~ A Woodworker's Journey ~

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Just having fun with my hobby. Always striving to learn my craft and improve my abilities. I enjoy making nice furniture for the house and other small things like decorative boxes, bowls/trays and other fun items. Also will often be building a lot of things to outfit my garage workshop.

15 July 2011

Woodwhisperer Guild Summer 2011 Guild Build Adirondack chair - Finishing the side legs

Posted on 14-July-2011 at:
  Wood Talk Online > The Wood Whisperer Guild > Guild Builds > Adirondack Chair  > Oh, put me in, coach - I’m ready to play today 

The following is a copy of one of many forum posts I made in the Wood Whisperer Guild Build Forum.  For summer 2011 Marc "The Wood Whisperer" Spagnuolo selected Greene and Greene inspired Adirondack chairs for the Summer 2011 Guild Build project.  I wanted to bring over my forum posts to this blog so family and friends could follow my progress without having to join the Wood Talk (Wood Whisperer) Online forums to see the progress.  I'll be copying and pasting all my Wood Whisperer Guild Forum posts over here as well.

I finished the side legs (minus the sanding and edge round overs that I will do just before assembly).

Last night the mortises got cut on all the legs, the curves on the first leg got cut and lots of sanding out the band saw marks happened last night. Tonight was a short night in the shop of just cutting out most the waste on the other three legs on the band saw then using the flush trim bit on the router to get the other three to match the first leg. I went with Aaron's partial cloud lift bottom edge profile - mainly because that will allow that feature to be in the stools I will build and the stool has very few opportunities to use G&G details.




At this point I am getting close to being caught up with Marc's videos. I've really been enjoying the combination of working with tools needing electrons and with the hand tools - over the past year I have slowly built up enough of a hand tool collection to feel its about time I began to get good at hand tools. Therefore I am thinking I will do the front apron with the router and chisels method and see if I can manage to make nice ramps in the slots with the chisel. I'm still debating on whether to try to do the ramps more freehand or use Tom Crawford's idea and build a ramp guide from a piece of scrap. It'll probably just come down to what mood strikes me at the time.


Woodwhisperer Guild Summer 2011 Guild Build Adirondack chair - Starting on the side legs

Posted on 12-July-2011 at:
  Wood Talk Online > The Wood Whisperer Guild > Guild Builds > Adirondack Chair  > Oh, put me in, coach - I’m ready to play today 

The following is a copy of one of many forum posts I made in the Wood Whisperer Guild Build Forum.  For summer 2011 Marc "The Wood Whisperer" Spagnuolo selected Greene and Greene inspired Adirondack chairs for the Summer 2011 Guild Build project.  I wanted to bring over my forum posts to this blog so family and friends could follow my progress without having to join the Wood Talk (Wood Whisperer) Online forums to see the progress.  I'll be copying and pasting all my Wood Whisperer Guild Forum posts over here as well.



Well I got some good shop time this past Saturday and this evening. I finished out the front legs by putting the short 1/4" tenon on the top of the leg and sanded out all the indent details Friday evening and Saturday morning. I got the side legs started on Saturday and got all the operations covered in side legs part 1 video. I still need to cut the mortise for the lower back brace into the inside of the side legs and cut all the curved profiles. I'm getting there slowly but surely - hoping I will get some good shop time in this coming weekend to really get some of this knocked out on the chairs.

 

Woodwhisperer Guild Summer 2011 Guild Build Adirondack chair - Adding the front leg indent detail

Posted on 6-July-2011 at:
  Wood Talk Online > The Wood Whisperer Guild > Guild Builds > Adirondack Chair  > Oh, put me in, coach - I’m ready to play today 

The following is a copy of one of many forum posts I made in the Wood Whisperer Guild Build Forum.  For summer 2011 Marc "The Wood Whisperer" Spagnuolo selected Greene and Greene inspired Adirondack chairs for the Summer 2011 Guild Build project.  I wanted to bring over my forum posts to this blog so family and friends could follow my progress without having to join the Wood Talk (Wood Whisperer) Online forums to see the progress.  I'll be copying and pasting all my Wood Whisperer Guild Forum posts over here as well.

Well I managed to get the G&G leg indent jig built last night and went to grab my set of porter cable router guide bushings only to discover the sets largest O.D. diameter bushing was 51/64. It was just as the local Woodcraft store was closing I made this discovery. SO tonight after work I picked up a 1" guide bushing and got to work cutting the indent detail on the bottom of four legs before I had to stop to go eat dinner. I just need to do the slight curve on the bottom of the leg edges with a hand plane and sanding and cut the short square tenon at the top of the leg. After that its find my sanding zen frame of mind and work on sanding out all the machining marks on the leg and putting slight round overs in the indent detail. Hopefully I'll have that done before the weekend so I can focus on 2 sets of side legs over the weekend.



