Movin’ In

It was definitely a weekend revolving around the new tool (understandably), from the pickup/delivery organising on, the assembly (and getting it into the shed) Saturday, and commissioning it with some real tasks on Sunday.

If you were wondering how I was going to fit a 2.5m x 1m tool in my workshop, well, you were not the only one!  With a large pry bar!  Archimedes once remarked (paraphrasing) that with a firm place to stand he could move the Earth (with a long-enough lever that is).

Makin' a Hole

Clearing space was a combination of moving the jointer to where the router table was, removing the corner bench and in future the sanders will (potentially) be on roll-outs from under the Torque, and the router table met an untimely end, with the top being amalgamated with the TWC.  A hole was born.

The Torque arrives in its new home

I did try the TWC along the back wall, but lost too much access around the unit.  The MDF top has yet to be added – will do so some time this week.

That 1300mm arm is huge – I’m going to fit the 600mm (or 900mm) arms for the majority of the jobs, and the 1300 will get used only when I need that much extension.  For some workshops it probably would remain, but that is the one compromise on space I will have to make.  Sure looks nice here (by the end of the weekend it sure ended up rather dusty!)

Adding the Router Table

Here I have added the router table (with Incra Positioner/Fence) to the end where there is some dead space (because of the way the tools are carried on the left side of the arm), so this really utilises that area. I’ve moved the bandsaw further back so I have adequate access to the router table, and it isn’t hard to swing the entire unit out from the wall if I need more in-feed area.  Since this photo, I have also replaced the first module of the top with a plain cast-iron wing – it won’t be a two-router table now (well it is, but one is overhead), and I’ve shortened the cast iron top to 3 wings from the original 5.  The MDF of the rest of the bed will be at the same height, so there is no shortage of area for the positioner now!  At 2.5m long, this may be the largest router table in the world!

The clamp roof

The clamp wall was a problem, both getting access to the clamps, and also having them interfere with the X axis of the TWC, so they have been moved to the roof.  If the clamps are any good, then it won’t be a problem where they are!  Added benefit – partway through a clamp-up, if I need another I just reach up!

Temporary Triton Mount

One minor glitch I had (and it will be rectified by the end of the week), is the router mount had support posts for a Makita (I think), and not the Triton – the Triton needs both a larger diameter and a longer post.  Converting the Triton to fit the table took a few seconds, as did reverting it back to standard operation.  I was surprised just how easy it was – a single circlip.  So that I could make use of the router before the parts arrive, I added the old Triton quick-release plate from the original Triton router table.  The setup is rather flimsy like this, but it got the job done.

Oven Doors

First job was the oven doors for the kid’s kitchen – setting the stops for the size of the opening, then routing it out.  I also used the same method for cutting hinge mortises.

Oven Shelf

The second job was creating the shelf in the oven.  Rather than just a plain shelf, I didn’t want the inside of the oven to look like a cupboard, so I cut parallel slots through using a 1/2″ straight router bit, and moved the whole setup 30mm for each pass.  Again, something that could have been done other ways, but this was a very simple (and accurate) method.  It’s like using a machine with a built-in, adjustable jig.

So that was all I had time for in the end, but already it has been demonstrating for me just how functional the concept is.

The Torque and the Triton

There is a NZ author called Hugh Cook who wrote a series of 10 fantasy books which all had titles “The something and the something“, such as “The Wordsmiths and the Warguild”.  He was planning a series of 60 books, but sales didn’t eventuate, which is a pity. I’d have needed another bookcase though!  Nothing else relevant in this, other than whenever I read (or write) “The something and the something“, I’m reminded of Hugh Cook.

Back when I bought my Triton Workcentre – the Workcentre 2000, I was concerned if there was going to be a 2002 version that was going to supersede it – the danger of using a name that also depicts a year.  A lesson that Microsoft are starting to learn – your product is dated by the name.  As it turned out, the WC2000 was the final version – a newer version that was ready for prototyping was binned by GMC when they took over.  When Triton still existed as a company, they did get the occasional prompt to bring out a new version – a 2005 version for example.  This never happened (obviously), but there were a number of existing owners who wished it would happen.

