Sidecar Cot

Finishing / Sidecar Cot / Woodworking — No Comments
06
Feb 17

More assembly…

Started off the day with the second coat of shellac on the mattress platform pieces.

Left that to dry and started working on the rear support for the mattress platform. It’s basically an inverted ‘L’ shape made with a simple rabbeted butt joint, and while it’s probably overkill, I decided to put some wooden nails into it just for a little extra strength. So out with the bit and brace…

And that funky looking thing on the bit is a nifty eclipse depth stop that I’ve not had much excuse to use up till now…

Much nicer than just marking off with a sharpie or messing about with tape. With those holes predrilled, I planed off the glue lines and smoothed the outside faces and then set that aside while I drilled the holes for drawboring the front panel and the joints between the curved uprights and the top crossbar. By the time I got through that, the second coat on the platform pieces was done, so I sanded that down and gave them another coat of shellac.

Then I rived more stock to make up the drawboring pins and the wooden nails and the locating pins for the front support for the mattress platform.

It’s a fast process, but good grief is it loud, especially in an 8’x6′ shed, even with the echo-damping soundproofing foam on the ceiling. I have to wear ear defenders when doing this. And of course, you have to hit your thumb at least twice during the process (happily with the deadblow hammer rather than the lump hammer; that one would delay typing up a blog post for a few weeks while the finger bones healed).

The weekend’s shopping and dinner intervened in the process here, and afterwards, I finished off the nails and then used two of them on the rear platform support.

Hide glue again to bind it all together. Smelly stuff, and almost instantly tacky in the 10C temperature in the shed, so after wiping off the excess with a damp rag, I had to step back out to the kitchen to wash my hands before the next step, cutting the tops of the nails off with a flush-cut saw and a spacer.

Why do you need the spacer on a flush-cut saw? You shouldn’t is the answer, but whomever made this flush-cut saw decided to set the teeth on both sides, so if you use it like you’re meant to, with the blade pressed up against the surface, you’ll scratch the surface like a severely-pissed-off hedgehog. So first the saw with a spacer, then the rest gets taken off by chisel, and then the entire surface gets planed down.

And now that gets set aside. The ends still need to be planed flush and I need to use the router to cut grooves for the bolts in this, so no shellac for it today (same for the front support and for the curved uprights because they’re going to take a bit of work for finish planing due to the curve).

By now the fourth coat of shellac on the platform pieces was dry, so I brought those into the shed, and a minor disaster:

All three pieces have bloom on the underside. I’m not sure where the moisture that causes that came from, this side was facing down on the table so it wasn’t rain; they were elevated off the table at either end so it wasn’t contact with surface water; maybe it was just that the table was damp and that made the air just above it more moist? I’m not sure. Regardless, the fix is straightforward – brush either another coat of shellac on the top or just a swipe of isopropyl alcohol. Either one dissolves the top coat and lets the moisture evaporate, leaving a bloom-free surface behind.

I’ll still assemble the platform today though. But first, some finish planing on the ash panels. The front panel was very straightforward, just a few swipes with the #4½; but the side panel was a bit of a bugger, with the grain swirling around the place. In the end, the #80 saved the day. Damn glad I got it now, the card scraper would have been a fair amount of work for what the #80 did in a minute or three.

Now, on to the top crossbar. I’d left this over-long on both ends for strength while morticing, but now I’ve cut it back, leaving an inch on either end from the mortice outwards. So there are still some “wings” at the ends, and I would cut those into graceful curves if I had a bandsaw or a decent fretsaw (the Stanley FatMax coping saw… well, it can’t cope, is about the kindest you can say about it. I’m going to have to get myself a Knew Concepts fretsaw. And a bandsaw 😀 ). But I don’t have one yet, so I have a plan for something decorative. Meanwhile, I managed to stab myself in the finger without noticing it while chamfering the edges, and now the finish has some blood in it too. Well, why not…

This piece will need holes drilled in it yet for the rear platform mount to attach to, so no shellac for this piece today either.

