tag:blogger.com,1999:blog-20524634882863164292024-03-18T08:35:02.430-07:00SilverHawkContraptions, Cars, Corvettes, and CognitionsJoehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.comBlogger295125tag:blogger.com,1999:blog-2052463488286316429.post-46788657909453755452024-02-03T20:11:00.000-08:002024-02-03T20:11:25.779-08:00Storing Pipe Clamps<p> Ever since that table project, I've had pipe clamps laying on the floor of the garage, and when it rains, everything is covered in water. I needed to get them off of the floor. I used a 2x4 for each end, and I used another one to create the braces to screw that too the wall. I bored them out using a 1-1/4" Forstner bit, and then finished the cuts for one side (I left the complete hole on the second end).</p><p>Bolted them to the wall.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje0_AEPSw4SDrE-SOYRyndkSwb_tkT9SlAhfEcS6TAvu5NlU1NQkQfiyfhcBngVmDjyVX5suxNzxriT91aUCMerPNWqbj4xMP-8hjntQb55_kl7It5Lxr__gdQ_ycQlEqSVbDvBX3kjZ0VW0AYGOcTJoXYnyzf17NnfhI1rMVp39qGNSCs0ZGFOUwW684/s4032/20240203_170329.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje0_AEPSw4SDrE-SOYRyndkSwb_tkT9SlAhfEcS6TAvu5NlU1NQkQfiyfhcBngVmDjyVX5suxNzxriT91aUCMerPNWqbj4xMP-8hjntQb55_kl7It5Lxr__gdQ_ycQlEqSVbDvBX3kjZ0VW0AYGOcTJoXYnyzf17NnfhI1rMVp39qGNSCs0ZGFOUwW684/s320/20240203_170329.jpg" width="320" /></a></div><p></p><p>Now, my clamps are off the floor!<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-67761619692660660192024-02-03T15:13:00.000-08:002024-02-03T15:13:20.143-08:00Ram 1500 Rack and Pinion Loose<p>As I've driven my Ram 1500 lately, I've had these weird thoughts that the steering was getting loose. And then, on Thursday, it started "popping" when I was cranking the steering wheel all the way right and then to the left as I've been parking it. I panicked, and parked the truck until the most recent snow storm finished.</p><p>I slid underneath and inspected all of the steering knuckles and bots to make sure the linkage was in good shape. Nothing looked off, so I started inspecting everything, and that is when I noticed one of the rack and pinion bolt fasteners (holds it to the frame) had about a 3/8" gap. I could turn it by finger. Probably not supposed to be like that.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0jiB4EbbavNyAzhj0YOjVVaYblr8vfWfen-AcvetIXfnAcH-ad6BdXes14AlKsA9_WW9VkQ0hnVnGe5WhoDWOaEhRO7O2gRlWmzrLCL2MyP6DZd45FtTzlE5PXy7gRZ62G25dmD4wjXBei4YOo6R2EfWIcVbUVdTKcxEbi8_78dTdo7_fBOGACcRpR0k/s4032/20240203_145750.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0jiB4EbbavNyAzhj0YOjVVaYblr8vfWfen-AcvetIXfnAcH-ad6BdXes14AlKsA9_WW9VkQ0hnVnGe5WhoDWOaEhRO7O2gRlWmzrLCL2MyP6DZd45FtTzlE5PXy7gRZ62G25dmD4wjXBei4YOo6R2EfWIcVbUVdTKcxEbi8_78dTdo7_fBOGACcRpR0k/s320/20240203_145750.jpg" width="320" /></a></div><p></p><p>I grabbed my tools, and secured the bolt.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4hP0BnQ8Z8Jp37horHT_ejIhV5pXP3UazNCNeUxGTRhjMVrkKfSOrjjnoYgiOLIp3l_G9IL8xDAfWfVr__N_Q92qU8MDdlRLn8xZmShN1IJiXyKTCbAsbTrcpW12oSE01UppPjdJGeF6myhH4Lxek5axreUAZn_JuWgF9YaLBtmjtIDIYeDSsosnylPY/s4032/20240203_145539.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4hP0BnQ8Z8Jp37horHT_ejIhV5pXP3UazNCNeUxGTRhjMVrkKfSOrjjnoYgiOLIp3l_G9IL8xDAfWfVr__N_Q92qU8MDdlRLn8xZmShN1IJiXyKTCbAsbTrcpW12oSE01UppPjdJGeF6myhH4Lxek5axreUAZn_JuWgF9YaLBtmjtIDIYeDSsosnylPY/s320/20240203_145539.jpg" width="240" /></a></div><p></p><p>Now, I don't have the torque specifications for that bolt - and I couldn't find them anywhere (I don't have a service manual for this thing). So, I slowly incremented my torque wrench and tried the other bolt until I got to the point where the other one would turn.</p><p>That is where I put the torque on this loose one. Steering is again tight, and I feel much better about driving this thing.<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-53659048445313277862024-01-11T16:16:00.000-08:002024-01-11T16:16:36.003-08:00Bernina 900 Foot Pedal Fix Request<p>I had some family hand me an old Bernina sewing machine (a Nova, looks like a 900 but I cannot confirm this). It's not working. The pedal is simply not allowing it to function. Apparently, they had taken the pedal to a repair shop, and the shop turned them away, because it was only used for a short time, and the parts stopped being made a long time ago.