Author Topic: Mission Control Project: 5 years on, what to do with the leftovers? (Read 553616 times)

nostrebor · « **Reply #520 on:** October 25, 2005, 09:03:46 pm »

Pixelhugger · « **Reply #521 on:** October 25, 2005, 09:07:04 pm »

Unexpected mishap #1- Jointer stopped working. My dad brazenly suggested opening up the beast to see what might have gone wrong. I never would have done that myself.

Turns out the setup and delivery guys who... errr... set it up originally had reversed the motor mounting brackets. This meant they had to mount the drive wheel half way off the very end of the motor's arbor. Yikes. Well the set screw loosened over time and the wheel chose my project to come flying off with an ominous ker-thunk.

This is me swapping the motor mount brackets to allow the whole assembly to be aligned without placing the wheel on the bleeding edge. Total downtime: approx 1/2 hour.

Santoro · « **Reply #522 on:** October 25, 2005, 09:17:49 pm »

That cab is gonna weigh 1250 lbs.

Pixelhugger · « **Reply #523 on:** October 25, 2005, 09:20:08 pm »

Switching gears... here the attachment of the paper master template (shown earlier in the thread) to the MDF sheet which will be the actual trimming template for the sides.

Zakk · « **Reply #524 on:** October 25, 2005, 09:22:32 pm »

What's worse...I even cheacked this infuriating thread on the now infamous "honeymoon night"

Pixelhugger · « **Reply #525 on:** October 25, 2005, 09:34:28 pm »

Heh- didn't mean to call you out Zakk.

I'd have done the same if I'dve had internet access.

After Mark and Nostrebor's super valuable feedback on CP height I decided to add a few inches to the base. Spent a while rummaging through the kitchen and found a serving plate to add to the curve seamlessly. Reminded me of when I was a kid and I'd use my dad's variously sized coffee mugs as circle stencils.

Pixelhugger · « **Reply #526 on:** October 25, 2005, 09:35:47 pm »

Cutting the template out of MDF

Pixelhugger · « **Reply #527 on:** October 25, 2005, 09:47:54 pm »

The template cutout with a guide for the straight cut at the base.

Pixelhugger · « **Reply #528 on:** October 25, 2005, 09:54:53 pm »

The final template. It was almost surreal to walk around this in "real" 3D. After having manipulated this shape in virtual space for soooooo long, and being so familiar with all it's dimensions from various perspectives, it's hard to describe the satisfaction of cutting it into reality and looking up at it.

Pixelhugger · « **Reply #529 on:** October 25, 2005, 09:56:52 pm »

....and.....

nostrebor · « **Reply #530 on:** October 25, 2005, 09:57:38 pm »

Is that 37" performax sander your Dad's?

*nostrebor drools*

template looking good!

Pixelhugger · « **Reply #531 on:** October 25, 2005, 10:05:16 pm »

Yep! Wish it were mine. Sadly, none of this stuff is... other than the cherry

More surfacing/squaring up stock....

Maybe I suck. But my dad and I couldn't get 2" thick 7 foot+ boards to edge joint perfectly on the jointer. Same for the (kick ass) tablesaw. So DK this one's for you. This is our homemade edge jointing jig... later replaced with a straight board (after the aluminum started to flex). We ran a router with a 2" (yes they make them) straight bit along the guide to square up/joint the edge. The bit was a champ. We accidentally routed into the table saw deck twice when the assembly shifted inward. It actually cut a smooth semicircle into the (iron?) table and didn't break or chip. The subsequent cuts were all as smooth as the first. Now THAT's a tool!

Pixelhugger · « **Reply #532 on:** October 25, 2005, 10:10:09 pm »

Nostrebor (or anyone else who knows) what's your tolerance for spacing between edges of boards in a panel prior to closing them up with clamps. We obsessed over this but only in one case got a joint that was absolutely flush without pressing them together. Everything closed beautifully when clamped, but I couldn't remember how much space is acceptable (if any

) seems like on a panel this big you'd have to have at least SOME gapping (I'm talking like 1/32 or smaller). Help anyone?

Pixelhugger · « **Reply #533 on:** October 25, 2005, 10:12:38 pm »

The template on the boards for layout before gluing.

Santoro · « **Reply #534 on:** October 25, 2005, 10:18:02 pm »

Are the boards glued up yet? Otherwise I am confused as to why you'd be laying it out yet....