As I was assembling the TWC, a feeling of familiarity, and deja vu struck, and stuck.  Even though I found I didn’t need any assembly manual to put the TWC together, the home-grown aspect to both companies did come through, but the differences also came through strongly – one being thin pressed metal and aluminium section, the other being steel, steel and more steel.

Despite there being no commonality between the companies, or between the workcentres (other than both being Australian Engineering, both being called workcentres, and both being woodworking related), there is a degree to which the Torque Workcentre (TWC) could be regarded as being a logical upgrade to the Triton.

Consider each function:

The Tablesaw.

The biggest criticism Triton owners hear, is the money they spent on the Triton Workcentre system over the years could have bought a significant tablesaw.  There are counter arguments to that, but not relevant for this article.  They then have a brushed-motor circular saw secured by plastic under a pressed-metal top, in an item that weighs around 30-40kg.  (Again, there are all sorts of other pros and cons, not my intent to discuss).  It can handle (with the extension table) a 2400×1200 sheet, with a cut depth of around 65-67mm.  A plastic-thread height winder.

The Torque workcentre is not an ideal tablesaw, and if you already had a tablesaw you wouldn’t consider the Torque as a replacement.  However, despite having a very good cast iron tablesaw I am still looking forward to being able to process sheet goods on the Torque with ease – being able to lay the goods out, and bring the saw to the sheet (with all the control the TWC offers) to safely process the sheet into the required sections.  For ripping, a tablesaw is still the preferred method, whereas for crosscutting, the TWC has it all over the Triton, as with a saw attached it effectively becomes a radial arm saw, which until the development of the SCMS (sliding compound mitre saw) was held in very high esteem in many, many workshops (and still is by existing owners).  The TWC could potentially give a radial arm saw some serious competition – increased range, support at both ends of the arm for 90 degree cuts etc.  A top quality RAS would most likely win, but for most workshops, the Torque makes the grade.

The Router Table.

The Triton router table was the first item that I left behind as my woodworking improved – I felt held back by its limitations – the top wasn’t flat enough for my needs, and I headed down paths seeking more and more accuracy, precision and flatness.  There is a definite benefit to a table-mounted router, but one thing I found missing (and had no solution for) was the ability to have the router controlled in an overhead position, without having to hand-hold it.

This is where the Torque absolutely kicks butt.  Even when all the other parallel functions being discussed here are removed, replaced with dedicated machines, you’d still look at the Torque Workcentre as an overhead router system – it is what the TWC excels at, and the primary reason for buying one.  All other functions of the workcentre are secondary to this – bonuses. IMO that is! There is so much potential that overhead routing capabilites provides, I’m going to be exploring it for a long time yet!

Now this doesn’t mean the table-mounted router is obsolete – far from it.  How I have dealt with that, is combining the two tools, and I have an area where the table-mounted router resides in the top of the Torque workcentre, and at this stage I don’t believe it does anything to detract from either machine.  While the table-mounted router is in place, I loose about 300mm of total capacity of the TWC because I have placed it at the end where there is some dead-space anyway, and I can regain that area by simply lifting the table-mounted router out to regain the full TWC capacity. The best of both worlds you might say.

When in place, the table-mounted router has the advantage of a cast-iron top (which I added), and the Incra LS Positioner and Fence, so that is pretty optimised, and yet I also have the overhead TWC to complement it.

I’ve long seen the router table as being a compromised tool – most workshops that have one have had to make it themselves (other than the low-cost Triton, GMC or Ryobi tables).  To get a machine as serious as the tablesaw as a router table, you’ve had to turn to the spindle moulder, and that machine has a very limited top speed, and is not effective for small router bits. (Not that I am belittling the Spindle Moulder – it is a very capable machine, and can be found in many professional workshops, but it isn’t designed for modern router bits.) The TWC is a machine built specifically for the router.

Drill Press.

Like the tablesaw, it is an additional (rather than primary) solution.  Like the Triton, take a hand power tool and give it extra functionality by providing a solid mount.  But again, in a pretty serious way – a drill press that can drill materials up to around 1000mm from the support pole, has massive work support, can handle angles, and drill points in arcs.

Jointer/Planer/Thicknesser.