</p><p>Granted, they have a few extra sewing machines, but they REALLY like this light weight machine, and were hoping I could get the pedal fixed. It's called an "air pedal". It seems to function just like other sewing machine pedals, but it "floats", or at least, it is supposed to. This one just floated without connection. So, I took it home, and promptly took the thing apart.</p><p> First thing I noticed is that there is a barbell of sorts used to connect the pedal to the actual hinge hardware, and it is not in position. Problem?</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCSkgPMQbIDP26R3nvMafyDB1neU4_TBTBmvrd60FPx2m0RG3nQvO2FyFc8PA-okqbFPF261vLzoVK9YY2Fh6DqPRvDO7zGsHzrzUC1hDnmG9i8Id3IB-HL3g3LS9G6aFWKvftVILbjslYCiFrQbvKFBptQlUsNW22W-sETl6jwAGhzY6oVY6SSf90m7g/s4032/20240106_142803.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCSkgPMQbIDP26R3nvMafyDB1neU4_TBTBmvrd60FPx2m0RG3nQvO2FyFc8PA-okqbFPF261vLzoVK9YY2Fh6DqPRvDO7zGsHzrzUC1hDnmG9i8Id3IB-HL3g3LS9G6aFWKvftVILbjslYCiFrQbvKFBptQlUsNW22W-sETl6jwAGhzY6oVY6SSf90m7g/s320/20240106_142803.jpg" width="320" /></a></div><p></p><p>Perhaps. The blue circle is around the barbell. The green circles are two concave holes where the two ends of the barbell are supposed to go (think of a hip joint - one round ball and one socket).</p><p> Here are some more views of the two halves.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTZXEaFGjY5tcVv5s2T50ohurAvZXDmqni0vgOUhwHxEd4T8U1ryXSOsIFiyQmPqWvy7vGrx5LWEsNb_9Yw6pf2lGsyw2DnF-7ryTWCtIwm2E-h0BwZvNsdieUkyw7RI2I73k99DC-xZYG5fUrp6d8ZY0gNd30SszteMxNLgaiGx_820aljrxWP5EEeAA/s4032/20240106_142824.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTZXEaFGjY5tcVv5s2T50ohurAvZXDmqni0vgOUhwHxEd4T8U1ryXSOsIFiyQmPqWvy7vGrx5LWEsNb_9Yw6pf2lGsyw2DnF-7ryTWCtIwm2E-h0BwZvNsdieUkyw7RI2I73k99DC-xZYG5fUrp6d8ZY0gNd30SszteMxNLgaiGx_820aljrxWP5EEeAA/s320/20240106_142824.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirG4WUkkTAeNsufBVq4GHa4zz-VVO5XTkorl7Lv56YuTzm4wQgOSEfzD1MatARG_9RBoxZ9vgFIIiYmQ2YsWVVIgqM1PuJ0fa7R12Xx68J7hp0h1KAJcTbgKNuT4b6pli0qZTS3zLGCJ8lO64mrStZuj-E_pHGqLSvk-uNXZJFc1fYPOexBWDu6P76lhA/s4032/20240106_142831.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirG4WUkkTAeNsufBVq4GHa4zz-VVO5XTkorl7Lv56YuTzm4wQgOSEfzD1MatARG_9RBoxZ9vgFIIiYmQ2YsWVVIgqM1PuJ0fa7R12Xx68J7hp0h1KAJcTbgKNuT4b6pli0qZTS3zLGCJ8lO64mrStZuj-E_pHGqLSvk-uNXZJFc1fYPOexBWDu6P76lhA/s320/20240106_142831.jpg" width="240" /></a></div><p></p><p>Let's put it back together in what we'd call "the Right Way" (trademarked?) and see what happens.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCfW1DjBBP6szfOSSkYsMZVmmaX7XIket1OFwH28JiHvEjw_7ZZYzftGaaBOJeR348pBguvNegQjqADE2oGLbQPrG0XWom-aGM8Qttxq3F6zJJXrXMxHUNwqdXw9_9de82Tp0Wig_kVYK1RjrLs01jlufYFlNsNU8xS92uq-vG5oxu7xjuefiy79FoDmg/s4032/20240106_142934.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCfW1DjBBP6szfOSSkYsMZVmmaX7XIket1OFwH28JiHvEjw_7ZZYzftGaaBOJeR348pBguvNegQjqADE2oGLbQPrG0XWom-aGM8Qttxq3F6zJJXrXMxHUNwqdXw9_9de82Tp0Wig_kVYK1RjrLs01jlufYFlNsNU8xS92uq-vG5oxu7xjuefiy79FoDmg/s320/20240106_142934.jpg" width="320" /></a></div><p></p><p>Here we can see the ball joint in it's natural habitat, with the actual pedal ready for installation.</p><p></p><p>So, was it the actual problem? Yes. The machine actually started up this time. It immediately stopped, which sent me home with the whole machine for some electrical tests.</p><p>I flipped it over, and a pin fell out (one you might see holding sleeves on a brand new dress shirt that is being opened, not machinists pins or internal pins). I paused, flipped the machine upright, plugged everything in, and hit the pedal.</p><p>Nothing. </p><p>While holding the pedal, I rotated the manual crank wheel, and it started working. That's it - a pin held the whole thing hostage. It's back online.<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-32221751326483937652024-01-11T15:41:00.000-08:002024-01-11T15:41:17.616-08:00Small Parts Sled<p>In the process of building the tool chests, I have encountered the need to do some small parts. Since I do not desire to lose any fingers, and since I didn't want to use my big panel sled used to cut the sides, it was time to tackle yet another sled. I've seen a <a href="https://www.amazon.com/Rockler-Table-Small-Parts-Sled/dp/B07FNX5C7W/ref=sr_1_1?crid=1RF7K38CQAJCF&dib=eyJ2IjoiMSJ9.-d8Wagt6B9JX2Y26hu18ygpljycEje2w3nET75-fmbLOGYRNh7sYY3V9cNqwiF2dUydVTI6QR4J-gQHjZrSnTg.EOV902C-40bwPWywMPpaGxlkjMK3Hd7Mtl5t4VlUB_c&dib_tag=se&keywords=small+parts+cross+cut+sled&qid=1705013451&sprefix=small+parts+sled%2Caps%2C222&sr=8-1" target="_blank">Rockler sled listed on Amazon</a> for $90, and it was severely tempting. However, I thought I could save a couple bucks and do it myself, since that sled likely had to be built for my specific table saw, anyway. So, let's see.