The Door to Completion

One question I have gotten about the cabinet job Paul and I are working on is what we are doing for the doors and drawer fronts. Something fancy with raised panels and beaded rails and stiles?  A wildly veneered flat panel door?

Actually, Paul wants to go simple.  Slab doors made of cherry. This way, the doors will match those in the tidy and well laid out kitchen.

And, no, we’re not building them.  He ordered them from Raw Doors online, an outfit that makes all kinds of doors including the basic solid wood slab doors.

Surprising, isn’t it?

Paul had his reasons, and when I left his house this past Saturday, he told them to me.

First, he said that he wanted to learn how to build cabinets.  That’s why he asked me to build them – this way, he could get the cabinets he needed and see how one woodworker does the task.  No truer statement could have been made – we have both learned a lot from this project. Did he need to learn how to edge glue boards together?  No.  That’s pretty much what we would have been doing to build the doors anyway.

Second, there is the time factor. Paul’s a busy guy. And, he also respects the fact that I’m eking out time after work and on weekends.  Building the doors and drawer fronts would have taken a considerable amount of time for all of the glue ups, but only a few weeks when ordered online.

Finally, we’re building this project in Florida. Solid cherry is available here – at a premium price. The cost between the complete set of doors built by Raw Doors and all of the stock wood wasn’t very large, so it made sense economically as well.

Paul and his wife Gail are finishing the doors in their garage, and they are looking very good. Visions of well-aligned drawer fronts and doors enclosing the insides of the project are dancing in my head…

Quick Poll

When it comes to woodworking, there’s more than one way to skin the proverbial cat.

Imagine you have a piece of wood that’s 3/4 inches thick, 1 1/2 inches wide and 36 inches long.  You have to accurately cut a piece 24 inches long for your project.

What would be your preferred method to do the deed?

[poll id=”138″]

Link of the Week

Greenwoodworking

Most woodworkers have to wait a while to use wood cut from a tree.  It needs to either have a trip to a kiln or spend some time in a stack to get its moisture content down.

Then, there are woodworkers who take the wood directly from the tree to build their creations.  At Greenwoodworking, Jennie Alexander takes readers through the techniques of working with wood fresh from the tree and shows a host of projects that can be made from green wood.

Sure, it takes a little bit more thought and consideration when working with the fresh stuff, but the results are well worth it.

Me, My Shelves and I

The cabinet project is moving ahead, and the end appears to be in sight…

Of course, this is when things get trickier. More refined. Every single boo boo stands out.  So I have to be on my game, otherwise that’s what everyone will notice when they look at the project.

Next up are the shelves for the bookcase units and the desktop that spans the two banks of cabinets.

The plywood that Paul selected is some very cool stuff. It has great grain, and it blends very well with the solid cherry, so it looks like the shelves are made out of one piece of wood – the ideal situation.

When you build plywood shelves, you have got to keep a few things in mind. How much space you will allow the shelves to ‘float’ side to side in the cabinet, how deep they should be inset inside the case… those basic aesthetic considerations.

Mechanically, though, you have got to consider how well the shelves will stand up to the weight of the objects placed on them. As you place a heavy-duty load (such as books) in the middle of a shelf, you will start to notice a sag in the shelving material. How much will it sag?  Well, there are a couple of ways to figure it out.

Sure, you could just build the shelf, load it up and hope everything works out … nah.  I don’t think I can handle getting an angry call from Paul in the middle of the night because a shelf full of family photos fell to the ground.

I imagine I could do a bunch of complicated math, but I was an English major… so math and I don’t do well together.

Fortunately, there is a great utility out there called the Sagulator.  Designed by the folks at Woodbin woodworking, the utility allows you to compute how much your shelves will sag under a load before you build them.

In my case, I selected the plywood option with an edging strip of solid cherry. Figuring a load of 40 pounds per linear foot (given as a standard load for a library shelf), I came out with a total of .02 feet for the total of the 24 inch span. Since the eye can detect a deflection of .03 feet per linear foot, I’m doing pretty well.

