Oklahoma Projects in Progress!

[BrokenolMarine]

NOT flogging.

Flocking... adding shredded velvet pieces to coat the wood for a crushed velvet finish. Sheesh.
The first step is to seal the wood. I painted it with flat black paint. Works good, dries in five minutes.

Next up, after all the various things we need are laid out, since the steps have to follow one another quickly....
We paint the bottom panel with the DonJer Undercoat to match the flocking we chose, I chose wine.

01 undercoat.jpg (257.68 KiB) Viewed 5748 times

You paint as even a coat as you can get but you must insure you get full coverage. Next you place the painted item in a container to catch the excess flocking and to allow it to dry in a protected space. I chose a shallow rubbermaid storage container.

02 painted.jpg (240.6 KiB) Viewed 5748 times

You'll see in a minute why this is important... Load up the flocking tube in advance and the next step is a breeze, this is what I had done.

03 load er up.jpg (259.86 KiB) Viewed 5748 times

When you actually Flock, OVER Flock, spray a generous coating of flocking over the entire project, it will only stick where the undercoating is present, the rest will shake off, brush off, when you clear the project after drying overnight. THIS is why you need a protected place to flock. I put the top on the container and no dust or MICE enter the drying area. (Don't ask about MICE prints in a Flocked piece. )

04 over flock.jpg (296.67 KiB) Viewed 5748 times

You can recover, re-bag, and reuse the unattached shredded velvet for later projects if it wasn't contaminated by dust and dirt. So make sure your container can protect your project while it dries.

05 protect during drying.jpg (249.69 KiB) Viewed 5748 times

After I put away the tools and set the project aside to dry, I (Hopefully) made one last pass at the top with the CT Thick Glue after the sanding of the last pass, and this should do it. Remember, those were DEEP crevices to fill.

06 top work.jpg (265.08 KiB) Viewed 5748 times

Tomorrow I should be able to install the bottom, and then install the rests for the tray insert. I will probably finish the interior before installing the bottom to avoid staining the flocking... (Remember? Learning Experiences?)

[BrokenolMarine]

Needed to stay busy and I don't watch sports or parades, and I am movied out. I am a bit anal about my projects. If you look at the pic I posted earlier showing the rabbits in the bottom of the "box" for the bottom to fit into, there is a slight gap. I went out and cut tiny plugs to fill those gaps. Miss Tina came out and saw what I was doing. "Really?" she said. She shook her head and walked back in after checking out the tray and flocked bottom. SHE has picked up a cold.

If you look in the corners here:

02 rabbits.jpg (264.28 KiB) Viewed 5742 times

You can see the small gaps of an 1/8" I'm talking about.

After the work, you can see I have filled the gaps.

02 details.jpg (270.93 KiB) Viewed 5742 times

I also marked the area where the tray supports will go with blue chalk hashmarks. When I apply finish in the morning, I will avoid that area as the glue won't adhere well when finish has been applied.

I wiped down the entire box checking for flaws, and as you can see, we are about ready to apply finish. I have to decide if I want to put the molding on the outside at the bottom before I apply the exterior finish.

01 checked.jpg (285.81 KiB) Viewed 5742 times

I also installed, then removed the piano hinge on the box. It will be fitted to the top the same way and then set aside until the very last. I forgot to take pics. Senility is a bad thing.

In this pic of the tray, you can see the tray supports laying in the tray, these will be installed tomorrow after the interior finishing is done and the bottom has been installed. In addition, you can see what I meant by the drying of the mineral spirits returns the wood to it's original state.

03 tray.jpg (305.12 KiB) Viewed 5742 times

We ARE getting close.

[CT_Shooter]

I hope Miss Tina feels better soon; but (surely because she didn't feel well), she said, "Really?"

Tell her for me, "Yup! Really." Thanks for being anal about your work and sharing it with us! It looks great.

Really!

[BrokenolMarine]

Thanks CT...
She has also decided she doesn't like the rustic fingers I want to leave.
"You NEED to sand those flush."
She says they make the box look unfinished.
They really ARE a design feature in projects...
I still haven't decided if my artistic freedom is worth her gnawing on my ear about it... until I die.

[dave77]

I was wondering if you were going to leave the "fingers". I like them, I think they go well with the lid.

[BrokenolMarine]

Thanks Dave.

[BrokenolMarine]

Went out this morning and got started... Six degrees outside, 68 in the shop. Things were going good, and I stained the tray, tray rests, and the inside of the box. Off to a great start.

01 Finish applied to tray.jpg (269.57 KiB) Viewed 5725 times

02 and the box.jpg (290.15 KiB) Viewed 5725 times

I checked on the flocked bottom panel and it looked good, so I sealed it back up in the Rubbermaid tub to keep it clean and safe. Back to work.

03 checked and safe.jpg (272.44 KiB) Viewed 5725 times

I decided to shape the edges on the top. Touched up the edges on the box plane, and got to work.
A few passes on each edge with the plane at a 45 degree angle, taking thin shavings on each pass. I just wanted to round the edges. After taking a bit off both sides, I'd come back with 220 grit sandpaper and roll both sides. Worked out very well and in just about 45 minutes I had that knocked out.