</p><ul style="text-align: left;"><li>$20 for a sheet of <a href="https://www.homedepot.com/p/White-Melamine-Wood-Shelf-23-75-in-D-x-48-in-L-252297/202089063" target="_blank">melamine shelving from Home Depot</a> (surprise! It was cheaper than Amazon?)</li><li>$36 for <a href="https://www.amazon.com/dp/B07ZV5NL3Y?psc=1&ref=ppx_yo2ov_dt_b_product_details" target="_blank">36" bars of t-track (4 pack)</a><br /></li><li><span style="color: #cc0000;">(not included on the Rockler) </span>$28 for <a href="https://www.amazon.com/dp/B099JZBG7Q?psc=1&ref=ppx_yo2ov_dt_b_product_details" target="_blank">two fence stops</a> (not on the Rockler jig) (could have gone for $14 for a single one)<br /></li><li> $28.50 for some <a href="https://www.amazon.com/dp/B09C8QDLNG?psc=1&ref=ppx_yo2ov_dt_b_product_details" target="_blank">UHMW pre-drilled bars</a> to build a jig (3/4" - I had to trim one of these down to fit) (HDPE will work okayish, too, but UHMW is a little more durable and wears better)<br /></li><li><span style="color: #cc0000;">(not included on the Rockler) </span>$10 for a <a href="https://www.amazon.com/dp/B01N5WC8BK?psc=1&ref=ppx_yo2ov_dt_b_product_details" target="_blank">t-track hold down kit</a> (ended up not needing this one until the angle bar is used)</li><li><span style="color: #cc0000;">(not included on the Rockler)</span> $21 for a <a href="https://www.amazon.com/dp/B0BF7TCVZP?psc=1&ref=ppx_yo2ov_dt_b_product_details" target="_blank">12" long 3"x3" aluminum angle</a> that is 1/4" thick (think of this as potentially holding a part at a right angle - I will need to trim this to length</li><li><span style="color: #cc0000;">(not included on the Rockler) </span>$25 for two <a href="https://www.amazon.com/POWERTEC-71168-5-1-Hold-Down-Clamp/dp/B07FMX7GXN/ref=pd_bxgy_d_sccl_1/145-9120131-9929842?pd_rd_w=gwpu5&content-id=amzn1.sym.101c7dca-f8ef-4330-838b-ed6e9ebb9e52&pf_rd_p=101c7dca-f8ef-4330-838b-ed6e9ebb9e52&pf_rd_r=4410WKSZ8YRW1X0T9245&pd_rd_wg=F6prO&pd_rd_r=3e53fcd2-7135-4586-a016-ee0b08cab664&pd_rd_i=B07FMX7GXN&th=1" target="_blank">t-track hold down clamps</a> for my inside t-track<br /></li></ul><p>Now, if I filter out the costs of the stuff that wouldn't be included in the Rockler kit, we're looking at the melamine ($20), UHWM ($29), t-track ($36), and a couple of screws that you likely have sitting around for a grand total of $85.</p><p>Hold on - I <b><i>ONLY</i></b> saved $4? [sigh]. But, the parts would let me build a second jig if I needed to, say for instance that I was going to build a jig for my router (which IS on the docket).</p><p></p><p>Anyway, I added t-track folding stops ($28), two t-track hold down clamps (I got mine from Rockler for $8 a piece on sale, but $25 on Amazon for two), an aluminum angle bar for some custom jigging on this thing for $21. All this, with enough to make a second jig, for $150, and that included stuff the Rockler kit did not for only $60 more. Off to the build (which you'd have to do with the Rockler kit, too, but most parts are pre-cut).<br /></p><p>First, mark up the melamine board for the parts.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaUj00GCNlmAS0uQ-P71PDa87zXt2Ne9vDQz6MJiR46fpXL7kG5WUMVoUjg-tbD66jmfH1xtjG0lhDkKaz9qni3SEv-MF4fRMho7YyrPZlAHp0fU7ZJb838maEvrIIR9uDNKg59U7T12LNKs45efhBTfXUkmGfheXRZx7nhZ3BmVmctlZgrxurGcgDdBc/s4032/20240106_160404.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaUj00GCNlmAS0uQ-P71PDa87zXt2Ne9vDQz6MJiR46fpXL7kG5WUMVoUjg-tbD66jmfH1xtjG0lhDkKaz9qni3SEv-MF4fRMho7YyrPZlAHp0fU7ZJb838maEvrIIR9uDNKg59U7T12LNKs45efhBTfXUkmGfheXRZx7nhZ3BmVmctlZgrxurGcgDdBc/s320/20240106_160404.jpg" width="240" /></a></div><p></p><p>The usual cutting of those parts out (yes, I have quite a bit of left over material - I could build a slightly larger sled, or [again] a sled for possibly cutting some custom grooves on the router) went pretty quietly.</p><p>With parts cut out, it was time to install the UHMW (again, slicker than HDPE, and the stuff I ordered came pre-drilled). Note that in my case, my table saw miter slots are NOT 3/4", so I had to use the table saw to trim the width down - and that was a bit harrowing because the blade wanted to grab that material BADLY and throw it at me. <i><b>Please take note of your own table saw slot dimensions!