Woodwhisperer Guild Summer 2011 Guild Build Adirondack chair - Yet another table design

Posted on 4-July-2011 at:
  Wood Talk Online > The Wood Whisperer Guild > Guild Builds > Adirondack Chair  > Stool & table designs to go with chair

The following is a copy of one of many forum posts I made in the Wood Whisperer Guild Build Forum.  For summer 2011 Marc "The Wood Whisperer" Spagnuolo selected Greene and Greene inspired Adirondack chairs for the Summer 2011 Guild Build project.  I wanted to bring over my forum posts to this blog so family and friends could follow my progress without having to join the Wood Talk (Wood Whisperer) Online forums to see the progress.  I'll be copying and pasting all my Wood Whisperer Guild Forum posts over here as well.

OK version 4 of the table. Simple rectangular bread board ends on both the top and the shelf. Ebony splines for the top and rectangular ebony plugs on the cloud lift stretcher covering two screw heads going through cloud lift stretcher into shelf bread board ends. The table has certainly been the tougher design - it is such a ripe pallet for throwing design ideas at, but it also seems its the easiest to get carried away on.

@Marc - notice in the table I tried the smaller 1/4" square plugs covering screw heads into the dowels of the bracket arms - I am not certain if I have the placement where you were thinning or not. I am trying to bring in the common thing the G&G brothers did of not always aligning the square plugs on the center line - there was often a few purposely put out of alignment. Let me know if this is where you were thinking the smaller square plug would go or not - I wasn't positive if you intended it to cover a screw head going into either the end of the dowel or directly into the end of the bracket.

@Aaron - just to see visually how plugs on the side of the chair legs matching the plugs on the side of the stools side legs. Only one of these would be a real plug covering a screw head into the lower back brace, the other would be a "faux" plug for balance and aesthetics (something else the G&G brothers did - not all the plugs were there for covering screw heads, or structural reasons, some where just plain decorative). It shows in the set picture - this was just a quick copy and paste of the plugs - again not sure of the placement and I am leaning towards no plugs on the side leg in either the stool or chair.

What do ya'll think - am I converging on a good clean design solution?

Woodwhisperer Guild Summer 2011 Guild Build Adirondack chair - New table sketchup model

Posted on 4-July-2011 at:
  Wood Talk Online > The Wood Whisperer Guild > Guild Builds > Adirondack Chair  > Stool & table designs to go with chair

The following is a copy of one of many forum posts I made in the Wood Whisperer Guild Build Forum.  For summer 2011 Marc "The Wood Whisperer" Spagnuolo selected Greene and Greene inspired Adirondack chairs for the Summer 2011 Guild Build project.  I wanted to bring over my forum posts to this blog so family and friends could follow my progress without having to join the Wood Talk (Wood Whisperer) Online forums to see the progress.  I'll be copying and pasting all my Wood Whisperer Guild Forum posts over here as well.

OK here is a third option for the table top with an edge profile on the "breadboard" ends of the table top that matches the edge profile on the chairs arm rests. Let me know what ya'll think.



Woodwhisperer Guild Summer 2011 Guild Build Adirondack chair - Routing the front leg mortises

Posted on 3-July-2011 at:
  Wood Talk Online > The Wood Whisperer Guild > Guild Builds > Adirondack Chair  > Oh, put me in, coach - I’m ready to play today 

The following is a copy of one of many forum posts I made in the Wood Whisperer Guild Build Forum.  For summer 2011 Marc "The Wood Whisperer" Spagnuolo selected Greene and Greene inspired Adirondack chairs for the Summer 2011 Guild Build project.  I wanted to bring over my forum posts to this blog so family and friends could follow my progress without having to join the Wood Talk (Wood Whisperer) Online forums to see the progress.  I'll be copying and pasting all my Wood Whisperer Guild Forum posts over here as well.

Well today was limited in the amount of shop time I got. Between family stuff (like going to see the new transformers movie with my wife and the girls) and working on Sketchup designs for a small cocktail table and footstools to go with the Adirondack chairs I didn't get as much time in the shop as I had hoped.

I did manage to get a little bit done this evening and get the front legs cut to length and the mortises routed into them.


Marc, my mimicking you from what you did in the video by putting painters tape on the rear and apron faces saved me from making a mistake during marking of the mortises and when referencing the router fence to the correct face. I wanted to make sure I kept the router fence on either the rear or apron fence to stay consistent on all four legs to remain consistent. I almost extended the start and stop lines from one face to the wrong face during markup, but I noticed the tape wasn't on the face I started to mark and I cam close to clamping the legs down with the wrong reference face out towards the edge of my bench. I came close to not putting the tape on believing I would have no problem keeping things straight, but even with the tape I almost got the faces of my legs confused.

