Small Steps

Probably seems like each ‘progress’ report is no different to the previous with the cot build, but there are a lot of small steps in between.

Lots of small other things too – floating tenons (aka dominos), holding everything together.  Little bit of thought required in setup for the Domino to ensure everything aligned, particularly where there were different thicknesses of materials, and offset joints, but once I got into it, the mortises were all cut in no time flat, despite there being about 40 to do.  They add so much

During glue-up, the Bessey K body clamps really started to shine.  The more I use them, the better I like them.   Increased my collection with a couple of 1250mm ones from Carba-Tec, along with a couple of Bessey extenders.

Ends

With all the components pretty much completed, what the final product looks like is becoming increasingly apparent.  And reflecting the multitude sketches of the various aspects of the project.

Building a project from pre-designed plans is a great way to learn woodworking concepts and techniques, but all the real problem-solving has been taken care-of.  It is not the best way to build, but I really enjoy building, designing and problem solving all at the same time, as in creating without pre-designed plans, and working out each step as I go.

Woodworking is a great mental exercise.

Progress Report

It seems like days of preparing components for the cot – lots of machining.  And that is pretty much exactly what it has been.  We have been working primarily with 190 x 45 Tassie Oak (kiln dried hardwood), although there has now been some pine thrown into the mix.  Each piece has been resawn, planed, thicknessed.  It really gives a sense of ownership of a project where every dimension is controlled by you, and not relying on standard timber sizes provided.

Clamping up the end-boards

The panels at the end of the cot are made from solid pine, so were reduced in thickness to 12mm, then joined with the Frontline Panel clamps.  With their unique action to cause the work to be held down, as well as together, they yield excellent results. More on these end panels later – we will leave them now while the glue dries.

Sorting out the components part 1

After machining so many components, it was useful to lay them out according to the parts they are made for.

Sorting out the components part 2

Lots of individual parts in one of these things!

Mortising for the slats

Cutting the mortises for the slats is made incredibly simple with the Festool Domino, and with the extension wings added on either side to get exactly the desired clearance between the slats (and in accordance with Australian Standards).  A job that could otherwise take hours completed in a matter of minutes.

Assembling the mattress section

The mattress section was assembled and glued, and there was a slight problem with the MDF sheet – it was not 6mm thick as it should have been, being up to 0.5mm out, which made it bind in the slot that was cut.  So the power of the Frontline clamps was bought into play – this time by converting to a standard panel clamp layout, then the Frontlines were closed up.  It took no where the full 4 tonne these clamps are capable of, and nothing can resist!

Now the observant among you will notice I have opened my Bessey account.  I decided to go with a brand that was readily available, so started my new collection with 2x 1000mm and 2x 600mm Bessey clamps.  Now I just need more (and more clamp sizes)

Assembling the sides

So once the sides were routered, it was time for it to go together.  The slats were not glued – easy to remove if they ever break (presumably not – we have already torture tested them).

Starting to really look the part

It is really looking like a cot now!

Routed end detail

Once the end panels were dry, it was time to add some details, so I chose to go with the 3D router carver from Carbitool.  One panel got a classic treatment. The other found something a lot more appropriate.

Adding 3d Routed Detail

So assembly has begun in earnest.  Hard to stop once the finish line is in sight!

Baby Bed Build Bis

Had a change to take another crack at the cot build this weekend, which was good – more progress.

After last weekend, we had the bed itself built (as in the surround and support for the mattress), so today it was time to build the side rails. Oh, and fwiw we are referring regularly to ensure compliance with the Australian Standard for cot design, so the maximum clearance between mattress and bed, height of sides, gap between slats etc etc are all being carefully adhered to.

Once again, we started with a large chunk of timber (around 250×45) and began machining it down.

A combination of jointer, thicknesser and tablesaw gave us the rails and stiles as the frame for the sides.

Despite having them for years, this is about the first time I have actually used the jointer MagSwitch featherboards. They worked very well to ensure even pressure across the jointer cutter. A quick tap down between passes to ensure even pressure is maintained as the board becomes thinner (I do 0.5mm passes on the jointer, so not a real issue in any case). And in case you were wondering, we jointed an edge so we had something straight and true to run up against the tablesaw fence, then ran the board through the tablesaw to get 2 lengths a bit over 90mm wide. From there, we started machining the boards from scratch, jointing a side, then an edge. Next onto the tablesaw to rip the boards in half, so they ended up 20mm thick after machining.

We then spent some time testing and preparing to make the slats for the sides. A number of test pieces, and setups done to fine tune the operation. We started with the Domino – when we need mortices, why not use the best tool for the job?! So with a 10mm cutter, and set to the widest mortice setting, we got a 33mm slot, and thus our slat size was determined. We then made one, and tested it for strength. That went well too.

With all setups done, all the spare pieces, offcuts from other pieces of this job were run through the tablesaw to create the number of slats needed, with a number of spares. Each was then tested, bent and abused. A few failed, but the majority were perfect, and will be able to survive even Arnold Schwarzenegger’s kid.

Still need to actually create the mortices in the rails, but will do that after some sanding and finishing.

To get the required slat placement, the Domino grows wings. It makes cutting the required mortices so incredibly easy, and accurate.

Now I know there are two main groups out there – those who cannot understand how any tool can be worth as much as a Domino, and those who love the tool. Unfortunately, I used to belong to the first camp, but since first using the Domino and then more recently (last couple of years) owning one, I cannot help but reside in the second. Awesome machine. Yes, I know – hideously expensive. But very, very cool. One of these days, I’d love to become permanently familiar with the Domino XL too.