</b></i></p><p>The first bar went on relatively straight forward. I used a 90-degree square (a carpenters square will work, too - pretty much anything that will get you close) and simply attached it to the bottom. It didn't have to be on the table saw to get it set into the right position. I actually set it on the left side when looking at the bottom, about an inch away from the side. This would become the right side of the jig when flipped over.</p><p>The second bar was where I was a little more careful. It needed to be parallel with the first (the board itself did not need to be exactly perpendicular). I used some super glue (it won't stick very well to melamine, so be gentle until it's screwed on). With the UHMW set properly in the left miter slot on the saw, and some super glue/cyanoacrylate set on top, I dropped the previously-attached board and miter into the other slot, and slowly dropped the board onto this new one. Give it a minute to set up. It should hold just long enough to pull the board and the two miter bars out, flip it over, and screw the second bar down.<br /></p><p>Now is when we get a LITTLE more careful with getting everything square.</p><p>Raise the saw blade on your table saw to be just above the top of the melamine board when it is in the slots properly. Yes, we're going to cut into it (not all the way through, yet). Start the table saw, and feed your sled base into the blade until we have the top being cut by 1/4". We will then back the sled base out, and set it to the top and pull back to do the same for the other side of the board. In this case, we want to cut 1" on the top surface of the sled base (1/4" more than our melamine material that will be used for the sides of the sled).</p><p>Now, drill all the holes to hold the fences/sides, and countersink for the screws. Use a square to make sure the fence/side is at 90-degrees, and then put the first screw in (pick the hole farthest away from the cuts on the sled base - it will be less finicky on the next step).</p><p>Now, use a right angle (I used a drafting triangle) to square up the fence to the two marks from the saw blade. If you are going to use this as a reference for your parts, make sure this is accurate.</p><p>Clamp that fence into final position. I used a 90-degree clamp I'd made for my tool chest drawers, just to make sure. Then, flip it, and drive the screws into position for the first side/fence.</p><p>The second is a little easier. Find a length of material that will set between them. Square the fence up to the sled base, and drive one screw. Move your material height block to the other end, square it, and drive that screw. Now you can drive the screws in that will hold those sides/fences in position. Make sure you have at least two screws on each fence/side ON EACH side of where the cut marks are to ensure it is secured. I ended up with 6 screws on each fence to attach the sides/fences to the sled base.<br /></p><p>Flip the sled, and install your t-track slot onto the tops of the fences. Now, raise the saw to where you will likely have it (I raised it about a half inch above the sled base), and make one final cut through the entire base.<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIBNbtP7QvzEriqmjctmlp1W82R_DZZoGlUZ9p5K8mZoAMlWge67dETmfOj2XRNClxrpxZF1OWWbSZBKyHtW9w6UIl6BPKm1zZfaexs8JZTf1Fi78DL8H8Qn4sWRxIguKeI2C0a150Iq4xmsJL63DAHyQ_wWL6TciKqwF-e7CMlC9RZ_G1tNfLKcWDNFw/s4032/20240110_132012.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIBNbtP7QvzEriqmjctmlp1W82R_DZZoGlUZ9p5K8mZoAMlWge67dETmfOj2XRNClxrpxZF1OWWbSZBKyHtW9w6UIl6BPKm1zZfaexs8JZTf1Fi78DL8H8Qn4sWRxIguKeI2C0a150Iq4xmsJL63DAHyQ_wWL6TciKqwF-e7CMlC9RZ_G1tNfLKcWDNFw/s320/20240110_132012.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi96gkWdWZljcjwrEnH7PoETnaFCMNf69Y0JznP3bgK59iYQqRjA1JHGh-QGXRq7PYVKCxIE87CgN3s3LvdyKbGfQGIlHwgnefYNr7yJxXEmTfKsv-_ndvVHE9sYzJW2mTg43mVdaq4GmDEY_qvcEbE2Z_-NSwzxJ0D8IIeLAjuQ0j27Ucku5f6gvyxyK0/s4032/20240110_132018.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi96gkWdWZljcjwrEnH7PoETnaFCMNf69Y0JznP3bgK59iYQqRjA1JHGh-QGXRq7PYVKCxIE87CgN3s3LvdyKbGfQGIlHwgnefYNr7yJxXEmTfKsv-_ndvVHE9sYzJW2mTg43mVdaq4GmDEY_qvcEbE2Z_-NSwzxJ0D8IIeLAjuQ0j27Ucku5f6gvyxyK0/s320/20240110_132018.jpg" width="320" /></a></div><p></p><p>You can use those fences to cut a perpendicular groove with a 3/4" straight flute router bit (parallel to your sides) for the hold down clamps. Rockler has this going parallel to the saw cut, I have two of them perpendicular so I have a little more range.