A Bench Building Machine

In addition to the 5-board bench by our front door, I have built a large bench for our dining table and one for our entry-way with shoe storage, per my sweet wife’s request. I have a couple of saw benches for the GROP and 2 narrow ones for my office all cut out as well, but not put together. These benches are traditionally “furniture of necessity” and not meant to be fine furnishings, but I think that there is still beauty in their simplicity and usefulness (useful and helpful are the highest Talley-family compliments). Additionally, they are simple, cheap to build, and lend themselves to hand-tool only construction. Not a single screw or nail is used: I used through-tenons, oak wedges, and dowels. With almost instant tangible results, the whole process in building these is therapeutic. When and if I have a super-crappy day at my J-O-B, I can go into the Garage/Shop/GROP after dinner and make some wood shavings and improve the bejesus out of my mood. Cheaper than counseling and less bloody than a rampage 🙂

7/3/14 Update:

So… The bench built for the dining table had ends that extended a little too far from the legs. It made the bench tippy if someone either sat on just the end or got up with someone also sitting on the other end. There were a couple of incidents where a butt almost hit the ground. I removed 7″ from either side and changed the stretcher detail a bit as the plain 45 degree cut didn’t really match the curl detail on the feet.

IMG_1906

IMG_1908

Roller Derby, St. Paddy, Dresser Building and an Anniversary Weekend

This weekend was busy with friends, a dinner out, St. Paddy’s Day activities, an outing to the Roller Derby (?!), and the 9th anniversary of the day that my sweet wife and I met was on Sunday. Even with all that, we still got bunches done around the house: Our under-bed dresser finished, bathroom table drawer installed (a little work on that left), wine crate storage boxes made, basement lighting installed, and the basement work bench is moving along.

The drawers for the under-bed dresser and the one for the bathroom all came from a wooden donor-dresser that my father-in-law drug home from a garage sale last summer. He paid $4 for it and it was in pretty bad shape, but it was solid wood and had potential. It was mistakenly left in the weather (plastic cover leaked) for a month before I salvaged the drawers, cut out off the top and used the sides for kitchen cabinet door panels. I re-squared the drawers, added dividers in the fall, and over the Christmas break sealed the insides (The Ruminator helped). After lots of filling and sanding and more sanding, I stained the fronts to match our bedroom furniture, then built ¾” plywood beams to hang the drawers from bed frame and used some scrap oak flooring as drawer guides/runners. The final product really looks good and is super functional. While some husbands bug their wives by filling the house with brought-home junk – I give my wife more and more and more storage and organization space.

On Sunday, I put the final coat of finish on the basement workbench top, let it dry, and then installed the three runs of aluminum t-track. Stamps-With-Foot bucked up and helped me wrestle its 200 pound beech and maple mass onto the steel base. I secured it with screws and covered the top with carpet squares while I finish the upper shelf/cabinet. I installed a outlet power strip under the main body of the topper and removed the old drawer dividers. I will soon add a plywood back with a mirror, a light under, a dedicated air supply line, install the desk drawers under the bench and mount 4 reclaimed letterpress drawers directly under the top as well. Happy with the progress so far.

A giant sealed dome over our place would solve most of this….

There are some days where I want to just drop everything I am holding, turn off the lights, lock the door, and go on an extended vacation involving a sugar-sand beach and copious amounts of fruit laden alcohol.  This Saturday was one of those days.

I decided to work on the kitchen cabinet doors, cut some plywood sheets down, and tackle a bench top while the sun was shining.  I opened the shop, brought out a plastic truck-bed toolbox to cut on (my 4 sawhorses are currently being used elsewhere), pulled 3 full-sized sheets of ¾” and ½” plywood out of the lumber rack and drug it all out into the backyard.  After marking the first sheet, adjusting my saw blade depth, lining up my rip fence, and checking for clearance – I started my first cut and immediately ripped a 6” long kerf-cut into the top of the tool box that the sheet was sitting on.  Dammit! I cut the rest of the plywood up without incident, but grumbled thinking about the mistake (I will fill and patch it with molten P-Tex plastic at some later point).  After stacking all the assorted pieces of ply back into my cluttered shop, I man-handled the 170+ pound beech and maple in-work bench top from the basement and placed it on the now-damaged toolbox – trying very hard not to either herniate a disk in my bask or tear what is left of my shoulder.

