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Old 12-26-2009, 01:03 AM   #391
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Gulf Island Building.


In the photo above, you will note that there are two grooves in the edges of each side of the guide. They are there to accommodate a pair of nasty little metal bumps on each side of the saw. The inconsiderate manufacturer obviously never envisioned such a guided use for this saw, a use which I consider to be obvious, and did not make the required allowances.
I also added two small strips of wood to each edge of the guide plate on the saw, which were necessary to cover yet another inadequacy on the machine.
Now the guide is obviously wider than the saw base to permit a wide groove to be cut in the bench top. By pushing the saw against one side and then the other, two lines are established showing the actual width and location in the guide itself as to exactly where the grooves will be cut.
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Old 12-26-2009, 01:05 AM   #392
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Gulf Island Building.


And as you can see here, several passes with the saw yields a nicely lined up hole for the bench dog.
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Old 12-26-2009, 01:10 AM   #393
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Gulf Island Building.


If you have an extremely sharp eye, you may have noticed that there is a small angle applied to each hole of precisely 3 degrees. This will allow for a dog to remain at least vertical, and have possibly as much as 3 degrees forward lean when in use. This helps prevent a clamped board from moving.
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Old 12-26-2009, 01:11 AM   #394
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Gulf Island Building.


Here is the jig lined up to make a cut...
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Old 12-26-2009, 01:12 AM   #395
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Gulf Island Building.


And here is the beast doing the damage...
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Old 12-26-2009, 01:13 AM   #396
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Gulf Island Building.


The first top section had 6 boards, the center section needed 7 boards, here it is.
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Old 12-26-2009, 01:16 AM   #397
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Gulf Island Building.


The center section went together well, so I was feeling pretty cocky about all this. Here is part of the last section prior to glue up. Making sure the leg mortise holes lined up...
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Old 12-26-2009, 01:18 AM   #398
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Gulf Island Building.


Here's a good view of the dog holes in the top front section. Plus you can see how many biscuits are going in this piece.
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Old 12-26-2009, 01:25 AM   #399
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Gulf Island Building.


When it came time to glue the last section...nothing went right.
I applied the glue to the first board, put the biscuits in and laid the next board in place. It just didn't want to go down properly at all.
I got way more exercise using the dead blow hammer than I wanted. So it was only by sheer force and ignorance that the first two went together.
Exactly the same thing happened with the third board. For the life of me I could see no reason why this should be.
It took so long to get the first three mated that I had to clamp them up and let the glue set for an hour or so.
You can see at the end how I put the biscuits in to make sure of adequate strength. It was probably serious overkill.
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Old 12-26-2009, 01:27 AM   #400
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Gulf Island Building.


Unfortunately the remaining three boards were no better. But at least the top is now solidly glued up in three sections.
Next will come some glue cleanup, thickness planing and a complete dry run check - with biscuits - to make sure the previous problem doesn't occur.
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Old 12-26-2009, 02:50 PM   #401
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Gulf Island Building.


Great to see you back in action!! I will take some of those 'words' to the scrabble board...and your expertise, speaks through your work! Nice to see that spiral staircase in the background! Cheers
Syd
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Old 12-26-2009, 02:59 PM   #402
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Gulf Island Building.


Hi scoggy: How the heck are you? Good to hear from you.
I just finished cleaning the worst of the dried glue off the top pieces, and with a little luck - the good kind I hope - I will get the first two sections glued together later today.
I may even be able to glue the third one as well later on, as this titebond sets up pretty fast.
Little bit foggy here today. Same over at your place? I can hear the occasional foghorn going off in the distance. Nobody too close however, we know when NOT to go out there.
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Old 12-26-2009, 03:16 PM   #403
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Gulf Island Building.


and speaking of the stairwell, I finally got the major portion of the wall covered with narrow cedar strips. That was a long job I can tell you.

When I went looking for the hardware to hold the stair rail, we tried to find the same kind as we put in the cabin. It was nice solid stuff.

Naturally, it was nowhere to be found and has been replaced with some flimsy stuff. Since it was all we could find, I got a whole bunch of these junky little mounts, in the hope that their combined strength will be adequate. I expect they will be OK, just nowhere near as nice as the older ones. Still and all...I guess it has been nearly 13 years since we bought the other ones. Can't win 'em all.

Here's a couple of shots from the bottom and top of the first set of stairs.
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Old 12-26-2009, 03:21 PM   #404
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Gulf Island Building.


It's about a 9' diameter inside that stairwell, so I went through a fair bit of cedar. The only trouble with doing something like this is that you have to use wood that is more or less clear, as anything with any size of knot will break almost every time. I had to thickness it down to just over 1/4" in order for it to bend without too much difficulty to such a tight radius (4' 6").

Still haven't started on the top well yet.
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Old 12-26-2009, 09:10 PM   #405
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Gulf Island Building.


OK, so I did a dry run with the first two top sections seemingly without any serious troubles. There was a very slight gap between the pieces about 2 feet long. That was fixed with a few more clamps.
Then the real McCoy with glue. Went together fine, but there was a small bow where the two halves met. Fixed by adding a couple of 2 bys on edge with lots of clamps. The first end fixed the bow, but added the other end anyway just to be sure.
There wasn't a lot of glue squeezeout, but I wanted to clean it off anyway - much easier wet than dry. So I hunted down a thin piece of suitably expensive hardwood for the job and scraped away.
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