TV Stand Entertainment Center Thinger.

The rare post! Run in fear!

So here's one project out of several that I've been working on; The TV stand. This is the biggest project I've done so far, and it's essentially finished now. There's one more thing that I have to do to it, but I have to build a three-ring binder type system to mount on the angled front piece on top, and it can be done later.



48 inches tall, 25 inches deep, and 56 inches wide. Constructed out of pre-joined pine, stained with an Early American flavor stain for color, and sealed with my usual glossy polyurethane. Exposed screw heads for character, and because Exe and I both agreed that the hole filler buttons look cheesy.

In regards to the screws: I know I could have joined all the pieces and eliminated the need for the screws altogether, (And I fully acknowledge it would look better) but there were two things working against me with that: I didn't have any bar clamps big enough, and I like to overbuild things. All the joints are glued and screwed. I sat on the top of this (And inside it too) and it never creaked.

All that said, this was fun to build. From concept to design to finished product, I think I have about 25-30 hours worth of work in it. I used pretty much every tool I had, got to use some techniques I haven't used for years, and a lot of the work was done using hand tools. I ran into problems and had to change the design slightly on the fly, or fudge out some math to make things work, but it's solving problems like those that I live for when I build things.

Now what should I build? I think a workbench for the garage is in order...

Just a teaser.

Yeah, I haven't been doing much in the way of artings. I've been too busy riding my bikes. But for the one or two people who may still look here, Here's a teaser:

Drying between coats.

Holy wooden projects, Batman!

Yeah, I've been lazy. I've got bowls done that just need to be photographed, and then posted about. All except for this one, which I hurried up and took pictures of before I gave it away to my roomie's parents... which was before Christmas... yeah, I've been lazy.

This is a bowl turned from a clear pine board, cut into squares and laminated before turning. It was an experiment, as I've been wanting to do some taller turnings, and this is the first one I've done. I don't remember the actual size, but it was between 4 and 5 inches tall, and roughly 7 inches in diameter. Finished with my usual combination of natural Danish Oil and polyurethane. If I had known it would turn out so light in color, I would have tried staining it, but as it is, it looks nice:


Next up is a project I became involved in at work. My boss brought in a chess table with a big nasty ugly crack right down the middle of the tabletop. My task was to fix it. I don't have any before pictures of it, but imagine a crack nearly 1/4 inch wide running with the grain along the entire width of the table, with evidence of glue having been poured into it in an effort to keep it from worsening, which failed.

I ultimately ended up disassembling the table completely, and finished the job that the table was trying to accomplish in the first place, splitting the table completely in half along the crack. I had to carve out all the old glue, sand down the joining areas, and save as many of the small chips of wood along the upper finished edge of the crack as I could. After all this, I put it on the press and joined the two halves together with generous amounts of Gorilla Glue.

Due to the different expansion rates of the wood in the center of the table versus the wood used for the border, the crack in the border did not close completely, though it was less than half the width it was. The crack across the chessboard portion closed up nicely, in comparison. I ended up puttying the cracks in the border, and staining the putty with a custom mixed stain to match the wood. After all this, I sanded the entire table top with 600 grit paper, and lacquered it.

Drying in the spray booth at work between coats.

Now, because the table was now over 1/8 of an inch smaller in one direction, none of the screw holes on one side were going to line up. And with age, all the holes had opened up to the point that if I had put the screws back in, the holes would strip as I tightened them down. So, I used a hardwood dowel to fill the holes, basically giving me a brand new spot for each screw.

In the end, I think my efforts paid off:
I'm happy with it, as it turned out better than I had hoped it would. It was also a learning experience for me, as well as a refresher for some techniques I haven't used since high school. Hopefully my repair will last another 50 years.

Random cool pictures

So, I was getting things ready to build a wheel truing stand, when I discovered a cool kaleidoscope effect with one of the parts. So out of curiosity I grabbed my camera to see if it would pick it up.










No photoshop effects, no processing other than to resize them. I was aiming the camera and the tube at random light sources. (a lamp, a window, another window, a wall...)

I thought it was a neat effect, and since it's been a while since I put anything here... here we go. I may have to build on this eventually.

Walnut

Further digging into my pile of scraps that my friends have given to me... I present this walnut bowl. It's rather hard to tell in the pictures, as the camera did a good job of washing out the color, but it's actually a cut spanning both the dark heartwood (black walnut) and the sapwood. It made for a very nice blending effect on the inside of the bowl.


I forgot to measure this one before I gave it away, but my guesstimates put it at about 7 3/4 inches across, and 1 3/4 inches tall. It is finished with natural flavors of danish oil and polyurethane. One of the things I like most of this bowl, besides the grain, is the fact that there are next to no turning marks in it.

Walnut is one of my favorite woods to turn, and this is the first piece I've done in quite a while, as well as the first time I've turned walnut across the grain. The last time I did a bigger walnut piece, I didn't have as much experience or patience with woodturning as I do now, and while what I made is pretty, there is a huge difference in quality between then and now. But then I go and look up what professional turners are doing, and realize I have a long way to go.

Step by step

Yesterday as I was sorting boards out in preparation to glue them together into blanks, the idea came to me to show a little bit of a step-by-step of how I prepare and turn the majority of my bowls.

First, we need a board:
That should work. I got some more cedar from one of my friends at work, and we planed it down smooth and cut it into 8 inch squares. When I laminate boards together for cross-grain bowls, I start by lining all the pieces up the same way they were cut out of the board. This helps the grain to line up and flow with an uninterrupted look around the outside of the bowl. The straighter the grain is, the better the effect, but the more figured the grain, the more interesting the look.

I figure out which end I want to be the top of the bowl, and which one the bottom. Most of the time, I try to have the more solid and straight pieces at the top to add strength to the rim of the bowl, with figured and cracked pieces at the bottom, so the larger mass of wood there will help keep it together. It doesn't always work out that way. But, once I've decided, I start at the end that I want to be the top, and pick that piece up, and set it down on the next one. Then pick those two up, and set them on the next one, and work down accordingly, until it looks like this:
Looking at the end grain of the boards, it looks like it'll be a nice flowy piece. Once I'm happy with it, I mark the boards in a way that will help me remember how to orient them with the rest, and start gluing. I try to do one glue joint at a time, which helps keep the glue lines narrow. For this block as well, I'm also using a jig to line the two boards being joined with each other as well. It cuts down on the frustration of having the two boards slide around as you're trying to clamp them together.
Once the glue is set enough, (the glue I use has a clamp time of 30 minutes, though I wait an hour or more) I laminate the next board on, until I have the entire stack glued together. Then, I find the center, and glue on my faceplate block. That's so that when I mount the faceplate on the bowl blank, the screws are going into the cheap scrap wood, letting me use more of the project wood for the finished bowl.
In the picture, the big stack is Spanish Cedar, and the small single board is cherry. Once the glue dries fully, about 24 hours, I take the blanks out to the lathe, cut the corners off to make them octagons, (much faster and less scary than roughing out the squares) and start turning! Hopefully these will get turned on Sunday.

In progress

Today was lathe day. I got to try my hand at turning something a bit taller than I usually do, as well as turning one of a few pieces of walnut I've acquired.

Before:


And middle:

Just need to sand them and finish them.