There isn’t to my knowledge a jointer on the market that can allow you to prepare the face of a board 2000×1000, yet that is bread and butter for the TWC.  And anything smaller.  I’d say many workshops will still have a dedicated machine, but when its capabilities are exceeded, the TWC takes over.  If you don’t have a jointer yet, the TWC puts off the requirement to invest in one.  It doesn’t do the jointing the edge to 90 degrees to the face however (although you can use a router bit to run down the edge to perform that role).  You can also thickness with it, and again with significant capacity beyond any affordable thicknesser on the market!  For smaller items, a dedicated machine will be faster and easier, but the TWC can still substitute until you have the dedicated machine.

So, what do you think?  Could the TWC be regarded as an upgrade to the Triton system?  Both fit hand-held power tools to increase their safety and functionality.  One weighs a substantial 200+kg, so has the stability (with a corresponding loss to portability).

Assembling the Torque Workcentre

It was hard having to wait to assemble the workcentre – having it sit overnight waiting.  At least it arrived on a Friday!

First job was unpacking the remains of the container, and seeing what, if anything was missing.  By the end of the build, only 2 things appear to have been lost – a single bolt of 4 that holds one of the wheels on, and the assembly instructions!

So a pretty fortunate outcome in the end.

Disassembly of the 'crate'

I was concerned about that gap in the middle, but I now think this is for the shorter versions of the support arm – this unit shipped with the longest 1300mm version, which gets packaged with the 2 main beams rather than in this crate.

After laying it all out, the assembly task did not look that daunting, and in hindsight it wasn’t – nothing like even assembling a Triton Workcentre – this assembly didn’t need instructions, let alone the difficulty caused by missing a single step of the Triton assembly.

Components laid out

Assembly begins upside down, and the tapped holes make it obvious how it goes together.  The two main rails are set out, with the cross bracing bolted across.

Main platform assembled

The legs are then added to either end, with the adjustable legs (which also are the ones with brakes) to the front.  Once this section is finished, the unit it flipped upright for the rest of the assembly.

Legs Assembled

I didn’t get any photos of the next stage – it went so quickly and smoothly it was over before I picked the camera up again.  Throughout the build, I did have the video running, so at least that (hopefully) caught some of the action!

Workcentre Completed

Throughout the build, with every component I picked up I was reminded of the significance of each component – they were heavy, strong, and it was both obvious that it had been built by hand (and not in a bad way), and wasn’t some mass-overseas-produced tool.  This is solid, Australian engineering as it should be.

The total build took all of 90 minutes – a very smooth assembly, even without the instructions.

Tool platform with router attachment

This is the platform for the various tools – in this case for the router.  It includes the optional dust collections shroud. There is still some fine-tuning to do, and a top to be added which I will cover in the next article(s).

Heavy Engineering

From the base, to the upright, the support arm and the tool carrier, it is solid components, solid construction all the way.

It is one thing to see such a unit set up and operating at a woodshow, but you get a real sense for the quality during the build phase.

Torque of the Town

Without exaggeration, it has been one crazy day, one crazy week.  Add on top of that the imminent arrival of the Torque Workcentre, and, well, talk about riding the troughs and peaks.

The Workcentre was meant to arrive today initially, as I confirmed yesterday afternoon with the courier, and was told that there had been so many express deliveries, that my express delivery had been delayed, and was now due in Melbourne lunchtime, which meant a probably delivery of Monday.  However, checking this morning and instead the new message was that it had arrived in Melbourne already, and the truck was coming out today, and by the way how was I planning on getting the two parcels off the truck, given that they weight 112kg and 140kg respectively and the driver is allowed to lift a maximum of 20kg?

Hmm, guess having a forklift in the backyard might be typical in some quarters, but certainly not around here.  For all the deliveries I’ve ever had, I’ve never before been expected to unload the truck myself.  That might hold true for businesses, but not for private addresses IMHO.

So after dwelling on it for a while, I was able to arrange for the delivery to be diverted to a company with a forklift who were happy to help out – thanks guys – much appreciated!  Being diverted meant it should again arrive on Monday, but the courier company to their credit was able to get the delivery happening today, so late this afternoon I picked up the TWC and drove it home.