</p><p>Then you can install the final bits of t-track onto the sled base.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLf4kUO_ti5-HdY55jVQKX4jXeHFg2OEmke6-p-Z9ycMgtOQxJzZOWqE49XhTBHN-N5xR5wsnMG9vtIO0dIk504Im6Eq0ZSLtapYxA8uaxlgOyufF2V2_zAB5Dy7HIBm1XsJGOshHYVjVI4HeEdYwleiLT9A9X-RxsxmFUIZPUHHDYcNIsmb_5yrAwL6c/s4032/20240111_154144.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLf4kUO_ti5-HdY55jVQKX4jXeHFg2OEmke6-p-Z9ycMgtOQxJzZOWqE49XhTBHN-N5xR5wsnMG9vtIO0dIk504Im6Eq0ZSLtapYxA8uaxlgOyufF2V2_zAB5Dy7HIBm1XsJGOshHYVjVI4HeEdYwleiLT9A9X-RxsxmFUIZPUHHDYcNIsmb_5yrAwL6c/s320/20240111_154144.jpg" width="240" /></a></div><p></p><p>Now, with potential hardware installed, you have a very solid, manipulable jig to hold small parts on. The angle block can use the t-track hold down to give me a 90-degree surface for clamping, too, so I am very versatile with this little jig.<br /></p><br />Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-1727796172968324032023-12-04T16:43:00.000-08:002023-12-04T16:43:07.631-08:00KrakenSDR - Monitoring Multiple Channels - KrakenSDR Not Needed<p><i><b>Disclaimer</b> - I absolutely know the KrakenSDR is intended for coherent radio work such as directional analysis. I absolutely know I am abusing the intent, and that I could use other equipment (or time) to do this work. Queue ominous music here... I thought that nothing else I have would give me access to monitor 5 channels at once, so this becomes one of the best options out there.<br /></i></p><p>In our local neighborhood, we've had an emergency radio network. This isn't for amateur radio operators (HAM's), and is much more broad. We use hand held GMRS radios for emergency communications, and for monthly network checks.</p><p>Now, we've had this radio network working for a few decades or so, and the last few years have been fraught with interference from other operators who are pushing frequencies beyond what I thought they should.</p><p>We've had an assigned frequency to use (channel 21, or 462.7 MHz) that is just getting pummeled lately by interference. We'd squash one, and another "abuse" would crop up. It was at this time I found out that the FCC has changed the rules. Channels 15-22 are no longer restricted to 5 watt systems. They are now only restricted to 50 watt systems, meaning you are allowed to push these MUCH further than you could before. NOW the interference all makes sense.<br /></p><p>I also learned today that the city doesn't really care <i>what</i> frequency or channel we use - we need to make sure we can communicate, and we need to use a different GMRS channel that doesn't have the interference, and one that doesn't <i>cause</i> interference around us. Enter the Kraken(SDR), er, enter the Dragon(OS).</p><p>Normally, equipment like this is used for fox hunting and other coherent applications (directional analysis is a big player). I have a KrakenSDR, and it has been set up for fox hunting. I have a completely mobile rig I can throw into my vehicle, slap the antenna on top, and be off.</p><p>But, since we're pinned to GMRS channels, and looking for the lowest power output channels we can find in order to not have more likelihood of interference, we're settling on channels 8 through 14. So, why not load the KrakenSDR up and take it for a monitoring spin?</p><p>I normally just use the Raspberry Pi, but I rationalized using a different installation here (an old 32 core desktop computer hooked up to some monitors), so I grabbed a download for DragonOS and installed it. The desktop has sat idle for a few years (four to be exact) after being used as a virtual server lab for work, and I was getting ready to just turn it back in to the office, so I figured, why not?</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMbi3yqffulst-4Wp6lQvsZI5OFBkrOFod6K5iyhxT2oW-dDJMXimfWtkUVVTd4VMI9pr3Uz54strAeLomfEi-C2w5yo2VRmZ9U-F5W4nXwWeuVQX3LKM9SVcxELK_znRDRAkAk2F6HGXUiiTFtAXCPI01OMyfgDechDPqqzMfqY0ljZcV0L8aX0alznY/s4032/20231203_151850.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="840" data-original-width="4032" height="67" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMbi3yqffulst-4Wp6lQvsZI5OFBkrOFod6K5iyhxT2oW-dDJMXimfWtkUVVTd4VMI9pr3Uz54strAeLomfEi-C2w5yo2VRmZ9U-F5W4nXwWeuVQX3LKM9SVcxELK_znRDRAkAk2F6HGXUiiTFtAXCPI01OMyfgDechDPqqzMfqY0ljZcV0L8aX0alznY/s320/20231203_151850.jpg" width="320" /></a></div><p></p><p>First, making sure I could plug the KrakenSDR in and making sure it connected was the focus (running cables, etc). I wouldn't know for sure that I got it all set up right until we get the first runs at this, so at this point, I was still running blind.