrieu Bench is done. Completely done! All bells and whistles added. It seems like it took me forever, but it fits perfectly in the shop and I started using the bench even before it was finished. I am very happy with the outcome and am currently working on projects that have been piling up all winter. Just in case you haven’t been following along for the past year and a half or so:

My GROP (garage and shop combo) in Seattle was too small for a proper joiner’s bench. I made due with a slim, high, wall-mounted work counter, a bolted on machinist-vise, Quick Clamps, and the top of my table saw. It worked – mostly/sort of – but was a pain in the ass a good bit of the time: I never once planed a board on a stable, solid surface. My GROP here in France is roughly the same size as the one in Seattle, but is absent the huge cast iron machines and saws. I have some room to move and finally have the space for a big, heavy, proper work bench as well as some time to build one – or so I thought.

It is an amalgamation of benches by M. Roubo, Roy Underhill, Chris Schwartz, and Bill Schenher. I am calling it the “Cornebarrieu Bench” after the small village in southern France where we live, where the lumber has been sourced, and where the bench was made and first used.

For anyone interested, here is a documented build process, build notes, and step by step guide – 115 steps – to build this beast.

Cornebarrieu Bench 2015  (30)_sm - Copy

Cornebarrieu Bench 2015  (31)_sm

Cornebarrieu Bench 2015  (29)_sm - Copy

New stools from an oak tree

This weekend I finished up a “little” lathe project I started in early February – I made a couple of stools out of a hunk of oak tree that was cut after a storm in our village. They are about 15.5″ (39cm) tall and 10″ (26cm) around and getting it that way pushed my Chinese lathe to its absolute max. It walked all over the floor when I first started it up – hence the kettle bells thrown on the middle shelf to add mass. It super did not like the out of balance logs. It would have been fine at a slower speed, but the slowest my lathe goes is 400 RPM and that is too fast for this size project. I managed, but there was lots of starting and stopping.

I really like both how the turned out and how comfy they are to sit on – just the right height for a quick stop-and-rest. I will add bow-tie joint if needed as they dry out and split, maybe out of some walnut that I have. They will make a nice addition to my home office.

Oak stool 23-2015 (2)

Oak stool 23-2015 (3)

Oak stool 23-2015 (1)

Oak stool 23-2015 (4)

Used my workbench today!

Today was the official first use of my workbench. I used it as a work table to lay out the shape of the leg vise, I cut the dados for the tail vise, cleaned them with a chisel, and after spreading plastic used the bench top as a glue-up table for the vice pieces. I had enough room at the other end of the bench to put together a French-cleat mounted battery drill organizer that I cut the parts out for yesterday afternoon. I have trouble staying with one project and do 3-5 at a time. It makes my wife crazy.

The bench top height is perfect and I am super stoked to have a real workbench here in France. I can finally get down to serious business and make some moldings and a small linen-fold panel chest.

Happy!

Workbench Progress

Progress on the Cornebarrieu Bench is coming along.  It has been slow going – I have been swamped with work, travel, lack of allowance (I spent it on Christmas and a classic fiddle/violin…), more work, etc…

Stamps-With-Foot gave me a gift card for our local Home Center/hardware big-box as a Christmas present that took care of the price for the last section of the top. I got a lot accomplished this last two weeks:

  1. The final sections of the top were glued up just before New Years eve- using every single clamp I brought to France and more than a little ingenuity.
  2. Installed (2 hours of cutting, drilling and chiseling) a pricey German-made cast iron end vice that I got on 65% sale – was missing two small metric bolts and the wood handle.
  3. Made final leg cuts: the tenons that go inside the bench top.
  4. Put 5/16 oak dowels in to the pieces that have cracked, even a little, to make sure that the cracks do not spread.
  5. Gave all the base parts an 80 grit sanding.
  6. Really like the sawmill marks on some of the pieces.  Am going to put clear poly on the base instead of milk paint to preserve the marks.
  7. The legs and stretchers shrunk and warped just a touch in the six months since I cut them even though I had it all clamped together.  It will be fine and could have been worse.
  8. Made the first dry-fit of the base to the top: Everything lined up , fit perfectly, and is as square as I could ask for.
  9. Drilled holes for connector bolts and lag screws.
  10. Installed base shelf cleats
  11. Cut the 12 sections of 5/8″ tongue & groove pine that will be the base shelf

Cornebarrieu Bench 08-2014 Cornebarrieu Bench 09-2014 Cornebarrieubench 12-2014 Cornebarrieu Bench 1-2015

 

 

 

 

 

 

Before I head to the US in a couple of weeks, I hope to have installed the end-vise block, given the base a 120 grit sanding, polyurethane the base &shelf, cut the hole for the leg vise screw and the rectangle cut for the vices’ parallel guide. I also want to install the leg vise nut in a pocket behind the leg while the bench is upside down.