I started unwrapping the unit, but after having a chat with Torque by phone, another complication came up.  When the unit was boxed and left the company, it had 6×16mm MDF sides (inc top and base).  By the time it arrived here, 4 of the 6 sides had vanished and had been replaced with metal banding and shrinkwrap, as was another unit delivered today apparently (which developed a case of missing parts).

The mysterious wrapping

I had started cutting the shrinkwrap – it was fully around the unit , rather than what is seen here.  The sides have vanished, and who knows if the load is now still complete.  Furthermore, the metal banding wasn’t there when the package left the manufacturers.

Parts

Not sure how a 16mm MDF box was broken, and mine wasn’t the only one for the day apparently.  These are normally strong enough to have one stacked on top of another.  What did they do? Drop it on an edge? Then patch it up in the hopes I wouldn’t know better?

Anyway, past all that – we will find out tomorrow if it is still all complete.

Got the rails out (different package) and placed them on the artificial turf alongside the house.

Rails

And yes, if that toy looks familiar, it is most likely exactly what you think it is – the original kid’s toy made on, and for Triton (not by me), and the toymaker competition it used to sponsor at the original woodshows.  I rescued it when the Triton factory was being demolished.

Torque 1300mm bar

So, assembly begins tomorrow!

There is no salvation for me!

I was sitting at my desk at work after buying lunch (stir-fry on rice) which came with wooden chopsticks that had to be split apart.  A colleague watching what I was doing then remarked he was surprised I didn’t then use my desk handplane to finish the job.  Hmm – good idea, and the next thing there was a small pile of shavings from the now smooth chopsticks on my desk.

Is that the definition of sad, or the fact that I currently use some tinted/UV rated safety glasses as sunglasses at the moment!

Spam – The Good, The Bad, and The Pointless

After something like 10 years (or more) of receiving spam emails I have no idea how many thousands I have received.  365 x 10 x 20/day (minimum!!) = 70,000 or more.

Today I actually got one that looked slightly interesting – one from a publisher of toy making woodworking books.

Scrollsaw Dinosaurs

Against my better judgment, I actually paid enough attention to the spam to have made it worth their while, and even jumped on Amazon to buy a copy.  (I know – stupid – only encourages the very practice I can’t stand (spam)).

However:

1. Wish companies would not regard spam as a valid marketing tool (although in this case I guess it achieved their objective, but from a customer’s perspective, 1 useful spam in 70,000 or more (probably a lot more) is a pretty crappy return.

2. Don’t spam people who can’t buy your product anyway!  Seems that Australians are blocked from buying this book.  Don’t know why but it gets really annoying to those of us down under when US companies deliberately choose to not sell in, or export to Australia.  That decision may not have been a conscious one in this case, but I have come across a number of examples of companies who have been approached to have their products imported into Australia, who have declined, preferring to sell only to the US/Canada/UK/EU marketplace.  Sure we have a comparatively small population, but why is our money shunned?

3. I hate spammers.

4. BTW – did anyone see the comment on this blog recently from “Steven” who accused me of being a spammer/marketer for Accu-line?  Hard to be a spammer if you didn’t send out an email!!

The Torque around Town

Is that Friday’s the day. The workcentre is at the courier dist centre and will be loaded onto the express Melbourne-bound truck this evening.

Can’t wait- already have a half-dozen jobs lined up for it – a number for this weekend! Going to have to do a pretty rapid build/assembly, so it is great that I’ve had such a comprehensive introduction by Larry and Aaron!

Laminates and Veneers

A few years ago when I was making my entertainment unit using pine veneered onto MDF (at the time it was what I could afford, and meant I didn’t have to do massive amounts of joinery to get the large panels I needed).  At that stage, the company I used (Australian Wood Panels) had an impressive array of veneered panels you could choose from – jarrah, blackwood, walnut, pine etc etc – about 10-15 different timbers.

It seems in recent times they are now primarily limited to raw MDF and ply (and melamine), and you have to order in the veneered panels (I’m talking about 1200×2400 veneers, not something you can do in the shed with a vacuum bag, or an iron!)

If anyone knows where a decent range of veneered panels on different cores can still be sourced, I’m sure there will be people interested in knowing.

