Oven Rack

Didn’t get a great deal of time over the weekend to really progress things – still a few hours meant things still moved forward.

Got to the end of the weekend, and realised that where I had mock-assembled the stove, it would have been better if I had mock-assembled the sink unit.  Just looked at it with (slightly) fresher eyes, and wondered how the sink will install when I have put a dovetail drawer in the way!  Oops.  Not hard to fix – but a bit of wasted effort making the second drawer that is now not needed.

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Grills and Drawers

The drawer now has the front attached – still needs a handle, but that is a minor issue.  I also had time to produce a shelf for the dishwasher, and the oven.  This is my interpretation of a wire tray, produced on the router table with a straight bit, cutting 1/2 way through.

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The Blowfly Flap Sander

There was a bit of feathering, so I wanted a way to clean it up without too much fuss.  Decided a flap sander would be an effective method, so got out the Blowfly from T & T Design.  By cutting each finger of the flap sander into three, I had something that would really get into the grooves.  Mounted in a drill, it made pretty short work of the issue.

Still need to make the mount for the grill – will end up being a C shaped piece of timber all around, adding some strength to the shelf (especially as it is about 6 lengths glued together).

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Adding the First Side

Finally got to the point that I thought I could start attaching the sides without causing any access issues.  Still have to resort to cheap clamps – don’t have enough decent ones!

So that is where the project ended up at the end of the weekend.  Having a side attached will make quite a difference – makes one feel like the end is in sight.

 

Starting Toy Kitchen Build

With Christmas approaching just way too rapidly, it is well overdue for me to make a start on the two toy kitchens I promised to build for friends of my daughter.  We’ve had a few discussions on what they wanted, and it came down to three individual modules – a fridge, a sink and a stove/oven.  They also intend to fully paint the units (the kids are going to be 3), so the material of choice became MDF.

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Breaking down MDF sheets

I priced some different sizes, and 2400×1200 sheets were 1/2 the price of the next cheapest.  Annoying there is such a price difference though.  It is easier to quickly break the sheets down into more manageable sizes using a circular saw, than to try to man-handle them through the tablesaw – bringing the saw to the material, rather than the other way around.  In the near future, the Torque Workcentre will definitely be the method of choice going forward.  Not that it is much different as a concept – a rail of some form controlling the circular saw through the cut.  In the case of the Torque Workcentre, it means a saw with a 1200mm crosscut capability.  In this case, I still have the loan of a Festool rail, which I have fixed to the board with a couple of Lidwig clamps.

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Creating Original Side Template

Once I cut out the first side, and shaped it, it became the template for the rest of the sides.  After using a combination of the tablesaw and the bandsaw to produce the initial shape, I then held it in place using some of the MagSwitch featherboards so I could hit it with the drill-mounted Blowfly to smooth the curves out.

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Pattern Copying

To then cut the rest of the sides, I used the first side as a template, and affixed it down temporarily using carpet tape.  I then ran around the outside of the pattern with a jigsaw, before moving onto the router table with a pattern copying bit to finish the job.  (A pattern copying bit is a straight cutter with a bearing)

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A Temporary Pattern Copying Setup

Given the amount of MDF I was expecting to generate, I had the air filters running at full speed, and the 4″ dust collector hose placed at the optimum position to maximise the collection. (That is a Lidwig Claw holding the hose in position).

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1st Kitchen Module

Using the Festool Domino and a bunch of 4mm x 20mm dominos, I then mocked together the first module to see how the design is progressing.  It doesn’t look much at the moment – adding tops and features (taps etc), as well as a door on the front will really improve the look.  I also want to break all the edges – MDF is rather sharp when cut, and rounding over the edges is the best option.

So obviously lots more to do, but at least it is a start.

T & T Design – Blowfly Sander

In the same YouTube chronicle episode that I showed the Spider Sander, the Blowfly Sander also made an appearance, and again in Episode 010 which was dedicated to the Blowfly. The Blowfly also comes from T & T Design. It is in essence a flap sander that can use a variety of materials. It fits your drill, or drill press.

The Blowfly

The Blowfly

The Blowfly uses the same concept as the Spider in that it utilises inexpensive versions of abrasives – in this case cloth-backed emery paper.  You can substitute a wide range of materials. simply by punching a couple of small holes.  The unit comes with a number of sheets of emery paper, including some (as seen here) that have been cut so it forms fingers for getting into details.

As the material wears, new sandpaper is exposed, and you can also turn the entire piece over to use the back half – getting the most out of your abrasive. As you can see in the piece of abrasive to the side, it only needs a couple of small holes punched to fit it to the Blowfly.

You could use a scourer for more of a polishing result, or let your imagination guide you.  Perhaps some robust cloth dipped in Brasso for polishing brass? Slip a number of abrasive sleeves on each spline?

The Blowfly Core

The Blowfly Core

As you can see in the base, each spline clicks in, making removing and replacing abrasives easy.  The unit (including some emery (both slotted and plain) to get you started) costs $A25.

SSYTC010 The Blowfly

SSYTC008 – Blowfly Spider Cookies

Now I’m sure that name makes little sense to anyone, so let’s clarify.

I grabbed the little digi-camera and shot a quick look at the Rockler Bench Cookies in action. They can be seen securing a board while edge routing with a hand-held router, while sanding with a ROS (random orbital sander), and while using the Blowfly Sander and Spider Sander, both from T&T Design.  There will be more on these 2 sanders shortly.

During the video, you’ll see the blowfly looking like it is catching my shirt- it isn’t, it is just generating quite a breeze, but it will be something I am more aware of in future.  Also, you’ll see me generating a ton of dust without breathing protection. I have a high volume air cleaner (Microclene MC1000) directly overhead, and during the dust production, I wasn’t breathing, so hopefully that puts anyone’s safety concerns at ease!

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