So, as I mentioned a little while back, the plan for something decorative is to steal this idea from Brian Halcombe:

But my testing showed I needed a narrower, sharper gouge. So I got two off ebay in smaller sizes than the ones I had, and sharpened them up today and started digging away into the crossbar’s endgrain.

The ⅜” gouge I got was still too wide to be easily controlled in the endgrain (I used another test piece) but the ¼” one was usable with slightly more care than I normally have 😀

Brian Halcombe’s is way better, but that’s a few decades of experience and practice for you. This will look nice enough when shellac’d and waxed though, so that’ll do.

At this point, I was closing in on the end of the day, so I got the hide glue into some hot water to heat up (it’s about 8C and falling in the shed at this point even with the heater – we’re due a cold snap tonight to below freezing), and prep some clamps and cauls and I get the platform pieces ready for glue-up. The clamps are only just big enough by about a half-inch, but they suffice, and the gaps all close up nicely with only mild pressure.

I’m rather happy with that. Then last job of the night, I take some of the frame pieces that need no further cuts or major work, which is everything bar the curved uprights, and I finish plane them and then use the block plane to round over the arises.

For pieces like this, I think this method’s faster than the spokeshave. But not by a huge amount. Still, if you have a #60½ that you’ve worked to sharpen, why not use it? I really must fix the paint on that when this project’s done, along with the twelve million other jobs to do in the shed bringing tools back up to spec…

Anyway, with everything finish planed (and various notes to match mortices and tenons back up made in sharpie on the tenons and in the mortices themselves), it was time for more shellac.

I’m really starting to like the look of the walnut when shellac’d. Second coat tomorrow, and hopefully it’ll dry fast enough to be able to sand it tomorrow as well and put on the third coat. The end is in sight now. One finicky bit with the router to cut three or four grooves (I’ve not decided yet on having one or two bolts in the rear platform); and a bit of work to build a drawer; and then final assembly and finishing with osmo.

And then I’ll find it won’t fit in the car for delivery…

To-Do List (stuff in progress in blue:

  • Cut grooves in platform supports and matching holes for bolts in the curved uprights and the rear support upright
  • Finish plane the curved uprights
  • Shellac the supports and the curved uprights
  • Thickness the boards for the drawer.
  • Cut the drawer front to size.
  • Cut the drawer back and sides to size.
  • Cut dovetails for drawer.
  • Groove drawer with #43 for plywood base.
  • Maybe add runners underneath the drawer?
  • Assemble drawer.
  • Drill for drawboring on the M&T joints that I’ll be drawboring (the long rail to upright ones and probably the back support and top crossbar joints).
  • Make drawbore pegs.
  • Finish plane all parts.
  • Finish walnut pieces with a few coats of shellac.
  • Paint drawer with milk paint.
  • Assemble and glue-up and drawboring of everything.
  • Finish entire assembly with several coats of Osmo wood wax.
  • Close door of shed, lock it, walk away and never do another project with a deadline ever again.
Finishing / Sidecar Cot / Woodworking — No Comments
05
Feb 17

Assembly, part one of many…

First coat of shellac on the back panel dried nicely overnight. And it was dry today, so I figured I’d put on the other coats today outdoors and then assemble.

Rather than brushing on the shellac today, everything got ragged on (hooray for being able to buy lint-free cotton rags off ebay by the kilogram). Much more even application, no brush marks, and much, much faster for the long pieces of the frame. While this second coat was drying, on to making drawbore pegs. I got a nice offcut of what I think might be sycamore a while ago, I’ve been riving off pieces for drawbore pegs from it and then using the dowel plate and sufficient violence to make the pegs.

I rive them down to around the half-inch size, then run them through the forming holes a few times at each size, gradually walking them down to the final size (which for here is a quarter-inch)

It works quite well, though it’s pretty obnoxiously loud.