Pixelhugger · « **Reply #535 on:** October 25, 2005, 10:20:19 pm »

Hehe.... yep. Errr I mean, no, not in these pics. But by the end of the thread, yes.

Here's the final panel pre-gluing. Like Santoro said... it's gonna weigh a ton.

Pixelhugger · « **Reply #536 on:** October 25, 2005, 10:21:49 pm »

To conserve wood and keep from having to surface too much more I traced out some of the smaller details to find unused areas of the panel they might be cut from. The board seen beneath them in the first was needed for the second side panel.

nostrebor · « **Reply #537 on:** October 25, 2005, 10:22:00 pm »

Quote from: Pixelhugger on October 25, 2005, 10:10:09 pm

Nostrebor (or anyone else who knows) what's your tolerance for spacing between edges of boards in a panel prior to closing them up with clamps. We obsessed over this but only in one case got a joint that was absolutely flush without pressing them together. Everything closed beautifully when clamped, but I couldn't remember how much space is acceptable (if any ) seems like on a panel this big you'd have to have at least SOME gapping (I'm talking like 1/32 or smaller). Help anyone?

7' long boards... I would expect the thickness of 2 playing cards in places prior to clamping. It is almost impossible to get glue joints on 7' stock w/o production level equipment. Good clamps and good glue will take care of that for you.

Pixelhugger · « **Reply #538 on:** October 25, 2005, 10:23:26 pm »

THATS WHAT I NEEDED TO HEAR!! Man, nostrebor, I should've had your phone number!

nostrebor · « **Reply #539 on:** October 25, 2005, 10:25:35 pm »

I'm too lazy to read back in the thread, so...

Are you using t-molding anywhere on this cabinet? Are you having 8/4 exposed edges on your side panels? How are you goint to treat the edges if left exposed?

BTW, that is some fine looking Cherry! I see almost no sapwood, and straight grain. You should give your Dad a hug or something.

Pixelhugger · « **Reply #540 on:** October 25, 2005, 10:26:26 pm »

My first time using a bisquit jointer. I've splined joints but never bisquited. Talk about simple!!! This little thing is a dream come true. Super handy and kept these long ass boards aligned for the glue up with no glue float (or whatever it's official term is).

DrewKaree · « **Reply #541 on:** October 25, 2005, 10:29:04 pm »

Quote from: Pixelhugger on October 25, 2005, 10:05:16 pm

Maybe I suck. But my dad and I couldn't get 2" thick 7 foot+ boards to edge joint perfectly on the jointer. Same for the (kick ass) tablesaw. So DK this one's for you. This is our homemade edge jointing jig... later replaced with a straight board (after the aluminum started to flex).

Are you sure that big-ass straight bit wasn't a shaper bit?

If a piece of notebook paper fits your gap, you're good. Another tip is to make it dished slightly to allow for possible movement to NOT eff up your nice boards. If you can make the middle of your joint the widest point of your gap, glue and clamps should take care of the rest, and you've got the added benefit of when the wood expands and contracts with seasonal changes, the edges won't split on you.

If you know what a caul is (and I'm betting SOMEONE you know sure as heck does, given all the woodworking apparatus), what I'm trying to explain is that exact shape on both.....crap, lemme know if you're understanding what I'm saying. If not, I'll photoshop a quick pic.

DrewKaree · « **Reply #542 on:** October 25, 2005, 10:31:18 pm »

Quote from: Santoro on October 25, 2005, 10:18:02 pm

Are the boards glued up yet? Otherwise I am confused as to why you'd be laying it out yet....

The MDF is going to be used as a template. That's my understanding, at least.

Pixelhugger · « **Reply #543 on:** October 25, 2005, 10:31:27 pm »

Quote from: nostrebor on October 25, 2005, 10:25:35 pm

I'm too lazy to read back in the thread

Heh me too

Pixelhugger · « **Reply #544 on:** October 25, 2005, 10:33:46 pm »

DK- yeah we made sure any gap was centered for (I think it's called) a spring joint. No gaps at edges. I just couldn't remember from college woodshop if a "spring joint" refered to a bad thing or not.

We did use a caul at one point. The bisquits took care of most of the alignment.

Great post DK. This feedback is tremendously helpful and reassuring.

