What that radial design became

Here is the finished product from the weekend’s shed excursion.  It is made from reclaimed timbers (Tassie Oak), and an edge of Solomon Islands Queen Ebony.

It is a quick jump from the pic the other day to the finished project – it was made as an article for the next edition of “The Shed” magazine, so you’ll have to pick up a copy of that (when it comes out) for the full 2200 odd-word article (and associated images!)

It made plenty of use of the SawStop, the Kapex, and the Domino.  On that last point, over 100 separate mortises went into this project.  Thank goodness for the Festool Domino!

Christmas Cooking

The kickstarter for this project came just over a month ago, and it has consumed a great deal of time and effort, but it is all worthwhile.  And she is the reason why.

My little one

Soon to turn 6, it was well overdue for her to have something significant out of the shed she loves visiting.

With a combination of conflicting priorities, it was always going to be interesting to see how it came out.  Short deadlines, a house purchase and a particularly busy work schedule all competed to derail the project, while making a great kitchen for my daughter, making the kitchen entirely from timber and having the experience of making two different toy kitchens before worked towards a decent result.  Especially wanting Jessie to have a kitchen that I’d made her.  I’ve never finished a project so late (and during the build I knew it wouldn’t be fully complete, as far as being fully finished, so already had some compromises), nor have I had so many nicks and cuts from rushing around a shed that was quickly running out of space, and being pushed for time meant I wasn’t working to keep things as orderly as needed for a limited space, while splinters were common from the hardwood.

The unwrapping begins

The two large wrapped parcels hardly gained a second look during the morning, but there were tonnes of distractions in the form of wrapped parcels!  Finally, it was time for the reveal – two large, fully wrapped presents.  It didn’t take long to reveal what was within, and it was pretty exciting!  You cannot tell from the photos, but I can see the different expressions there, and can still hear the excited squeals.

The great unwrap!

It did look very cool breaking through the wrapping paper.

Amidst torn paper

Kitchen full of……wrapped stuff

Once the main sheets of wrapping paper were removed, there was another surprise.  The units were packed full of more presents (and this after a morning of unwrapping).  It was all the real tools of the trade- saucepans, cutlery, mashers, bowls, jugs etc.  We had been shopping at Kmart a week earlier – they have a whole range of kitchenware, most with a $2 price tag.  At the checkout, they fully expected us to be first-home buyers given the range of items in the cart.  They are perfect – cheaper and better than any sold in toy sections, and that they are ‘real’ not ‘toy’ added to the experience during the reveal.

Proud new owner

I’m very pleased how the units came out, and the small details of jarrah and redgum stood out against the quality of the Tassie Oak.

Learning the ‘controls’

I couldn’t help myself from pointing out some of the details I had included (mainly what each of the controls said, that I had burnt into the knobs with the pyrography set).  Then it was a matter of sitting back and enjoying the soups, cupcakes etc that were being produced for the family.  With playdoh food, the imagination play is endless.

Checking out the oven

Cooking up a storm

Making tea

Washing up

All fitted out

Some of the details then: the sink is laminated Tassie Oak and Redgum, as are the drawer fronts (with a jarrah handle).  It is all glued, and in some cases also using Dominos.  I avoided any metal fasteners until near the end, when it became obvious that it would be a significant compromise to continue with that ideal.  That was when I first made some hinges for the oven, using wooden dowels, and that caused breakages.  Once I had decided on brass hinge rods, then a few other places benefited from a minimal amount of metal.  The drawers are dovetailed, the shelf a lattice, and the lower shelf using offcuts.  In fact this project had less wastage from offcuts than I can remember seeing in a long time.  There are hardly any at all, with wastage being small pieces assigned to the firewood bin, or are sawdust in the collection bag (and that is full).  I went through two full bottles of glue – about a full litre of yellow PVA on this project.  Again, the result of joining so many boards together to create the panels required.  The Frontline clamps got a significant workout.  The side panels each have a routed picture – one of the little surprises.

Oven detail

I love the strap hinges – they came up awesome!  The Incra Hingecrafter was a significant asset.  The Hingecrafter is not just the drilling jig, but also the box set of router bits that match.  Being able to make your own hinges is a great feeling – you really come away ‘owning’ the project being able to make, rather than buy the accessories.  About the only thing I purchased for this was the castor wheels.

Stove / Oven controls

The toy wheels, repurposed as control knobs were supplemented with the pyrography kit burning in names, and values.