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyRxq8ZhnqQY8DfdGF5D62pMf8T_3GQTAQPWswDrrk63up4gFhNseddkPHMP48zgTfV7ruT3lnJPGpXV9iQryPvsFVsSCHWuoE-PfIXzpWWAC08Wd9GEbm37f7ghLUlJ7F5gqqAjM6_wsYGPSTy2zm5-PzJek9X3grlXozLGUsShhR4-V4Hd-3HQgfE54/s4032/20231203_150747.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyRxq8ZhnqQY8DfdGF5D62pMf8T_3GQTAQPWswDrrk63up4gFhNseddkPHMP48zgTfV7ruT3lnJPGpXV9iQryPvsFVsSCHWuoE-PfIXzpWWAC08Wd9GEbm37f7ghLUlJ7F5gqqAjM6_wsYGPSTy2zm5-PzJek9X3grlXozLGUsShhR4-V4Hd-3HQgfE54/s320/20231203_150747.jpg" width="320" /></a></div><p></p><p>My next order of business was to get the right application running that included the waterfall. On the Mac, I'd normally go with SmartSDR, but that was not installed on DragonOS. So, I punted and went with CubicSDR. it is essentially the same thing, and it is installed.</p><p>Considering I had five separate radios, I loaded up 5 instances of CubicSDR (one for each channel).</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2BG8jPRD2AIfDxUjPHYRL7ACQY_KDzngct49IW8pXgC76msK4y3ubXnEX-Hxy3jgZ7TnTZA5e9mmyr6YkkRggS7usMWibm0fZytEXNfXsdc_FlnMb1dBD8vu0a2z6r9NxS1sdXMbYvQidYa_ulCElaW2colR5dAWAGjqYB9cr03MSkVfcgUA23rLL2yE/s4032/20231203_164951.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2BG8jPRD2AIfDxUjPHYRL7ACQY_KDzngct49IW8pXgC76msK4y3ubXnEX-Hxy3jgZ7TnTZA5e9mmyr6YkkRggS7usMWibm0fZytEXNfXsdc_FlnMb1dBD8vu0a2z6r9NxS1sdXMbYvQidYa_ulCElaW2colR5dAWAGjqYB9cr03MSkVfcgUA23rLL2yE/s320/20231203_164951.jpg" width="320" /></a></div><p></p><p>It was at this time that I realized every time I broadcast on the radio, it threw some serious chatter out (these Motorola hand held FRS radios are terrible - there are harmonics all over I didn't know were there - they are leaps and bounds worse than the Baofeng UV-5R radios), and that I could see ALL of the channels I was interested in across the entire spectrum on one display. I closed the other CubicSDR windows and went with a single one.<br /></p><p>Suddenly, I remembered my old RTL-SDR days, and had a few "well, duh!" moments. Knowing I could adjust the spectrum and see all channels in one was one of these.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-Q0qHr-c-SJatzjoAPfvzgjcZjAhzE4sy7-dfeSlpjGy4dlRrP4dZiOuTZ8bfxqXxUefDUeFAbUsTb4WkzqQtQPo_hbyIFeVGJrK0c4nEF805bcQdNJVlIyi4zreDkTl5h6psWoAXf9muaOtJK0gkf9NWlcWvLpZhY4X_OUi8dbamMR-4K-mHLJJkWqI/s1680/frenquency_watch-1701656341-show_everything.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1050" data-original-width="1680" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-Q0qHr-c-SJatzjoAPfvzgjcZjAhzE4sy7-dfeSlpjGy4dlRrP4dZiOuTZ8bfxqXxUefDUeFAbUsTb4WkzqQtQPo_hbyIFeVGJrK0c4nEF805bcQdNJVlIyi4zreDkTl5h6psWoAXf9muaOtJK0gkf9NWlcWvLpZhY4X_OUi8dbamMR-4K-mHLJJkWqI/s320/frenquency_watch-1701656341-show_everything.jpg" width="320" /></a></div><p></p><p>I defined all channels (8 through 14) in my bookmarks on the left side (they are called "modem", or a modulator/demodulator).</p><p></p><center><table border="1px" cellpadding="3px" cellspacing="0"><tbody><tr><th>Channel</th><th>Frequency</th><th>Use</th><th>Bandwidth</th><th>Max Watts</th></tr>
<tr><td>1</td><td>462.5625 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>5 W</td></tr>
<tr><td>2</td><td>462.5875 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>5 W</td></tr>
<tr><td>3</td><td>462.6125 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>5 W</td></tr>
<tr><td>4</td><td>462.6375 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>5 W</td></tr>
<tr><td>5</td><td>462.6625 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>5 W</td></tr>
<tr><td>6</td><td>462.6875 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>5 W</td></tr>
<tr><td>7</td><td>462.7125 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>5 W</td></tr>
<tr><td>8</td><td>467.5625 MHz</td><td>FRS</td><td>12.5 kHz</td><td>0.5 W</td></tr>
<tr><td>9</td><td>467.5875 MHz</td><td>FRS</td><td>12.5 kHz</td><td>0.5 W</td></tr>
<tr><td>10</td><td>467.6125 MHz</td><td>FRS</td><td>12.5 kHz</td><td>0.5 W</td></tr>
<tr><td>11</td><td>467.6375 MHz</td><td>FRS</td><td>12.5 kHz</td><td>0.5 W</td></tr>
<tr><td>12</td><td>467.6625 MHz</td><td>FRS</td><td>12.5 kHz</td><td>0.5 W</td></tr>
<tr><td>13</td><td>467.6875 MHz</td><td>FRS</td><td>12.5 kHz</td><td>0.5 W</td></tr>
<tr><td>14</td><td>467.7125 MHz</td><td>FRS</td><td>12.5 kHz</td><td>0.5 W</td></tr>