By the time that was done, and a cup of tea was had, the shellac had dried and cured and it was time to sand over the second coat lightly with 600 grit paper.

And then rag on the third coat (it’s about a 1.5lb cut for those wondering, and made up from liberon shellac buttons and isopropyl alcohol).

Not too bad. While that was drying, I took the mattress support platform and disassembled it, and drilled two holes in the front of the platform for dowels that will go into the support at the front (the back will have enough of a ledge that it can’t fall down unless you smashed it to pieces). The front support had to be planed as well, it had developed some twist in the last few weeks, and the corresponding dowel holes got drilled there too. I’ll make up dowels the same way I’ve been making the drawbore pins, but these will be a little larger than the quarter-inch pins.

In the middle of this the last coat of shellac went on the back panel and lunch was had, and shortly after, the back panel pieces were ready to be assembled…

It was a bit cold in the shed, so the hide glue wouldn’t flow, so out came the thermos of hot water to heat it up a bit.

Then the left side tenons of the long rails got a coat of hide glue, and a little into the mortices as well, fitted the rails into the legs, coated the drawbore pins with glue and drove them home (no clamps required for this glue-up).

Then I put the panel in between the rails, and found it needed a few swipes on the shooting board to square up the end just a tad (don’t you love finding this mid-glue-up?); did that, put the panel back into the frame, and repeated the assembly and drawbore process on the other end of the rails. Flush-cut the drawbore pins to within a few mm of the surface with a flush-cut saw and a spacer (a piece of scrap wood) and then flushed them level with a chisel. This had a minor mishap on one corner, a touch-up on the shellac will be needed to fix that.

But that was the assembly done. And it looks quite nice, the walnut does pop out compared to the ash when you shellac it.

Then dinner, and then back to the mattress platform, and finish planing everything in it, and rounding over every corner, this time using a spokeshave instead of the block plane I’ve used before on the slats and the back support. It’s just as easy and as fast, there’s not much between the two methods to be honest. I can see the spokeshave being a better choice for curved pieces and the block plane for longer rails and the like.

Sure, a router table with a roundover bit could do the job, but for this few pieces, it’s faster to do it by hand because there’s so little setup time. Plus, it’s quieter and there’s less chance of losing a finger, which is always a plus.

Next up was the front platform support. I wanted to give it a bit of an arch on the underneath so it didn’t look quite so much like a sodding great plank, so I found the midpoint and sawed straight down by a few centimetres, then took my 1.5″ chisel and whacked out large chunks down to that kerf from either side, and extended out that v-shaped cutout on either side until it reached a foot away from the centerline on each side. Then out with the spokeshave and a heavy set on the blade and lots of pushing to even out the curve, and make it look a little more fluid than the “blind boy scout with a hatchet” level of chisel work it was at. Then finally rounded over the corners with the spokeshave (and a sharp chisel for the edges on the end grain) and that was done. I need to cut two grooves on either side for the carriage bolts that will attach this to the frame (so that there’s some adjustability). I can’t think of a cleaner way to do this other than a router with a straight bit at the moment. Drilling a series of holes and then trimming them together with a chisel might work if I’d a drill press but with my eggbeater or power drill, the holes wouldn’t be perfectly vertical and it’d be a mess. I might have to admit defeat here and use a power tool for this particular task. Still, it doesn’t look too bad so far.

Next up, I wanted to check the fit of the side tenons into the curved uprights because of the mixup between sides yesterday, so I took the already cut slats and cut the mortices to fit the tenons (which is an ass-backwards way to do it). Seemed to work though.

There are some small gaps (less than a half-mm or so), but those might close up when it’s fully assembled. We’ll see. I’ll have to do this again tomorrow for the other side.

And with that done it was on to the last job of the night, the first shellac coat for the walnut parts of the mattress support platform. After finding somewhere to put the side frame that was (again, the problem of a small shed – nowhere to put components as you work on them…)

Sheesh.

But on to the shellac.