Chinese Lathe Build Update – Pimp My Lathe Edition

As mentioned in a previous post, I purchased a Chinese manufactured wood lathe shortly after moving to France. Putting it together and getting it running true was not a Herculean task, but it wasn’t a plug and play affair either. In addition to the initial setup, I have taken an hour here and there to make it bit more ridged and add some features that did not come stock, just to pimp it out a little:

  1. The base is now sheathed in 1/2″ plywood, glued to the wood supports and screwed into the sheet metal legs.  It makes the base a LOT stiffer and clean-up is much faster.
  2. After 4 months of weekly run-time, I have had to replace a couple of set screws and re-tighten the short bed extension outboard of the head-stock. The clamp bolt holding the head stock shattered and caused me some grief.  Chinese bolt quality sucks.
  3. The bottom of the base was finished with 2″ thick scraps and I added a couple hundred pounds of pavers, gravel, and crushed brick to add even more stability.  It is not enough when I try to turn a 15″ hunk of cherry outboard,  It still wobbles and jumps around a bit.  There is just no way to make the sheet metal frame more ridged.
  4. On the French cleats above the lathe, I added a tool holder and chuck/drive center/tail center tool mount for convenience.
  5. I hung a long compact florescent over the work area and on the side there is an IKEA floor lamp/spot light that I can move about.  Scored it used for $8.00!
  6. A tool grinder the I picked up for about $45 is mounted are the end of the lathe on a small table for easy mid-project tool sharpening.
  7. The capacity is only 12″ and that is not the magic number.  16″ – 18″ would be perfect for the bowls and bases and platters that I am doing here.  If I added 2″ iron risers to the head and tail stocks, then it would give me a 16″ turning capacity (swing).  I have thought long and hard about doing it, but haven’t yet as it might be a complication that is more headache than useful AND I don’t want to put anymore time or money into the thing.  I just want it to work.
  8. I designed a steel bed extension – modeled it in 3D and everything, but I am not going to have it made… I would be trying to turn an under powered Hyundai into a V8 4X4 Toyota Truck.
  9. For tuning large objects with the head swiveled, I designed a sweet swing arm tool post as well.  I modeled it up too, and decided not to have it built for the same reasons.  I will use the tool post arm that came with the lathe with a wood post under for support when I turn bigger stuff outboard.
  10. This Lathe will get me by for the next couple of years and I will go over it and repair/replace any worn parts before we leave France to ensure the next owner has relatively trouble free tool, but This is my last “cheap” lathe.  I am going to plop down some funds and get a Robust, Vicmarc, a huge Powermatic, Oneway, Oliver, or a Stubby – Something with power, mass, lots of heavy cast iron and reliable parts that I don’t have to screw with.

 

IMG_3410 Lathe Chisel rack 2014 Lathe clean aug 2014

 

 

Rainy Day Projects

I spent a few hours this past Saturday cleaning up and re-arranging the GROP. I had bits and pieces of projects strewn about everywhere and I had to wiggle my way in through both the garage door and the door from the house – like I was in need of a hoarder intervention. It just took a couple of hours and only two utterances of the F-word to make sure that my on-going and future tasks were staged for completion and arranged in an orderly fashion.

Months ago, I picked up an antique copyist’s lectern (the top part only) taken from a French Abby. It was in ruins and the wood was full of worm holes, but I saw treasure and have planned on rebuilding it “…when I have time...” This is what rain days are for! Running and biking would have beeen cold and muddy, the dogs wouldn’t budge from the warmth of the pillow filled couch, I had already slept late and there was serious wife snuggling, so might as well make some wood shavings!

I sketched up a few column profiles in my ubiquitous little black notebook (currently a Rhodia Webbie) and decided on a somewhat simple design that MIGHT have been found when the piece was made. It is not some object of high art – no Gothic arches, no carvings and it seems to have been made for a specific task which didn’t require flourishes. I tried to follow that ascetic and kept it all fairly simple, only using a gouge, parting tool, and skew to work the column. While my lathe is modern, the tools are the same that have been used since the ancient Egyptians turned on their horizontal lathes, so I figure that the re-made version would be recognizable to both the maker and user of the original piece – that and it feeds my own mild form of wood working OCD.