<tr><td>15</td><td>462.550 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>50 W</td></tr>
<tr><td>16</td><td>462.575 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>50 W</td></tr>
<tr><td>17</td><td>462.600 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>50 W</td></tr>
<tr><td>18</td><td>462.625 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>50 W</td></tr>
<tr><td>19</td><td>462.650 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>50 W</td></tr>
<tr><td>20</td><td>462.675 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>50 W</td></tr>
<tr><td>21</td><td>462.700 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>50 W</td></tr>
<tr><td>22</td><td>462.725 MHz</td><td>GMRS/FRS</td><td>20 kHz</td><td>50 W</td></tr>
</tbody></table></center><p></p><p>Then, I activated all 7 channels, and zoomed in on the spectrum I wanted to monitor (you can do that using the mouse scroll wheel on the frequency chart above the main waterfall).</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6QO9qgKdpMO_1JU47sBu6tsCtNI5_0QQjRM1vvoRgbbKAduFc6BMS5K0HYt13SglqSrxEaYpld3uieGIaAD_kkoCFnQgco0o722goS1etekbqt199e6fAomSqITBQixdKUgLNSin2BNA2fRI2dpPgMbGaWUgLRHmY9UhX7q1UpYiL9iq09tnrZrE-Qjs/s4032/20231203_170343.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6QO9qgKdpMO_1JU47sBu6tsCtNI5_0QQjRM1vvoRgbbKAduFc6BMS5K0HYt13SglqSrxEaYpld3uieGIaAD_kkoCFnQgco0o722goS1etekbqt199e6fAomSqITBQixdKUgLNSin2BNA2fRI2dpPgMbGaWUgLRHmY9UhX7q1UpYiL9iq09tnrZrE-Qjs/s320/20231203_170343.jpg" width="320" /></a></div><br />I noticed one of them appeared irregularly placed (attention to detail will do that to a guy), and indeed, I was 50 kHz off on the frequency center. Not really a problem - I just need to see the windows of what broadcast.. Still, I fixed it, because my attention to detail would have irritated me. Yes, there are two broadcasts on the screen shot above - one is on channel 8 (467.5625 MHz) and the other is on channel 14 (467.7125 MHz). I did that so I could have my book ends and see the entire range for all channels.<br /><p></p><p>I adjusted the waterfall rate so that it was about 10 minutes of historical data.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0Vgy_xeMUK4aQgnILHnAZTZAi7UIMbgdFv2bn-F_BYXuGmFy1e38VUNhSJ4QlT5658y2KCAe15VA24a6aZb7b5xGpsUTzhlbNCpWS6vrJ1WoJhyphenhyphenalCTvMh6eHIMPer9i0TZF4ShaBgPObsMRShqvyJmzI95MNTRZD7sslXN0JSAxoRXEepVuBN1T7qhE/s4032/20231203_170708.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0Vgy_xeMUK4aQgnILHnAZTZAi7UIMbgdFv2bn-F_BYXuGmFy1e38VUNhSJ4QlT5658y2KCAe15VA24a6aZb7b5xGpsUTzhlbNCpWS6vrJ1WoJhyphenhyphenalCTvMh6eHIMPer9i0TZF4ShaBgPObsMRShqvyJmzI95MNTRZD7sslXN0JSAxoRXEepVuBN1T7qhE/s320/20231203_170708.jpg" width="320" /></a></div><p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiDOPtBM59CtZTiVKUR2vb1h680UB11YmU3s8tsjtJ4Ya2nGHrYyNs_-ZFDsH3TMPCb0bfXNNX6PEYMR95Dyjb8nejgYe2bgtZwDONBSxPjjXWwozuuefYLi56kidDi_6z8Td9mCUaNMMQWTEF5xbEJ98i_K3w4iVIaWy4U2lTq9M0bkxT2O1rlSe0WMw/s4032/20231203_195941.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiDOPtBM59CtZTiVKUR2vb1h680UB11YmU3s8tsjtJ4Ya2nGHrYyNs_-ZFDsH3TMPCb0bfXNNX6PEYMR95Dyjb8nejgYe2bgtZwDONBSxPjjXWwozuuefYLi56kidDi_6z8Td9mCUaNMMQWTEF5xbEJ98i_K3w4iVIaWy4U2lTq9M0bkxT2O1rlSe0WMw/s320/20231203_195941.jpg" width="320" /></a></div><p></p><p>Then, in a fit of absolute laziness, I changed it to about a minute and a half, and then scheduled a cron. DragonOS includes ImageMagick, and that means it has command-line-based screen capture tools. So, I created a quick shell script :</p><ul><pre><code>#!/bin/bash
DATE=`/usr/bin/date +%s`
/usr/bin/import -display :0.0 -window root /home/bubba/frenquency_watch-$DATE.jpg > /home/bubba/screen.log 2>&1
</code></pre></ul><p>And then I created my cron entry :</p><ul><pre><code>* * * * * /home/bubba/run.sh > /dev/null 2>&1</code></pre></ul><p>This forced a screen shot every minute while I was running my scan. I could simply scroll through the images and see anything that jumped out at me. Hooray for laziness! I could walk away, not store hours of audio that I'd have to scan through, and I wouldn't have to sit by a computer for hours on end, my eyes pinned to a screen watching for blips on the proverbial radar.<br /></p><p>With the active modem's (or channels) shown on screen, I had a great indicator at each minute of when something was broadcasting, which included the entire previous minute.