The desk span is essentially another shelf that will bridge the base units. Since it will be nearly three feet long, I decided that perhaps I should beef up both sides of the desktop to make it even sturdier. Again, it’s a simple piece of cherry plywood with a 3/4″ wide by 1.5″ tall solid cherry edge. I glued the edges in place, using biscuits to keep it aligned and provide some additional reinforcement.

Later, we will drill a hole for a grommet to allow monitor and keyboard cables to come up from below. Once the glue dries, it will be ready for some finish sanding and installation.

And, yes, that’s it. The desk shelf is the last piece of the project I will have to build (Although I will need to mill a little bit of molding…)

We’re getting closer!

My Mythic Labor

For those playing along, today is Labor Day in the United Sates and Canada, so let’s hear it for those hard working men and women who bust their butts every other day of the year!

Today, sit back, relax, and I’ll tell you a story about a guy who really did some work.

His name is Hercules, a mythical Roman figure (who went as Heracles in Greece…) who was asked by Jupiter (Zeus in Greece) to come over for some pizza and beer in order to help scratch a few things off the to do list around Mount Olympus.

Well, just as everyone knows, when you are asked to ‘lend a hand’ tackling a few chores, the magnitude of the tasks at hand seems to grow exponentially. Before he knew it, Hercules was asked to go and handle some tasks that were believed to be so difficult that no mortal could complete them.

You know, easy stuff like slaying the Nemean lion, capturing the Golden Hind of Artemis and obtaining the Girdle of the Amazon Queen. I can see the exchange now. “Jupiter, seriously?  You want me to go on a panty raid?”

One of the most demeaning tasks for our hero was that he had to clean the Augean stables in a single day. Since these cattle were immortal, they created quite a healthy layer of cow pies. And, since everyone looked the other way for the  30 years prior to his job, well, it was piled higher than you could find on Capitol Hill.  Just barely.

Our pal Hercules had a trick up his sleeve (he’s usually painted at least half-naked, so I’m wondering where he may have actually hid that trick.  In his boot, perhaps?) and turned hydraulic engineer, diverting a few rivers through the stables.  Before you can say, “Don’t drink the water downstream!” the stables were sparkling and shiny new.

I’m wondering if I can give good old Hercules a call to give me a hand with my shop…

Now that the cabinet job is entering its final phases, just about all of the pieces that need to go to Paul’s house are there.  Which means I no longer have any excuses for not being able to get to the dust anymore. All of those piles of sawdust and tools I took out but never put back immediately are out there, taking up space. The plug ends of tools are mixed together in a knot on the floor near my power strip…. so I have to sort those out. The vacuums are full of dust and shavings and need to be emptied … aww, heck, it looks like my day off from work is going to have me out in the shop.

Well, at least I have a barbecue on the schedule today… that will give me some time to rest before my next labor.

Quick Poll

Football season. Baseball season. Hunting season. The holiday season.

There are times in the year for just about everything. For some woodworkers, there is also a woodworking season – the time of the year when they can get into the shop and start building.

Woodworkers may wait for the temperatures to warm up or to cool down. Others may have to wait for kids to start school or to start their summer break. And, for others still, there isn’t any let off at all – it’s woodworking year round.

This week, let us know when your woodworking ‘season’ happen.

[poll id=”137″]

Link of the Week

The Basics of Woodworking with Stone Age Tools

Are you a woodworker who likes to use old tools?  You know, hand planes from the mid 19th century? Reproductions chisels from the 18th century?

That’s not old…

Try knapping a piece of flint to use as a plane and then tell us about old woodworking tools.

Torjus Gaaren of primitiveways.com takes readers on an adventure into really-old-school (up to 2.5 million years ago) woodworking with stone and antler tools for splitting, hewing, sawing, carving and planing wood.  While it may seem like a crazy thing to even consider with today’s modern steel tools, the write up is fascinating and can give you a unique look into the history of our craft.

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