My Shop/Garage is pilled deep and high with lumber, hardware, undone winter projects, wood shavings, tools, sawdust,  flotsam & jetsam, etc….  I spent an hour trying to set up my router and in all the clutter and mess I couldn’t find a ¼” collet for one router and the other does not have an integrated fence, so using my big monkey brain, I improvised a fence.  All I really wanted to do with the top was to route channels for t-track and thoroughly sand it down before taking the beast back into the bowels of the basement to apply stain and a tung oil finish.  All was going as planned and my first cut was perfect.  The second cut went just the same, but at the very end of the third cut my improvised fence failed and the router wobbled – gouging the top that I had spent a month building.  Jesus H. Christ I was pissed! – Mostly at myself, but there was some vitriol left over for the machine in my hands.  I said dirty, hateful, vile things while resetting the fence and making an adjusted cut.  I moved on to make my last cut in the very front lip of the bench and while the fence held, I stood up mid-way through the pass and the router wobbled, making the bit chew into a section of wood where I did not want it to go.  I gritted through the rest of the pass and finished the cut, but the second I was clear of the wood, I wanted to throw the still running router on the ground and beat the electric life out of it with the pruning shears that were leaning against the garage wall.  I had to walk away, hand over my mouth, and just breathed deeply with my back to the offending router, my own incompetence, and the damage they had both wrought.  My moment of reflection was short lived because just as I turned, I felt the first drop of rain fall from what was minutes ago a blue sky that had ominously darkened while I was focused on my router-rage (I swear it happened just like that – strait out of a hip urban dramedy…).  SHIT!!  I ran for something to cover the bench top.  The only thing I could find was a pink tent fly and a sheet of cardboard.  I covered everything and retreated into the shop, right eye twitching with disbelief/confusion/anger.  I spent the next hour drinking coffee laced with sawdust and moving piles of crap around in my shop.

When my sweet wife got home she MAY have found me in the shop muttering to myself, pacing, covered in saw dust, contemplating the logistics of building a giant sealed dome over our entire lot.  She talked me off the ledge, helped me put the top back into the basement, patted me a little, told me I was pretty and smart and a good boy, put me in some fresh, sawdust free clothes, and took me out to see a movie.

I got up the next morning and after a yummy breakfast of flaky croissants, bacon, eggs and two cups of coffee, I went downstairs and chiseled out the offending screw-ups, then cut and glued maple patches in.   After calming down some and after a good night’s sleep, I felt better about the whole thing, but me and that router are still not on speaking terms.

Lawn Furniture done!

As I mentioned in a previous post, there had been parts for Adirondack lawn chairs all over the house and shop for 9+ months waiting on me to gather the will to glue them up and drive some weatherproof screws home.  The Ruminator and I put together when he was here this summer – he supervised while waxing poetic about dressing up like a viking – and I spent a combined 12 hours priming and painting them candy apple red.

Since I don’t want to repaint them every spring I used an oil-based exterior paint.   Holy crap, it was hard to find!   It seems that everyone has switched to latex based paint for homeowner use (ease of use, easy cleanup, better for the environment, etc…) and I had to resort to having gloss deck and concrete paint custom mixed.  It went on like glass though and should be impervious to our rainy long winter weather for three or four years.  My sweet wife super loves them and could barely wait until they were dry before giving them a proper, reading a book in the sun, test.

Below is a gallery of the whole build process:

Sawdust and paint fumes

It has been roughly eight months since my shop was robbed.  It is just now that I have found the will and desire to start building furniture again.  I have let projects and repairs pile up and let my garage shop digress into a sawdust filled junk-room.  There have been parts for Adirondack lawn chairs in my basement and shop since December.  I finally got around to gluing them up and screwing the pieces together when my son was here this summer.   That little project led me to start cleaning the shop and find all the stuff that has been waiting on me.  I dabbled with a couple of boxes, then started making pieces and organizing tools and supplies to tackle the larger stuff.  Below is a list of current projects that are in work:

  1. Painting the Adirondack chairs
  2. Re-build of my father’s 1971 bookshelves
  3. Kitchen cabinet doors
  4. Misc. Lathe tasks
  5. Kitchen cabinet pullouts
  6. Camp Kitchen box build and paint
  7. Campaign furniture for luxury car camping
  8. Hall mirror
  9. Copy of a 12th Century Abby oak door
  10. Fireplace surround and mantle
  11. New Kitchen cabinet pulls and knobs
  12. Garden tool shed
  13. Christmas gifts
  14. Garden table

The above are started and in-work.  I have plans to also build the below items soon:

  1. Small basement work bench (reloading and winter projects)
  2. Rebuild bookcase in master bedroom
  3. Murphy bed for my home office
  4. Box ceiling for master bedroom
  5. Home office bookshelves
  6. Chicken coop
  7. Ornamental planter box
  8. Cookbook shelf in kitchen
  9. Rebuild my standing desk
  10. Basement stairs rebuild

What I want Thursday – 4/12/12

A list of stuff and things that I want currently – not that I necessarily need, but that i wuold like to have or see done/happen:

1. More time to read, write, build, snuggle, climb, bike, run, laugh…
2. A twin Murphy-bed in my office disguised as a mid-century modern wardrobe so that we have more guest space.
3. For my year-long kitchen project to be finished
4. To remember the password for my old laptop so I can have access to 10+ years of pictures…
5. My very own spending money that I can do with what I wish without submitting to a vote/need analysis
6. To have my FVCKIN’ tools back that some asshat stole…
7. A few new t-shirts for summer and a flat belly to reside under them.
8. For my Mother and Sister to find the perfect place in life
9. For all the dandelions in my yard to cease to exist
10. I would very much like for the really sad, really pregnant girl I say in Seattle yesterday to find someone/something/someplace that makes her warm, happy, and safe.

Campaign Furniture

Charleston, SC is one one the places that makes Marta Stewart go all weak in the knees: it is antiques heaven.  I had just finished reading a post on the Lost Art Press Blog about a shop there that deals mainly in campaign furniture (a type of furniture made specifically for travel and/or military campaigning and something that makes  my inner Martha breathe heavy), when I got the serendipitous news that my J-O-B was sending me there for a few days. Well then…  I had one afternoon off and I drug a couple of coworkers to the antiques district downtown and hunted for the shop.  My, my, my….  The proprietor had original pieces from the British Raj that he let me fondle and covet.  I really wanted some personal alone time with a specific teak and wicker lounger.  Me, the chair, some port, candle light, and sweet, sweet love….

I am in the process of building my own campaign-style camp kitchen, chairs, table, and wet bar to take with us on the Lukowski-Gahagan-Talley Glamping trips planed for this spring and summer, where roughing it means the mushrooms are crimini instead of chantarails.   I snagged a few ideas from the shop and some additional research that I am incorporating.  I will post when somewhat complete, but in the meantime, take a look at some of the pictures I snapped and have included below.

MIA – last seen with paint on new pants and sawdust in eye

I realized yesterday that haven’t posted anything for almost a month: no astute observations, not one pointed remark, no weird OCD-driven lists, no pictures of adventures at home and afield…. Nothing. Hmmmm.  I have just been REALLY busy!! It started with painting the living room, the kitched paint was next, we expanded into wiring a hot tub, I decided to finish up a furniture project, the breakfast table “needed” to be cut down, fancied up, and refinished.  I am heavy into finishing my incredibly overbuilt and way too complicated kitchen cabinets, Halloween came, there was Thanksgiving prep, I had to put the garden to sleep for the winter, blow all the water out of the yard irrigation system, clean the gutters (4th time this year – grumble, grumble… hate neighbor’s tree… grumble, grumble…). On top of it all, my J-O-B was INSANE: lots of late nights, weekends, travel, OT, pressure, stress, etc…

There is some proof of all the work that we have been doing – I have semi-updated the pictures on my project page, but remember that most were shot with an iPhone in crap conditions.  None of this pics are going to get me into National Geographic!

It hasn’t been all work though:  I have been able to go to the range with my cuddly .45s and punch holes in some zombies a good bit – fine, fine stress relief.  I mentioned Halloween – Stamps-With-Foot and I outdid ourselves again this year at our local Halloween party. We went as Wednesday and Pugsly Adams – a big hit at the festivities.   I went as a pimp to work – think Will Ferrel in The Other Guys movie: grill, blond ‘fro, leopard coat/fedora, purple faux croc high-heeled side-zippered boots, a pimp cane, crunk cup, loads of bling, coke nails – I had it down. A my fellow engi-nerds let me down though… Not one other costume in my group – not even a funny t-shirt!!  Sales had some good ones this year, HR was all in, the fiber optics group brought game, but Engineering sucked it! How is it all those people with big brains, imagination, and vast amounts of reasoning ability could not come up with something?! There are WOW players, Trekkies, SGA initiates, one D&D uber-geek, and every single one of them (including the female members of our team) have slave-girl Leia dreams…. They let me down, but I soldiered on and even gave a new-hire tour and orientation in my pimp-o-rific attire. I will not forget or forgive their breach of the nerd code! Philistines.

Speaking of my J-O-B, the long hours, travel, all the late meals out, and my general lack of physical motivation has gifted me with 20 extra pounds of fat compared to this time last year.  In essence, it is my own fault – my bikes are all sitting there waiting on me to love them, I have a sweet pair of new running kicks, A gym membership that we pay for every month, and a dusty yoga mat.  I HAVE to dig deep, put away work and get my butt moving or I will be the size of Jabba the Hutt in no time and the Wife is not into Slave Girl Leia…

I think that brings it all up to date for the most part. I will try to be more diligent about keeping up when life starts swirling around me.