Ragged on first coat and it really does pop.

That’ll dry overnight and I’ll do the second coat in the morning, then sand and then two more coats (as for the back panel). Then glue-up and assembly.

After that, there’s the back support piece (that got done today as well but it’s glued up and curing at the moment), that’ll need to come out of the clamps and get cleaned up. It’ll have to have slots routered in as well. Then I want to make the locating dowels for the front support, and more drawbore pins for the front panel of the cot and the curved uprights, and those joints have to be drilled for the drawbore pins, and the back top crossbar has to be cut to length, it’s currently a few inches over to give strength while mortices were being chopped; I need to cut that to length and possibly on a curve to make it a bit more interesting. Then it can get shellac’d in prep for final assembly.

After that, it’s rounding over the side slats, finish planing all the slats and the curved uprights and the rails, and shellac’ing the last of the walnut pieces and then assembly of the front panel, then putting the front and back panels together along with the slats in the overall final assembly.

And then there’s a drawer to do, but that should be fairly fast. The big question is where the hell do I put the cot while I build the drawer on the bench?

 

To-Do List (stuff in progress in blue:

  • Measure off side slats (because they’re going into a curve, this is going to be fiddly)
  • and cut tenons.
  • Thickness the boards for the drawer.
  • Cut the drawer front to size.
  • Cut the drawer back and sides to size.
  • Cut dovetails for drawer.
  • Groove drawer with #43 for plywood base.
  • Assemble drawer.
  • Drill for drawboring on the M&T joints that I’ll be drawboring (the long rail to upright ones and probably the back support and top crossbar joints).
  • Make drawbore pegs.
  • Finish plane all parts.
  • Finish walnut pieces with a few coats of shellac.
  • Paint drawer with milk paint.
  • Assemble and glue-up and drawboring of everything.
  • Finish entire assembly with several coats of Osmo wood wax.
  • Close door of shed, lock it, walk away and never do another project with a deadline ever again.
Finishing / Sidecar Cot / Woodworking — No Comments
04
Feb 17

Starting to finish…

Late night in the shed tonight. Over the last few days, I’ve cut the groove for the top panel, gotten the side slats all roughed out and half of them have had the tenons cut and the curved upright has had the mortices cut in it. Then I discovered I’d matched the wrong side’s slats to the curved upright. I don’t think it’s fatal, but I’ll have to reassemble things for the tweaking needed. This was annoying, so I decided to switch tasks a bit for the rest of this evening, and I finish planed the frame and panel for the back panel and drilled the joints for drawbore pins (I have the drawbore pins riven but not yet shaped; seemed rude to be driving pins through a plate after 2300h). And then I put some shellac on the walnut frame bits (the panel only gets osmo, so that happens when the entire thing gets osmo). I also rounded over the corners with the spokeshave.

So by the end of this weekend, I’ll have at least one part of this thing assembled and partially finished.

Before first shellac coat:

After:

And the magic happening:

It doesn’t look terrible. It’ll look better after a few more coats of shellac though.

To-Do List (stuff in progress in blue:

  • Measure off side slats (because they’re going into a curve, this is going to be fiddly) and cut tenons.
  • Cut grooves for top panel in long stretchers.
  • Thickness the boards for the drawer.
  • Cut the drawer front to size.
  • Cut the drawer back and sides to size.
  • Cut dovetails for drawer.
  • Groove drawer with #43 for plywood base.
  • Assemble drawer.
  • Drill for drawboring on the M&T joints that I’ll be drawboring (the long rail to upright ones and probably the back support and top crossbar joints).
  • Make drawbore pegs.
  • Finish plane all parts.
  • Finish walnut pieces with a few coats of shellac.
  • Paint drawer with milk paint.
  • Assemble and glue-up and drawboring of everything.
  • Finish entire assembly with several coats of Osmo wood wax.
  • Close door of shed, lock it, walk away and never do another project with a deadline ever again.
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