The lectern top is now stabilized and bug free after months of treatment and I spent a little time on Sunday turning a new pedestal out of beech scraps from my workbench build that I had. I glued them all up into a single 5″ X 5″ x 32″ hunk of wood. I then measured and turned matching intermediate supports so that it all blends in as one piece. I need to give it a good all-over sanding before I remove it from the lathe. What I have left to do before I call it done is to replace one book ledge, rebuild (or find at junk shop) the second tin candle holder to match the single original that is left, turn and fit the pedestal base plate, and then everything gets stained and oil-finished to match.

It will look amazing in living room next to the book press with a reprinted copy of one of the four volumes of Roubo’s L’Art Du Menuisier on one side and Viollet-le-duc’s Dictionary of French Architecture from 11th to 16th Century on the other side, tall beeswax candles in the holders… Jesus, I am getting nerdier with each passing year!

Lectern rebuild 11-2014 (1)

Lectern rebuild 11-2014 (2)

Lectern rebuild 11-2014 (3)

Lectern rebuild 11-2014 (4)

Free Wood is the Best Wood!

Prospects for Fall wood-turning are looking up!  I am 98% done with the Chinese lathe build-up into a proper tool. I am waiting on the arrival (had to resort amazon.uk.co as there are not turning shops in a 100 mile radius?!) of two huge bowl gouges and I will be set up to make shavings all winter. I was also given a free electric oil-filled heater for the garage, which should keep things toasty!  On the raw material front: I am taking an old apricot tree out of a small orchard for some friends a few villages away tomorrow (National Holiday) and I am really excited to turn some bowls and jar tops out of it.  A few weeks ago, I mentioned the project to a friend of my wife’s and a couple of hours later she called and said that her husband was cutting an old ornamental cherry down and would I like the wood? Like the Pope wants Jesus, I did!! I went over with the chainsaw and helped him take it down and to cut a few larger limbs and the trunk into sections.  Some of the images below are what it looked like inside the tree just after my chainsaw went through. We were stunned. Not just the center was beautiful – a fire purple, but there are bright reds and oranges in the outer wood as well. The tree had over 70 rings and grew next to a couple of big cedars so the rings are real tight and as I had to sharpen my chain twice during the cutting, the wood is VERY hard and dense.

It took two loads in the car to get it all home.  I sealed the ends right away and stacked everything in the GROP near the lathe. They had cut a plum down earlier this week and I scored two 12” rounds from that as well – the ones with the flame purple center in the pictures below. I told the couple that I would make them a vessel or large bowl out of a hunk of the tree in trade for the lumber.

Fast forward to this past Saturday: I rough turned 6 bowls (one not pictured) in about 2.5 hours from the large limbs. The trunk sections will be cut into starting next weekend.   I will let the small pieces dry for 4-6 months and then finish turning them. The larger bowls from the trunk will take a year to dry.

Am feeling reasonably optimistic about upcoming projects :-)

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Update 11-9-14:

Well, the apricot tree wood harvesting didn’t quite go as planned. I had chainsaw issues right away – needed to tear it down before the first cut and unclog the chain oil hole. Holy crap the wood was hard. It had 65+ growth rings that were stacked in tight. It was slow going with a couple stops to sharpen my chain. The clincher though was that there were two twisting veins of rot that went from crown to root ball with lots of bug damage spidering out from the rot as well. Dammit! There was was maybe 12” of trunk that I can spin a bowl out of. Per my agreement with the owner, I cut up the other trunk & big limb sections to a length that will fit in a fireplace and stacked it up for them. You win some you lose some. If not for this tree I wouldn’t have the amazing wood from the ornamental cherry and plum tree and maybe karma will smile on me the next time I lug my saw into a field.

Apricot Tree 11-2014 (3)

Apricot Tree 11-2014 (1)

Apricot Tree 11-2014 (2)

Medieval Benches in Art

As I have mentioned in previous posts, I have been on a 5-board bench kick this year. I have built five so far and two more are in the works. I am also putting together at least three 6-board benches in the next 6-8 months, which share similar design and construction. Both items are classified as “Furniture of Necessity” or “Early Rustic” if you go shopping for one or the other. The patterns for them are roughly the same now are they were 2000 years ago and they lend themselves to hand-tool only construction.