Santoro · « **Reply #545 on:** October 25, 2005, 10:34:34 pm »

Quote from: DrewKaree on October 25, 2005, 10:31:18 pm

Quote from: Santoro on October 25, 2005, 10:18:02 pm
Are the boards glued up yet? Otherwise I am confused as to why you'd be laying it out yet....

The MDF is going to be used as a template. That's my understanding, at least.

I was looking at the photo of the MDF template laying on the boards, but Mitch hadn't mentioned glue-up yet.

Pixelhugger · « **Reply #546 on:** October 25, 2005, 10:35:02 pm »

DK = another person whose phone # I wish I had available at the time.

Pixelhugger · « **Reply #547 on:** October 25, 2005, 10:36:34 pm »

Quote

I was looking at the photo of the MDF template laying on the boards, but Mitch hadn't mentioned glue-up yet.

Pixelhugger · « **Reply #548 on:** October 25, 2005, 10:39:27 pm »

*tries to think of a witty Monty Python quote about clamps and torture.... gives up*

Here is the first half of the first side glued up and clamped. Neither of us had ever joined up a panel of this size.... effectively we are making two large sized dining room tables. So... baby steps. One half at a time.

Pixelhugger · « **Reply #549 on:** October 25, 2005, 10:42:41 pm »

First half of one side complete. This end is a bit uneven, as I'm guessing the widebelt sander isn't a perfect replacement for a planer when working on stock this long. We'll take out the 1/16" or so top and bottom before joining it to the other half.

DrewKaree · « **Reply #550 on:** October 25, 2005, 10:45:48 pm »

It was bugging me not to be able to 'splain what I was talking about, and you pegged the term. Here's a pic, exaggerated to demonstrate what I was talking about. It'd be heartbreaking to find out a year or so down the road that seasonal changes started your cab sides splitting.

DrewKaree · « **Reply #551 on:** October 25, 2005, 10:50:39 pm »

* DrewKaree screams upstairs

MAAAAAAAAAA!

*deep breath*

MAAAAAAAA!

C'MERE AND LOOKIT WHAT HE'S DOING! C'MON QUICK!

she ain't comin?

THROW DOWN SOME MONEY! THE ICE CREAM MAN IS COMIN'!

I feel like I SHOULD be calling my mom to come see this, though!

Pixelhugger · « **Reply #552 on:** October 25, 2005, 10:52:31 pm »

The morning after.

Both halves of each side done. Template awaits final surfacing of subpanels and final glueup.

Like I said... 70% Sorry to leave it at this, but it's that blasted glue cure time before I can stress the panels again. Unfortunately that won't happen for a little while.

ARGH... road trip complete.

jcoleman · « **Reply #553 on:** October 25, 2005, 11:04:38 pm »

For the love of VidKids, make sure you put that thing on the ground floor.

Lookin' good...

Pixelhugger · « **Reply #554 on:** October 25, 2005, 11:06:38 pm »

Hehe... we live in a one story. Good thing too. I think I'll need piano movers to transport the thing. It will, however, be on massive casters (inset to be hidden) to make repositioning within the room easier.

Bones · « **Reply #555 on:** October 26, 2005, 01:57:25 am »

Certainly a different approach with the thickness of the wood and assembly. A question I don't know the answer to, with this much material is temperature expansion going to be an issue?

nostrebor · « **Reply #556 on:** October 26, 2005, 09:54:05 am »

Quote from: BrokenBones on October 26, 2005, 01:57:25 am

Certainly a different approach with the thickness of the wood and assembly. A question I don't know the answer to, with this much material is temperature expansion going to be an issue?

Shouldn't be any worse than a dining table made from hardwood. Once it is placed in a climate controlled environment, it will have little chance to move anyway.

pathdoc2 · « **Reply #557 on:** October 26, 2005, 10:49:40 am »

Unless you are going to use a transparent stain finish why use real wood for the sides?

markrvp · « **Reply #558 on:** October 26, 2005, 11:51:38 am »

Quote from: pathdoc2 on October 26, 2005, 10:49:40 am

Unless you are going to use a transparent stain finish why use real wood for the sides?

He is staining the wood a deep rich color.

AmericanDemon · « **Reply #559 on:** October 26, 2005, 12:05:34 pm »

Its looking real good there PH. Good progress.


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Author Topic: Mission Control Project: 5 years on, what to do with the leftovers? (Read 553616 times)