Oh a frustrating thing I discovered about my Milwaukee router. It does not have a center line reference mark on the plunge base so I could not line up with my center mark. I had o use the other method Marc showed us in either the last video or the one before of lining the cutting edge burr of the up cut spiral bit up with the the outside line mark on the leg. Why Milwaukee could not have put a center line reference mark on a couple of sides of the base plate, especially the two sides of it that are parallel to the edge guide fence when it is mounted on the router, is beyond me. I get not putting marks on the base plate itself since it may not have been screwed on centered, but it could have been cast in the base edges itself since the motor is always centered in the base. For the most part I have really liked the Milwaukee combo set, but this is definitely a strike against this model of their router.

BTW in the pic you will see an easy convenient way to clamp the piece down if you do not have the convenience of a good vise on a woodworker's bench. I could have pulled out my Black & Decker workmate as well but the clamps on the edge of my radial arm saw bench just seemed quicker and easier to set up.

Off to shower and rest and relax before bed time. Happy Fourth of July everyone!!! 

Woodwhisperer Guild Summer 2011 Guild Build Adirondack chair - Sketchup designs for matching table and footstools

Posted on 3-July-2011 at:
  Wood Talk Online > The Wood Whisperer Guild > Guild Builds > Adirondack Chair  > Stool & table designs to go with chair

The following is a copy of one of many forum posts I made in the Wood Whisperer Guild Build Forum.  For summer 2011 Marc "The Wood Whisperer" Spagnuolo selected Greene and Greene inspired Adirondack chairs for the Summer 2011 Guild Build project.  I wanted to bring over my forum posts to this blog so family and friends could follow my progress without having to join the Wood Talk (Wood Whisperer) Online forums to see the progress.  I'll be copying and pasting all my Wood Whisperer Guild Forum posts over here as well.

 Ok I have been spending less time today in the shop, between going to the new Transformers movie with family (it was good but maybe not quite as good as first two) and time on Sketchup working out some design details for a table and stool to go with the Adirondack chair. First I need to really thank Aaron for some help on Sketchup - he knows what hurdle he helped me get over but it really was easy once you knew the trick (kind of like many things in woodworking actually). Here I thought I was pretty good in Sketchup - but like with most things there is always something new to learn. His input and critique on the design itself has also been helpful and I appreciate all his design advice as well.




OK so now I am throwing these out here for ya'lls (yes I am a southerner from Texas so we spell the plural you - ya'll - sure beats youse guys - LOL) input.

First off the simple design issue is the stool - there is very little involed in its design. The only elements you can bring in from the chair design is the front legs, the front apron, the seat slats, and the side legs. Given there is hardly anywhere to incorporate the cloud lift in the stool I choose to use Aaron's 2nd alternative side leg design with a half cloud lift on the bottom edge of the side leg and I will be doing that in my version of the chair as well so that the chair and stool flow together.

Structurally the slats of the stool probably give enough support for the side legs that the second apron down at the low - I suppose that's the front - end of the stool is maybe not needed, but I felt it really helped make the chairs front face apron more of an element in the set. Plus when the stool is up near the chair it hides the front apron on the chair.

The table is giving me more grief in terms of design details and I am not sure I am satisfied with the design ideas I have thus far. One of the features I wanted is a small shelf below the table top so that it would be a convenient place to put a citronella candle without it eating up space on the small table top. They say things are bigger in Texas and damn it!! - its suretainly true of the mosquitoes. Here, let me just throw the different combinations of design ideas I have thus far out there on the table (pun intended).

The first is putting slats in for a table top and for a lower shelf. I did discover in this version that the shelf slats end up slightly above the top of the cloudlift side stretcher - though that could probably be fixed with some tweaking of the dimensions.









The second version is my attempt to bring in another G&G element that is not used in the chair or stool - through tenons that are rounded over. I am a tad concerned its bring in an element that's not needed for the set, but I do think its a much cleaner design then the slats and ebony plugs design.










 Lastly a bit of a hybrid of the slats and ebony plugs for the table top mixed with the through tenon design for the lower shelf.