I am not a Luddite that eschews a table saw, not in the least. I just don’t have one in France and am not buying one (If someone dropped off a new 10” cabinet saw and a compound sliding miter saw at my door, I guarantee that I could shoe-horn them nicely into the GROP). It has taken me almost 10 months to decide that I need a plug-in circle saw, but only to speed up the breakdown of thick planks and beams – I will be shopping at a pawnshop in the city though. I am just not spending the money to set up a new cabinet shop when we are leaving in a couple of years. Tools here are CRAZY expensive and most of the stuff available to non-professionals is crap. A Ridged-type contractors saw (bottom rung of what I consider acceptable for cabinet work) here with a real fence and a solid top will set you back the equivalent of $1100.00. Same saw at any Home Depot in the USA is about $500.00. A 7.25” Makita circle saw is the equivalent of $230.00 and an 18vt Ryobi drill with two batteries? $195.00!

Anyway, back to benches and chests… While in Paris last month we visited a plethora of museums and I kept finding little nuggets in the paintings, tapestries, and stained glass: top edge profiles, proportions, leg cutouts, etc… I am going to incorporate a couple of the details into my planed remaining work this year and next – just because I can. Below are a few of those details. They were for sure more to see, but not all museums allow pictures in their halls.

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stools from Book of hours 2

stools from Book of hours 1

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Small parts holder for French Cleat wall

What happens when you are 99.98% done turning a bowl, there is a millisecond of inattention and BAM! And the bowl explodes off the chuck?? After you check your britches and finish saying dirty words, you pick up the pieces and make lemonade from lemons.

I thought about tossing it all in a fire, but decided to use the largest intact piece to make a small parts holder that mounts on a French Cleat. I am forever looking for a jar or a can to put small parts in while I am voiding a warranty or rebuilding something small and complicated.

Bowl to French Cleat 2014 (1)

Bowl to French Cleat 2014 (3)

Bowl to French Cleat 2014 (2)

Cornebarrieu Bench – Redesign & first cuts made

I did a full redesign of the Cornebarrieu bench… As per my normal modus operandi, I was over designing/building it. With all the tweaks and gadgets and new parts, it was going to take me 6 months to build, some serious math to layout the interlocking joint angles and cost $1900 in material – I may have priced solid 4” thick seasoned Eastern European beech and walnut for the top and legs…
Anyway, I came to my senses and decided on using the pine I had already purchased for the legs and stretchers, lap joints with bolts instead of compound dovetails, a liberal amount of hide glue here and there, and a top made from re-purposed IKEA counter tops and will install a leg vice salvaged from a junk shop near Limoux, France instead of the $300 Benchcraft scissor vise that I was eyeballin’. The top will be solid all the way across instead of the split-top design.

The pine slabs have been drying in my GROP for 5 months and were ready to be cut down into their rough size. I had a little time this last weekend and spent 4 hours making all the leg and stretcher joint cuts – hogging out the material with successive circle-saw cuts and then chiseling them out. I am waiting to cut the tenon that fits into the top on each leg until I have the top in-hand. I chiseled and planed all the joint cuts smooth and I really wished I would have had a timber framing slick. When I do another bench or some large furniture with this type of joint anytime again, I will pick one up as it will pay for itself with the labor saved, in comparison to a 1.5” bench chisel, on 4 lap joints. I did the rough math and I think that I will have made 1023 total handsaw and circle saw cuts by the time the bench is done. There will be 16 bolts, 6 sections of 7/16” all-thread, 12 large screws, one 2’ ACME thread rod, 2 large dowels, 4 lag screws, 32 nuts & washers, and some sweat, blood, and curse words that will all go into it by the end. The new dimensions of the bench will be 25.5” wide, 34” tall, and 8.2 feet long. I believe the finished weight will be around 320 pounds.

My next milestone is the dreaded IKEA run. It will be a couple of weeks before I have the enough spending money horded together from my allowance (I want to be debt free in two years and retire at 55 so yes, I have an allowance…) and get the top cut out and fitted. I will update as I go.

Cornebarrieu Bench update (2)

Cornebarrieu Bench update (1)

bench drawings 2014 (3)

bench drawings 2014 top detail

Very Productive Weekend – except in the yard.