Oven hinge detail

The hinges for the oven – very functional, strong, and compared to commercial hinges I have used before in the same situation, less likely to rip out of the timber as the load is distributed over a larger area.

Sink

A bandsawn faucet (rounded over on the router table), and a couple of oversized wheels for taps made with a wheel cutter on the drill press.

Dishwasher

The tambour door looks the part, and I added a spinning nozzle to the base to complete the dishwasher.

To finish this project off, I need to replace the hinges on the cupboard door (a short job with the hingecrafter), sand, roundover edges, and apply an oil finish.  Even so, a very satisfactory conclusion to the project (or at least a major delivery point).

Next, the kitchen needs a microwave, sandwich press, toaster (to start).  A storage cupboard may be in order, and a fridge.  The possibilities are endless.

Merry Christmas Jessica!

Invisible Progress

More progress made today on the kitchen, but not much to actually show for it. A lot of the day was spent doing the same sort of activities as the past few: machining timber to size, joining it up with glue (and Dominos as a whole).

I am still trying to maximise the yield I get from the timber, keeping any offcut of decent width, or length, and surprisingly so much of it is able to be used. I had a whole stack of offcuts, all thicknessed up just in case, and saw they were the perfect size and thickness for the base of the units. What is more, the pile was exactly the right number, and they had already been cut to length, which was exactly the length I needed. I’m sure it isn’t coincidental (being cut from stock that was the right size), but it is cool when it happens in any case.

The tops of the unit are done, excluding the machining (cutting a sink opening, and machining the elements into the stove surface).

Speaking of sinks, I have started preparing the material for the wooden sink.

Sink Laminations

This time I am doing it how I always planned, and envisaged it to be – laminated with contrasting timbers. The light timber is the Tassie Oak, the red timber is Australian Red Gum.

Rudimentary Form

To create the final sink, each lamination needs to be machined before glueup. Way too hard afterwards! So a whole bunch of clamps later (I’m rapidly running out), I managed to get it all glued up, ready for the net stage.

So a day where progress seemed slow to non existent, but it will prove itself during assembly, where all these stacks of dressed timber about the place will transform into the various parts of the project.

Bending Timber

Many years ago (I can say that now, being 5 or so years ago!), I wrote a post about bending timber using kerfing. To this day, it remains one of the most clicked-on posts of all time. It would certainly justify a revisit, and expansion to the original post.

Out in the shed today, I was using the Amana Tool Tambour Bit set to make a large tambour door for the toy kitchen (and the full article about the construction will be in the next edition of ManSpace magazine). When I had finished it, and assembled all the slats, it was surprising to see just how flexible the interlocking slats were. It made me think of kerfing, with a different surface texture (obviously). (The bit set is available from Toolstoday.com)

If flexibility was not the desired end result, but the forms that could be created during assembly, this could produce some really organic structures – lounge chairs, curves around structures etc. Although (like kerfing) there are some inherent weak areas, (which don’t compromise the structure if used for a roller door but would if used for a deck chair), these could be easily overcome with good glue, and supporting structure, allowing the form of the tambour, with the strength required for the alternate purpose.

Tambour Door

So there is the teaser. The full door (and in this case, it will be a door for the toy kitchen), is 450mm wide and around 750mm in length, and is made up of 52 individual slats that require no joiners, no backing tape or canvas: just pure, interlocking timber slats. Total distance of timber passing through the various machines in getting it sized correctly, then shaped by the router table was around 1/2 a km. Not relevant, just interesting!

Misan Timbers and Craftwood

I recently received delivery of a boxmaking pack of timber from Misan Craftwood in Tasmania. I was hoping by now that I would have been able to make a box from it to show off the timbers, but I was not expecting my router table to have taken as long as it has, and it is kind of integral to my woodworking!  So as not to hold it up any longer, I thought I might at least take a photo of the pack of timber that arrived, and show what I make from it when I get the chance.

Misan Craftwood Box Pack

The pack was delivered to dimensions I had specified from a box plan I want to make – it was all Tassie Oak, with a piece of Jarrah for some contrast pieces. The cost of this pack would be $45 (for Tassie Oak), or $55 if in Blackwood, Sassafras, Celery top Pine and Jarrah

Misan Craftwood have a new thicknesser which gives them precise sizing and a fine finish. They have recently move to Tasmania from WA, so they still have a good range of timbers from the west too.

Looking forward to having my router table back in action so I can get the box made that I’ve been intending to make with these timbers!