One of the main features of the table is to repeat the arm brackets in a way commonly used by the G&G brothers as brackets between a table apron and table legs. It helps tie that element well between the table and the chairs, but it does mean not using the cloud lift profile on bottom edge of the aprons. As far as I know, and granted I am by no means fully versed in everything G&G, the G&G brothers never mixed those two design elements in the same piece. So the best way I saw to bring in the cloud lift was to do something I have seen done before (either by G&G themselves or in G&G inspired furniture designs that came after them) is to make a table stretcher in a cloud lift profile.
Well that's the design ideas I have thus far on this. I think for the most part it all fits well together as a set - here see what you think of them together in a set:


So please comment and throw ideas out there and feel free to critique to your hearts content on the designs I have proposed. Nothing is set in stone - or maybe more appropriately cut in wood yet. I am not even going to begin building the stools and table until after I have two chairs built so, for me at least, there is still plenty of time to solicit comments and input from my fellow guild mates.

Has anyone else thought through a table or stool design yet? If so care to through the design out here to share with the rest of us? Hell if its paper and pencil design scan it in and through it out here. I am sure we can all come up with some good inspiration from it.

Well I am off and back to the shop to finish my two sets of chair front leg mortises and bottom leg details.

Woodwhisperer Guild Summer 2011 Guild Build Adirondack chair - Milling the rough lumber to final thickness and rough dimensions

Posted on 2-July-2011 at:
  Wood Talk Online > The Wood Whisperer Guild > Guild Builds > Adirondack Chair  > Oh, put me in, coach - I’m ready to play today 

The following is a copy of one of many forum posts I made in the Wood Whisperer Guild Build Forum.  For summer 2011 Marc "The Wood Whisperer" Spagnuolo selected Greene and Greene inspired Adirondack chairs for the Summer 2011 Guild Build project.  I wanted to bring over my forum posts to this blog so family and friends could follow my progress without having to join the Wood Talk (Wood Whisperer) Online forums to see the progress.  I'll be copying and pasting all my Wood Whisperer Guild Forum posts over here as well.


 Well its the second day of my build of 2 Adirondack chairs. I didn't quite make my goal of getting the two front legs finished - turns out there is a a damn lot of wood to mill. But at the end of the day there are two stacks of milled cypress sitting on my radial arm saw bench. Here is what two stacks of milled cypress for two chairs looks like -












Here's the mess left behind after jointing and planing that much cypress.


Someone please call my wife and explain to her why a $1500 cyclone dust collector is such an important investment - please I can use whatever lobbying help you can provide ;) (just kidding the dust collector is planned for a bit latter this year).

Hey Marc, since Jet/Powermatic is in such a marketing blitz over their single stage collectors with the vortex cones maybe you can convince them how well it will help their efforts if The Woodwhisperer just happened to have a drawing and/or contest to give one of those away to a lucky Guildie (free schwag is always better then having to buy one - LOL).


Well I am off to shower and take it easy for the rest of my evening
.

Woodwhisperer Guild Summer 2011 Guild Build Adirondack chair - Rough Lumber purchase

Posted on 1-July-2011 at:
  Wood Talk Online > The Wood Whisperer Guild > Guild Builds > Adirondack Chair  > Oh, put me in, coach - I’m ready to play today 

The following is a copy of one of many forum posts I made in the Wood Whisperer Guild Build Forum.  For summer 2011 Marc "The Wood Whisperer" Spagnuolo selected Greene and Greene inspired Adirondack chairs for the Summer 2011 Guild Build project.  I wanted to bring over my forum posts to this blog so family and friends could follow my progress without having to join the Wood Talk (Wood Whisperer) Online forums to see the progress.  I'll be copying and pasting all my Wood Whisperer Guild Forum posts over here as well.

 Well the lumber is bought and just hit my shop by lunch time today - just barely shy of 110 bf total of cypress.



Marc when my wife asks why so much I'm blaming you - you said if its possible overbuy - I got you on video saying it - LOL!!!! Really I am hoping its enough to pull off two chairs and accompanying footrests and a cocktail table for in between the chairs on the deck with a bit left over.







 When I was in the lumber yard with the fork lift driver puling stock all we could find is about 6" wide 4/4 stock and i was trying for about 7 to 7.5" wide on most the boards (except for the 10.75" wide pieces to cover the center back panel of the chair). The jump- up from 6" that we found in the stacks was to about 9.5 to 10" wide boards (which came with a wide board up-charge unfortunately). When I took the pull ticket back in the inside sales guy swore there was 8" wide boards out there but after being in the heat and rummaging through the stacks I decided to just pay the up-charge then go on a hunt for the narrower 8" boards.

So this afternoon is all about cutting down rough stock and milling it. Hoping to have four front legs done by end of day tomorrow - will depend on how my energy and motivation holds up - LOL (and the wife wants to go see Transformers this week and we have family BBQ to attend so we'll see how much family duties/activities pulls me out of the shop as well).