I did not mow the yard this weekend. It just didn’t happen. I meant to and I wanted to… I even took the mower and cord out, but it just didn’t happen. Instead I did this:

1. Redesigned the top of the workbench that I am building.
2. Threatened for 148th time to quit Facebook.
3. Didn’t quite
4. Updated status
5. Cleaned and organized GROP a little while grumbling about my lack of willpower
6. Worked on a J-O-B related spreadsheet
7. Finished bookends for wife – made from Victorian andirons.
8. Cut the base (legs and stretchers) for my workbench.
9. Turned two sets of TINY rosettes for our neighbor to replace a couple that are missing from a piece of furniture – help the neighbors when you can.
10. Put together a set of I-beams to reinforce a table top that is warping – they do that after 250-300 years…
11. Gave my wife a foot rub.
12. Glued up some maple blanks to turn later on
13. Played with the puppies – there are two now.
14. Got sucked into Pinterest
15. Watched a little TV/YouTube
16. Took puppies for a walk around neighborhood
17. Turned a small jar lid for wife out of some scrap cherry
18. Drank some Spanish rosé with wife and had a nice home cooked Thai meal
19. Fixed front door lock at 1:00am
20. Had weird dreams Saturday night
21. Slept in – new puppy had first good night’s sleep 🙂
22. Puppy sat while wife got her hair cut.
23. Told wife her hair was very pretty
24. We took puppies into Toulouse to meet some friends for coffee
25. Walked in park with wife and puppies.
26. Cut and chiseled joints in to ½ of the workbench legs
27. Sucked into Pinterest vortex again
28. Sent some J-O-B e-mail
29. Talked to my mom
30. Text messaged with my daughter
31. Tried to call my son – he was out with friends. Teenagers… 🙂
32. Played with puppies
33. Sent some more work-related e-mail
34. Told wife hair was pretty again
35. Made a tiny adjustment to kitchen island at wife’s request
36. Wrote a snail-mail letter to my aunt and son
37. Filled out a couple of post cards
38. Updated website a little
39. Looked at work calendar for tomorrow – very full.
40. Said dirty words…
41. Went downstairs to snuggle wife, puppies and to stay up too late on Pinterest or stupid Facebook.

Cornebarrieu Bench update (2)

Cornebarrieu Bench update (1)

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andirons 2014 (1)

Truffle 8 -2014 (3)

TRuffle and Brodie 7-2014

a couple of saw benches for the shop

I needed a couple of saw benches for my GROP, so I put a together two of different designs. They are both simple, plain and sturdy – no nails or screws, just glue, dado joints, and oak dowels. One is an old V-notch pattern that I have seen 1000 times and the other is combination bench/tool tote of my own design. I made the tote handle of the second one from a baseball bat that was cracked. I turned down the ends on the lathe to make 1-1/2″ round tenons and captured the tenons with wedges and 2 dowels – placed at 6:00 and 12:00 as keys. This permanently locks the bat and will keep it from twisting loose. the Louisville brand is facing up when carried – It adds a little flair to something that would normally be utilitarian and is big enough to carry everything I need to do a household fix/honey-do.

Grop Bench 2014 (1)

Grop Bench 2014 (2)

GROP update – French Cleats

Since I live in France, it only makes sense for me to have a shop organization wall that using French Cleats. I have wanted to do it for years, but just never found the time between house and furniture projects when we were in Seattle.

I ripped down some pine sub-flooring that came from the local French Big Box (Leroy Merlin), cut the edges at a 45, ripped the board in half, and glued/screwed them to a section of 1/2-ish (13mm) plywood. Exterior water-based poly was added to both the back and front before it went up on my clay-block garage shop wall with 8 large anchors. For my first French Cleat accessory: I had three small cut-off sections left from a picture shelf wall I did in my home office that I tacked to section of scrap ply to hold my #5 1/4 Jack, #4 smoother, and a couple of block planes. I keep the rest of my planes in a chest, but I use these constantly and wanted to have them in reach. I was so happy with how it all tuned out that I started building all sort of other holders and organizers: ones for squares, chisel rolls, Mallets, cords, apron hooks, saw horses, clamps, Japanese saws, etc… I ringed the garage with a single cleat about 6′ up for all sorts of diabolical organization plans, then hung two more above the lathe so that I would have a place to suspend my lathe chisel rack that is currently in progress and for a spot light that shines down on projects as they are turning.

I will update and post as I add new stuff.

French Cleat 2014 (2)

French Cleat 2014 (3)

French Cleat 2014 (4)

French Cleat 2014 (5)

French Cleat 2014 (6)

Talley - French Cleat attachments 2014 (1)

Talley - French Cleat attachments 2014 (2)

Talley - French Cleat attachments 2014 (3)

Talley - French Cleat attachments 2014 (4)

Talley - French Cleat attachments 2014 (5)

Talley - French Cleat attachments 2014 (6)

Talley - French Cleat attachments 2014 (7)

Talley - French Cleat attachments 2014 (8)