04 edge work.jpg (179.77 KiB) Viewed 5725 times

05 little at a time.jpg (262.07 KiB) Viewed 5725 times

Time to set the hinge on the top. Measure, measure, measure, check, measure. Critical here. Mark, check, measure. Drill the pilot holes and carefully set the first screw in one end. Tah Dah! Carefully set the screw in the other end and just as the screw bottomed out... the head sheared off. *&!#$

Okay... I can deal with that later. I stepped up a bit size and will use glue when I install the hinge. I carefully install the next screw. Snap, a second screw snaps off. THIS is not good. This Black Walnut must have concrete centers. I stop and look through all my screws and find a stainless steel version of the same size. Sometimes you have to TAP the hole with a stainless steel version and then use the brass for the installation.
I use the bigger bit and tap the hole. As the screw nestles into the countersunk hole in the hinge... SNAP... I hear the hinge laughing at me.

I give up, and take out the initial screw that seated fine. Half a turn with the #1 phillips... SNAP. That screw head shears off. You have GOT to be kidding me. I DON'T throw the screwdriver against the wall sticking it into the finished walls. I lay it on the workbench, and walk to the specialty tools draw and remove the screw extractor for the drill press. Here we go....

06 extractor.jpg (214.53 KiB) Viewed 5725 times

I cut around each screw to my preset depth, working my way slowly down.

07 drill em all.jpg (262.54 KiB) Viewed 5725 times

Then I use a chisel to work the wood from around the screws.

08 expose it.jpg (261.37 KiB) Viewed 5725 times

I take my mini vise grips and remove the screws.

09 mini vise grips.jpg (231.09 KiB) Viewed 5725 times

I use a 3/8ths forstner bit to cut the previously drilled extractor holes to a consistent size
I inspect my collection of wooden plugs

10 collection of plugs.jpg (340.24 KiB) Viewed 5725 times

Choose mahogany, you won't really see them anyway, and they worked when I screwed the hinge on the box.

11 mahogany.jpg (298.61 KiB) Viewed 5725 times

Roll the plug thru the glue for an even coat.

12 coat it.jpg (222.69 KiB) Viewed 5725 times

Set the plug in the hole

13 start it.jpg (224.6 KiB) Viewed 5725 times

Seat it as deep as it will go with the rawhide mallet

14 seat it.jpg (253.91 KiB) Viewed 5725 times

Now we wait.

15 dreaded drying time.jpg (243.59 KiB) Viewed 5725 times

[clovishound]

Well, not to throw stones at your artistic sensibilities, I'm with your wife on the finger joints. I love the look of nice finger joints. Sand those pups flush. You should get nice contrast between the end grain and side grain. I would think the protruding fingers would end up suffering from damage during use.

[BrokenolMarine]

My wife is a gold medal nagger. Probably end up getting rid of the fingers in the end.

[BrokenolMarine]

Oops... daughter chimed in after Miss T said to ask her. She likes the look. The fingers stay.
Got the plugs trimmed flush and the hinge safely mounted. Pics, but too tired to deal now. Done for the day.

[BrokenolMarine]

As promised, here are the "after pictures" pictures of me saving my butt with the broken screw issue on the underside of the top for the box.
Actually, they are kind of a fizzle after all the work, because, as intended... they will go completely unnoticed. The best repairs do.

First, I stropped a nice wide chisel to make sure it was as sharp as possible, then with the back of the chisel flat against the wood, cut each plug flush.
Then sanded with 220 grit to get it as smooth as possible.

01 flush.jpg (235.42 KiB) Viewed 4943 times

Testing with the hinge showed that NONE of the patch job would show.

02 hinge hides the patch.jpg (234.86 KiB) Viewed 4943 times

I could have sworn I took a pic after I installed all five screws, but senility is a be-otch.

[BrokenolMarine]

All Done....

View from the outside...

01 outside.jpg (233.38 KiB) Viewed 4928 times

02 outside high view.jpg (244.6 KiB) Viewed 4928 times

Open with the tray in place.

03 inside.jpg (225.43 KiB) Viewed 4928 times

Tray out...

04 tray removed.jpg (241.11 KiB) Viewed 4928 times

flocked bottom

[BrokenolMarine]

I started the box with this piece.

unique cutoff.jpg (268.61 KiB) Viewed 4914 times

It was a cutoff from the walnut slab I used to make the walnut trim pieces for Izzy's toybox.

[bmsma]

Yeah, yeah. Miss Tina won and I added the Sassy Arms.


01 arms.jpg
:lol:02 yup tina wins.jpg

you sir have serious skills, that kind of craftmanship is a gift.

im slowly starting to do a bit woodworkig, we bought a older shopsmith and so far i make some real good quality saw dust

[dave77]

I wish I could try to do anywhere near the quality work he does, I've never had a place where I could set up any kind of a woodworking shop.

Been waiting to see his next project.