Entertainment Unit

An old photo of the entertainment unit from years ago – at least 6 years ago, if not more.  The unit wasn’t completed in this photo – still had the doors to go (all raised panel for the 4 lower ones, and glass for the 2 display cabinets) (and I don’t think I ever took a photo of the unit completed).  It is now scattered around the house – the two side modules are still there, but the TV when upgraded to a plasma no longer fitted, so the central module is now in a different room, and the TV itself is now in the shed!  (Even the digital camera used is ancient – 0.3MP)

In the (old) shed, during the build

Boy, some of these photos go back!  Back to the old shed days when I still had plenty of room in it! Triton Workcentre there in the foreground, GMC lathe in the background.

Assembly and finishing

Back in the days before I had grass – the back yard was sand, and that’s my dingo asleep beside the blue rubbish bin.  As you can see from this photo, I finished as I went, so areas that were going to be hard to get a decent finish on after assembly were pre-done.  All finished with a jarrah stain and Ubeaut traditional wax. The sides, and shelves are pine veneered MDF, the fronts are solid pine (so I could rout detail into them, and for added strength for hinges etc.  I mush have done a pretty good job of the build as the cabinets are still going strong.

Random Orbital Sanders

The can of worms otherwise known as sanders is more of a Pandora’s box that I’m not ready to really spring the lid on.  Needless to say there are a whole range of different sanders out there, belt, 1/4 sheet, orbital, random orbital, finger…

The Random Orbital Sander (ROS) came into existence in the early 90’s and is particularly good at finishes without introducing swirl marks because of its random action. Where non-random sanders are not particularly useful above around 400 grit, the ROS can be used to 1200 and beyond.  They are not particularly suitable for bulk material removal – there are much more aggressive sanders out there.

Now that I’ve sold, given away, or had fail every ROS I had in my arsenal, I’m having to look around for a replacement (and that doesn’t rule out getting a replacement pad for the Triton ROS, from somewhere….)

After the recent experience with the Domino, I thought I’d check out the Festool range.  There are a few sanders in the collection, and the two most suitable are the Rotex and the ETS.

The Festool Rotex at a bit under $1000 is rather impressive (and is around 12x more expensive than the Triton!).

Rotex RO 150

The ETS 150/5 is around $580, so still 7x.  That may be the end of the story, except for the number of people (including finishing experts) that swear by the Festool.

ETS 150/5

Whether I am going to be able to go down this path or not is pretty up in the air at the moment – need to give it some serious thought.  Not sure what other options there are either (yet).  More investigation required!

Becoming Boxed In

No, not the shed (not yet!), but the Torque Workcentre!  The build is complete, and it is getting boxed for shipping to Melbourne first thing tomorrow – awesome news

 

Continues….

Today was very much more of the same – I broke down the last 2 sheets of 2400×1200 MDF (one 12mm, the other 16mm) using a circular saw and a guide.  I really have a very low opinion of circular saws – dislike using them at the best of times.  The real danger comes with kickback, and unlike a tablesaw where the kickback results in the piece of timber being thrown, when you are using a handheld circular saw, and it tries to kickback, it is the saw that jumps and bucks, and tries to rip out of your hands.  It doesn’t take much to cause that to happen either.  The blade only has to bind just a little in the cut for the blade to stop doing what it is meant to, transferring the power of the motor into the cutting tips of the blade, and instead transferring the motor power into a rotational force that your hands and arms have to resist or risk a runaway saw (and potentially serious damage).  Even if you get away with it, your large sheet can incur some significantly horrendous scars.

I hate circular saws.  It kicked back more than once on me – each time I twisted the blade slightly during the cut.  It was a moderately powered saw – 1800W with a thin kerf blade, so I don’t know what was contributing to the (user caused) problem.  Was it that the blade was thin, so could distort under incorrect loading easier and therefore bind? Was it the saw itself was too powerful vs its weight? Not powerful enough, so it stopped cutting when conditions were less than ideal?  Whatever the cause, there is an underlying cause – I didn’t cut perfectly straight.  I got past that task, but I’ll be happy if I never have to use a circular saw handheld again (and with the imminent arrival of the Torque Workcentre, which has a circular saw mount and can cut a full 1200 wide panel, I’m hoping it means I will never have to).

