The Ghost of Weekends Past

Not really sure what happened to the weekend – vanished in a puff of ethereal smoke (or was that just a cloud of MDF dust that got so dense it momentarily became self-aware?).  The workshop is covered in the stuff, despite 20 cubic metres/hr of air filtration, and the 2HP TruPro dusty.  Some of the tools are insufficiently (dust) guarded, particularly the router table, which, being under significant rework has lost connection to the standard collection system.  If all the MDF dust got wet, it’d probably papier mache together into to a mold that I could cast copies of Stu’s Shed from.

Come the end of the current project, there will have to be a major cleanup/dust-off out there, and a vow (which I typically can never stick to) of not starting any more projects until the proper systems are fully in place and working.

I was out there last last night (hope the neighbours are still talking with me!) fighting to get the kitchens close to completion.

Aaron from Torque Workcentres came for a visit yesterday morning (we started the day at 6:30am to get the maximum possible done), and we got my Torque Workcentre running like an impressively well oiled machine (or not, as the case may be – inside joke).  It is working exceedingly well – the main arm that supports the tool (router typically) now glides along the X axis with the lightest touch of a finger.  There are more adjustments for the machine than I was aware of – there has been a lot of thought put into the engineering, and it really makes a difference all the subtle tweaks that can be done.  I’ll document those in future articles.

I was going to have the MDF top flush with the cast iron router table, but late last night got sick of trying to get it all sorted, so decided instead to stick with how it was originally designed, and mounted the MDF directly to the workcentre.  I still maintained the cast iron router table at one end, and just accepted I’ve lost some working range.  It isn’t a huge amount, and it may not have any real impact on me anyway – time will tell.  I was using the router table, and the Torque Workcentre happily last night, so both router positions are well justified.  If you don’t have/need a cast iron router table, then cutting an opening for the router mounting plate at the right end of the table, directly into the MDF is a good solution.

I didn’t photograph it, but I set the pin routing guide into the table – this is a metal pin with a small diameter end (7mm) that engages into a template channel so the overhead router cuts identical items.  In this case, my “channel” was a single hole, and the router was offset to one side, resulting in probably the easiest circle I have ever cut or routed.  Ever!

In this case, I was only routing a partial depth pattern – a circle cut with a cove bit, repeated in 4 locations and with 2 different diameters to produce the stove ‘elements’

Kitchen Detail

I was quickly switching from tablesaw, bandsaw, disk sander, linisher, router table, torque workcentre, drill press and Domino, turning out component after component.  When a workshop is set up properly, it is amazing how easy and quickly tasks become.

Cut an opening for a sink? Done.  Duplicate the opening on the router table? Done.  Stack-cut a handle for the oven, then round the edges? Done.  Join it accurately and strongly to the project? Done. Elements cut, wheels made. Fun stuff.

Cutting Toy Wheels

Using the Carb-i-tool wheel cutter, scrap MDF was utilised to produce stacks of wheels.  Here the Lidwig Claw can be seen being used to good effect, holding the 4″ dust collection hose right at the point of shaving and dust creation.

So a profitable weekend – just don’t know where it went so fast. There is still a few small tasks to do to finish the cabinets off, then they can head out to their new homes for painting, and playing.

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