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Old 10-03-2010, 05:46 PM   #2851
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That is better than putting a few drops of oil in there. I was going to ask you how the Moskeets were up you way. At one time I thought they were our state bird down here. Your friend should market that stuff, it is by far better than poison.
I don't even know what the stuff is called Jim. But the local garden centers sell it in small brightly coloured little packages for $25 a pop. I think my neighbour said his dad gets it for something like $1 a pound in bulk.

Up in the Yukon, they used to sell T-shirts with a pic of a diving mosquito...the caption was "Yukon Air Force".

Truer words were never spoken.

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Old 10-03-2010, 05:49 PM   #2852
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I love the Bosch top handle, I have worn 2 of them out and the one I have now I tore the shoe up when I dropped it. I made another shoe for it and it is still going strong. What sold me on the Bosch was a fellow demonstrating one at a supply store one day, he took the saw and while it was running he plunged the saw blade all the way through a board and just went to cutting, I was sold and still am.

I had the chance to buy one of the spindle sanders several years ago but didn't, I wish I had a bunch of times since then. One other tool I passed up was a Williams and Hussey molder and I still to this day hate that I passed that one up.

I love the dust on your roller stand, it just looks natural.
Isn't that interesting about the demo...I saw exactly the same thing going through 3/4" plywood and bought the saw on the spot. But what was even more interesting, he let go of the saw and tipped the plywood up a bit and the saw kept on cutting!

That barrel saw is my fourth. I use them more than anything else here.
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Old 10-03-2010, 10:42 PM   #2853
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I spent the entire afternoon milling up just over 100 pieces of clear cedar for the two panels to go in the door.

The plan is to have alternating pieces of 5/8" square stock and 5/8" x 1 5/16" stock. The wider stock will be perpendicular to the door face.

In order to make it a little easier for the panel glue up, I machined two very shallow grooves - one in each side - in the wider stock. This is to allow the square stock to snuggle in to this shallow groove and hopefully remain square.
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Old 10-03-2010, 10:47 PM   #2854
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The next step was to add some relief to the ends of the wide stock.

A combination of the dado blade followed by sanding on the spindle sander did the trick.

Here is the dado setup for cutting the board ends. Four cuts per board, two of which were a little deeper. I want the raised portion of the panels to be higher on one side of the door than the other.

To facilitate this, I made the two shallow grooves slightly offset from center.
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Old 10-03-2010, 10:53 PM   #2855
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The destructions with the spindle sander caution you to bolt the sander down with through bolts or lags. Failing that, you must attach the machine to some thick plywood and then clamp that securely to the work bench.

Naturally, I was expecting this thing to head off in all directions once I hit the go switch, but it just sat there spinning calmly away. No vibrations...nothing. It seems to me that it has more than enough mass to prevent such untoward behavior.

And one other thing, sitting it on the workbench brings the sander to the perfect height for working on.
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Old 10-03-2010, 10:57 PM   #2856
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It still never fails to amaze me when the camera stops the action. I assure you, the machine is running in that pic.

After completing the sanding - a very rapid operation with this machine by the way - I put a few pieces together for a test fit.

Since everything seems to be in order, next up will be the actual panel glue up.
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Old 10-03-2010, 11:02 PM   #2857
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Hmmm...I see in that pic that the ends of the panel appear to be touching the center rail. Once the panels are glued, that will be remedied with some judicious trimming. There needs to be some room for the panels to float in the event of seasonal wood movement.

In this case the wood will be mounted vertically, which will have the least movement. The side gaps will need to be larger in anticipation of the greater horizontal movement.
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Old 10-03-2010, 11:04 PM   #2858
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Isn't that interesting about the demo...I saw exactly the same thing going through 3/4" plywood and bought the saw on the spot. But what was even more interesting, he let go of the saw and tipped the plywood up a bit and the saw kept on cutting!

That barrel saw is my fourth. I use them more than anything else here.
I didn't know the saw could be plunged through 3/4 plywood. I had, a Porter-Cable and Makita but I really like the Bosch best although the older Porter-Cable saws did cut smooth they just didn't oscillate.
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Old 10-03-2010, 11:06 PM   #2859
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I didn't know the saw could be plunged through 3/4 plywood. I had, a Porter-Cable and Makita but I really like the Bosch best although the older Porter-Cable saws did cut smooth they just didn't oscillate.
...and that's the secret of a good jigsaw. The adjustable oscillations. Bosch has had three positions for that as long as I can remember. Sure makes it a dream to cut with.
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Old 10-03-2010, 11:21 PM   #2860
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I can't wait to see the panels in place, they are going to be sharp. Is your oscillating sander variable speed?
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Old 10-04-2010, 12:15 AM   #2861
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I can't wait to see the panels in place, they are going to be sharp. Is your oscillating sander variable speed?
The sander is single speed Jim.

The up and down oscillations are quite slow, perhaps 1 per second.
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Old 10-04-2010, 01:33 PM   #2862
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Last night I glued up a small test section of one panel and it proved to be a little slower than I thought as well as trying to turn itself into a very minor curve.

After checking on some of the other non-glued pieces this morning, it may have been that the dado blade was not cutting a perfectly square bottom in the groove. So I ran the boards through the dado again this morning, but reversed from last nights' cut. It appears that it may work.

The short piece I glued last night was clamped down to the end of the bench, so it did come out flat this morning. Count another point for a good strong benchtop.

I had quite a time trying to glue and nail the pieces last night, so I decided that I would make a panel buck (like a door buck only smaller) to assemble the panels with. Really just a big jig.
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Old 10-04-2010, 01:34 PM   #2863
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After it was loaded up, it looks like this.
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Old 10-04-2010, 01:38 PM   #2864
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The small piece was the test done last night. One other thing I found handy was that I was able to sand the ends of the small panel on the oscillating sander all at once. Can't go any higher than that small panel though, that's as far as the sander reaches.

I guess I could maybe glue up half a dozen pieces at a time, then sand them gang style, then glue those small sections together. I'll give that some thought.
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Old 10-04-2010, 01:55 PM   #2865
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Wow! That's going to be one beautiful door!

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