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Old 10-31-2010, 03:03 PM   #3601
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Gulf Island Building.


Well, these custom things always seem to take longer than we plan...but it all went well.

I couldn't find a piece of Douglas fir that was good enough to make the mould from, so I ended up wasting a perfectly good piece of yellow cedar. I know I should be hung for that, but whattareyagonnado?

Here I had it planed to thickness, and it has just come off the table saw after being ripped.
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Old 10-31-2010, 03:04 PM   #3602
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Gulf Island Building.


You can see here the original mould shape, which has to be modified for the corner post.
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Old 10-31-2010, 03:07 PM   #3603
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It's quite straight forward as to how this is calculated...just draw the line from the original first.

Then I marked off lines at every 3". Drew a straight line in front of the curve.

Then measured the distance between the two lines at each of the cross lines - every 3". Added 40% to that on the outside of the curve. Then put some small nails on the intersecting lines.
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Old 10-31-2010, 03:09 PM   #3604
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Using that thin batten in the above photo, I pushed the batten against the nails and drew the line to follow the new curve. It should show easily here.
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Old 10-31-2010, 03:10 PM   #3605
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Remove the nails and cut the new shape out on the line.
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Old 10-31-2010, 03:11 PM   #3606
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Following the completion of the cut, I did a dry test with the cedar strips - ALWAYS do a dry run first - you never know what might crop up.
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Old 10-31-2010, 03:14 PM   #3607
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Now both the end hand rail and the post are glued up, and will stay clamped until tomorrow.

One thing to remember when clamping up something with many layers of wood - once you have it clamped tightly...wait about 5 minutes and re-check the clamps. There's a good chance that some of them will tighten a little more.
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Old 10-31-2010, 03:23 PM   #3608
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Good method on the post layout... should be WAYYYYYYYYYYYYYYYYYY within tolerance.
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Old 10-31-2010, 03:46 PM   #3609
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Good gravy, you don't let any grass grow under your feet. Thanks for the explanation buddy.
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Old 10-31-2010, 05:02 PM   #3610
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Quote:
Originally Posted by jlhaslip View Post
Good method on the post layout... should be WAYYYYYYYYYYYYYYYYYY within tolerance.
Thanks...I sure hope it is!

Incidentally, on those diamond hones...all mine came away from the backing when they were cold.

I haven't actually re-fixed them yet, but perhaps a few dots of silicone around the outside would hold them.

You mentioned rubber with yours...Is there a rubber backing? I don't have that on mine.
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Old 10-31-2010, 05:03 PM   #3611
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Quote:
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Good gravy, you don't let any grass grow under your feet. Thanks for the explanation buddy.
Hmmmm...just exackly what kinda grass we talkin' 'bout here...
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Old 10-31-2010, 05:24 PM   #3612
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I was just talkin about regular grass, not that left handed kind.
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Old 10-31-2010, 05:32 PM   #3613
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Quote:
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I was just talkin about regular grass, not that left handed kind.
Gotcha!
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Old 10-31-2010, 06:32 PM   #3614
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Old 10-31-2010, 06:38 PM   #3615
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Gulf Island Building.


Maybe you should burn a bale of that green stuff to keep those diamond hones together...

Yup, cold weather did it here, too. They were so cheap I didn't worry about fixing it.
Silicone *might* work, but I've spilled 3-in-1 oil over mine, so it might not work for me.

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