You might ask why I am using a handheld saw if I dislike them so much, when I have a large tablesaw?  Simple answer – I might have a big saw, but a small shed – I have to break the sheet down smaller to be able to handle it in there.  There is another reason – single-handedly managing a sheet that size through a tablesaw can still result in twisting the sheet (and having the sheet stop contacting the fence), and there is every potential of a kickback in that situation too.  In future, if I have to do it by hand again I am going to take Marc Spagnuolo’s approach, and have the sheet resting on the ground, with a sacrificial board underneath (he uses polystyrene) – it will take more of the variables out of the picture and result in more ability to focus on, and control the saw through the entire cut. (I found I was overreaching near the end, and that is when things were going pear-shaped).

Despite the couple of….issues during the breakdown, things were pretty productive and I got both fridges made, as well as all the doors and tops cut.  Now they are getting close to needing the finer details made and fitted – taps, knobs, handles and the small things that take the build from the ordinary just up to the next level.

All coming together

Some of the additional details I want to add include the fridge door- adding a shelf (on the inside obviously, like a real fridge), and an egg holder shelf.  It is little, easy details like that which will elevate the overall build to a level I will be happy with giving these to friends.  I still need to cut the stove elements, and the sink cavity, make the stove knobs, door handles etc etc – now that hard work (not necessarily the heavy work) begins.  I’m really looking forward to this part of the project – when it comes to life.

While I was working today, I found myself using one tool (other than the Domino) a number of times – one I find really useful.  It is the Black & Decker PowerFile.  I’ve had it for a number of years, and it is great for getting into areas, minor shaping, quick hinge mortising etc.

B&D Power File

It is a belt sander, running a finger-wide belt with an exposed end.  Not very clear in the photo, but the notch seen here in the MDF to fit around the cabinet upright was cut on the bandsaw.  I then needed to round the edge, and that is where the power file came into its own.

Toy Kitchen Build

Got to kick the build of 2 kids’ kitchens on quite a way, and made extensive use of the Festool Domino in doing so. The precise, and repeatable placement of mortises really came into its own, and certainly helped a great deal with part alignment and project strength.

Module Sides

With 4 modules, all with identical sides it made the job even faster working out the position of the required Dominos, then repeating it for each unit.

To aid the layout, I found the Woodpeckers Story Stick absolutely invaluable.  It is the first time I’ve actually used the Story Stick in anger, and found it so relevant that I’d hesitate to say it is a much have if you are doing this sort of repeat work, particularly for larger constructs. The Incra Rules are perfect for smaller scale projects/jobs, and have also made a constant appearance on this build.  I find the Incra T Rules especially useful – inserting the 0.5mm pencil lead in the relevant hole for the required dimension, then slide the T Rule along the edge of the work to draw a line an exact distance in from the edge.

Using the Story Stick to Accurately Place Dominos

Repeatable Domino Placement

It is not just for dominos, but that was the application I was using it for.

Failed Triton ROS

I recently had the Triton ROS pad fail, rendering my TROS unusable, so had to resort to using an original Triton ROS that fits to the angle grinder.  This was new in packet, and fell apart after sanding just a single unit (poor tolerance control by the looks of it).  Frustration, and it has left me without any random orbital sander at all.  Just goes to show – you can’t have too many spare tools!

Carcasses in Process

So here is where I got up to – the carcasses of the sink (smaller unit) and oven/stove (larger unit) assembled – dominoed and glued.  I’m making two complete kitchens – thus the doubling up.  They are made to the design and specification requested by the respective parents.  The units don’t look like much at the moment, but this is the important part – the frame that the features get added to.

Cutting Shelf Support with the Domino

The Festool Domino really dominated this build – with all the parts making up each unit having dominos to increase strength, and ensure alignment.  Some shelves in the units I wanted to be removable, but still being kid’s furniture, I didn’t want the shelves able to simply be pulled and slip out.  So instead I went with dominos as shelf supports, and then cut a domino slot into the edge of the shelf, half exposed.

Using Dominos as Shelf Support

At this point, I think it simply appropriate to say thanks to all the earlier converts who persevered and persisted, and finally convinced me that the Festool Domino was a machine worth having.  It certainly is. And I never expected to be saying that!