Doors Ahoy!

Once the doors were sanded, I set on installing them. As I had previously dry fit each door with a single screw, the final fitting was fairly straightforward. I clamped the door to the hinge and sunk a screw into the hole from the dry fit.

A sanded door.

From there I alternated between my drill and screw gun, pre-drilling and screwing as I worked my choice down the hinges.

Doors Ahoy!

They installed fairly quickly and as the screws are set in the end and back faces of the ¾” baltic birch door panels, they seem more than strong enough.

Unfortunately, they’re also uneven. The left door sits about ?” higher than the right. I suspect that the unevenness was present and would have been noticed during my dry fit, had I had the presence of mind to check. As this point, I’m not 100% sure how bad the unevenness is (could be from racking of the carcass) and what I’m going to do about it (if anything). At this point I’m going to wait until I hang the cabinet on the wall and then I’ll see how the doors are sitting relative to each other with the cabinet hanging naturally. If it’s still choice off, I may try to clean it up.

So close, and yet . . . not.

Does your tolerance for error grow as project completion approaches too?

Other Bastard Wall Cabinet PostsWinter Wall Cabinet WonderlandThe Bastard Wall Cabinet (for tools!)Trudging Towards Tool StorageCutting the Cabinet Carcass (in relative terms)A Home For My PlanesContinued Wall Cabinet AssemblyWhats a Bastard Wall Cabinet without Shelves?

Boxing in the Bastard Tool Cabinet

Door Hinges on the Bastard Wall Cabinet

Oh, You Mean That Was Supposed To Lift?

Door Tops & Bottoms

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Window Trim Fascia A Photo Essay

This is a little out of the norm for a post here at the Penultimate Woodshop, but I was working on the trim to my bay window today and I photographed the milling of the relatively complex (for a fascia board) trim which caps the sides of the bay window. I thought Id take a brief break from the Wanderful Saga and present the fascia milling photos as a photo essay. The trim is Versatex PVC and once milled it is fastened using stainless steel trim head screws. Here goes:

The trim piece set up under the jig I made for milling the 30 degree angles next to a test piece.

Milling the angle.

Using relative dimentioning to mark the slight cut that gets made at the end.

Cutting perpendicular to the main 30 degree cut. This cut to to adjoin the fascia  on the wall adjacent to the window. Yes, I know the saws not cutting, but I couldnt cut and take a photo at the same time.

All cut.

Determining the width of the fascia above the window by referencing the adjoining fascia.

About to cut of the excess at the other end.

Cut and ready for milling.

Determining the router bit depth by adjusting it to my line.

Marking of the angled cut needed to fit tight to the soffit, which is not plumb.

Using a melamine shelf as a reference for the bushing guided bit to mill the angled cut.

I didnt clamp the melamine to the trim piece well enough and made a small mess with the cut. Luckily this is the top and the joint between the fascia and soffit will get caulked anychoice so I can hide this.

Trimming the wide end ever so slightly so that it is perfectly flush with the adjoining fascia piece.

A test fit. So far, so good.

Milling the notch to accommodate the window.

I clamped this board to the fascia piece and used it as a reference for my hand saw to square up the router cut.

Cleaning up the inside corner (yes, you can chisel PVC trim).

The notch to accommodate the window.

A nice, tight fit between the fascia on the side of the window and the fascia along the eave.

The installed fascia piece.

The next piece of trim to mill and install will the the extension of the eave fascia to bring its bottom edge flush with the fascia on the sides of the window. Ill biscuit the fascia along its length to ensure the pieces stay flush.

The bay window, almost completely trimmed.

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Its Wanderful Part 4 Carving

Now that the wands were just about shaped, I thought about the carving. Kenneth’s wand that I was using as a design basis is covered in wonderful carving that he managed to create using just a set of cheap carving tools. I had picked up the same set of tools, so off I went. First I practiced on the initial blank that I had turned to a dowel with my spokeshave. Then I went on to the first wand.

Marking lines I drew on the initial blank to carve. In the background
you can see a close up of the awesome carved handles of Kenneths wand.

I found the carving results to be acceptable (I certainly wasn’t thrilled with the results). They were however, far too time consuming. At this point I was beginning to seriously run low on time. Knowing that un-carved wands derived in time for the movie premier were better than carved wands delivered weeks later, I completed the carving on the business end half of the first wand handle and called it quits on the carving.

The one wand I half carved (dont tell that the order of the
description is slightly out of  order for better continuity)

Even though the carving phase of the project was aborted due to time and the results leave something to be desired, the process did intrigue me enough that I plan to take Kari up on her offer to provide some guidance. Having gotten my feet wet and seeing the beauties she’s able to turn out, carving is now certainly on my list of woodworking skills to learn.

Whos ready to sand?

Once the carving was done aborted it came time to sand. Though I normally enjoy sanding (thanks to my nice random orbit sanders, vacuum boom arm and headphones), I found the hand sanding of these damn wands almost unbearably tedious. By the time I had worked though the 80 and 100 grit sanding pads I was ready to call it quits. Luckily the small windows of evening shop time I get meant that by the time I was fed up with it, it was time to call it a night anychoice. Over the course of a few days I did manage to sand all four (4) wands to 320 grit.

Do youre natural work breaks break up the tedious tasks too?

Its Wanderful: Part 1

Its Wanderful: Part 2

Its Wanderful: Part 3

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