<br /></p><p>Mid way through the scanning session window I wanted to proof out, I ran a few tests just to see. Not being able to remember which channel I ran the test on, I could look at the screen and see :</p><p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwlGbqWaPgCfXS_eMRQrm_aExW94aUOPEPvGUUPwvBo7XkO9_64de8A1ganQjQn_n_jnA4VYZ3_qdFoxrL1n87jqjrTDfUy15SEqXZ2bF5UTgnMVslXR7rTqI6Zqzno6SzBbXA7zPaaUprMFNwEZvHg2Z0ZJXU6sKJWdnorjjgIaYyHO9b-5GVeRZTs5w/s1680/frenquency_watch-1701658441.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1050" data-original-width="1680" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwlGbqWaPgCfXS_eMRQrm_aExW94aUOPEPvGUUPwvBo7XkO9_64de8A1ganQjQn_n_jnA4VYZ3_qdFoxrL1n87jqjrTDfUy15SEqXZ2bF5UTgnMVslXR7rTqI6Zqzno6SzBbXA7zPaaUprMFNwEZvHg2Z0ZJXU6sKJWdnorjjgIaYyHO9b-5GVeRZTs5w/s320/frenquency_watch-1701658441.jpg" width="320" /></a></div><p></p><p>That showed me I was on channel 14. Sweet! It works! <br /></p><p>After finishing the scan for the entire evening to see if other neighborhoods are also using the frequency, I could scan through any images showing an anomaly like the above, and....</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZNCNekhC7aTK9R2mDkIOK9sLpz2J1IjEVcPSEvg0c2XtSm-bhF13MbbIfhi9TidwMO9Ef9yCfqVmoC8yuTqief3QrbbHZTGeY50MRQJ80Ikz3wNIZ8hhTRt_gEU8m-n7G9QPvIo1o_TYmtQ60-mZJKsMIaNDk41njPTs3yg289qUo3vPKHFWRVU5OvZI/s1680/frenquency_watch-1701657181.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1050" data-original-width="1680" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZNCNekhC7aTK9R2mDkIOK9sLpz2J1IjEVcPSEvg0c2XtSm-bhF13MbbIfhi9TidwMO9Ef9yCfqVmoC8yuTqief3QrbbHZTGeY50MRQJ80Ikz3wNIZ8hhTRt_gEU8m-n7G9QPvIo1o_TYmtQ60-mZJKsMIaNDk41njPTs3yg289qUo3vPKHFWRVU5OvZI/s320/frenquency_watch-1701657181.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz4pbPbAfj5Z01hxeW3GGQKtIaerRMjBrTZRidBiQbVwnB0mUGekFq7AAKkRlOVUWZVrYH2WSeaENmhZ_L4juUIR-xBsu4vRUx0ep_1btNWqIwHjhpRm7JIRnsZY-OLsZ1QuiqWv8y6kC-dYBpbtoSJdH1WFn5Jtybf-vIQt-MXK7Qp88GwjvEZdibHow/s1680/frenquency_watch-1701664561.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1050" data-original-width="1680" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz4pbPbAfj5Z01hxeW3GGQKtIaerRMjBrTZRidBiQbVwnB0mUGekFq7AAKkRlOVUWZVrYH2WSeaENmhZ_L4juUIR-xBsu4vRUx0ep_1btNWqIwHjhpRm7JIRnsZY-OLsZ1QuiqWv8y6kC-dYBpbtoSJdH1WFn5Jtybf-vIQt-MXK7Qp88GwjvEZdibHow/s320/frenquency_watch-1701664561.jpg" width="320" /></a></div><p></p><p>It looks like there was an out-of-band (higher than channel 14) at 7:00 PM (my time was 33 minutes off - I didn't care), and something was playing on channel 10 for a brief blip around 9:03 PM.</p><p>With the harmonics (probably won't do much) showing interference on channels 10 and 12 (it is, frankly, not enough to worry about - but I'm so wanting to clear these channels for the neighborhood that I'm eliminating 12, too), in addition to that brief blip just outside of 14, it looks like we can use 8, 11, and 13. channel 9 was just a little too close to the harmonics for comfort.<br /></p><p>Now we can lay claim to any of these clear FRS channels for the emergency preparedness work we do as a neighborhood.</p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-50808445497995044072023-11-17T13:29:00.000-08:002023-12-20T15:47:59.511-08:00Puffed Out Chest - Part B<p>I started a machinists tool chest build. Part A was over at <a href="http://www.silverhawk.net/2022/12/puffed-out-chest-part-a.html" target="_blank">http://www.silverhawk.net/2022/12/puffed-out-chest-part-a.html</a> . Anyway, moving on to the next task of filling the box joint imperfection with epoxy to strengthen and make it a more interesting build.</p><p>Before I get there, I need to have the internal vertical boards completed. Transferring the outside slots to the inside slots was something I put off as long as possible because I didn't know how. I had an epiphany one night about how. I grabbed some paper from the printer, scissors, and a crayon. I trimmed a piece of paper to fit perfectly in the space that the boards would fit, labelled the paper with where edges were, and then used the crayon to mark the grooves on the paper.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkxv4NsATAs2tXFpAZwRJorWJyFN7d73PFGNaII4Bv4w5XF1zBpgNNs81fCH1xt9-477WFE6xu9gVsSjbMHI59mVD_lKL6mKo_E0_pt05Ha5FrwtVTxidh1NIwMdUHFkUYE3L5YbJ6yqDpq_t-cNuXF4tbkFxqz7hEfNZ05T0Bf100OW4dOkVOMNVa/s4032/20230408_120903.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkxv4NsATAs2tXFpAZwRJorWJyFN7d73PFGNaII4Bv4w5XF1zBpgNNs81fCH1xt9-477WFE6xu9gVsSjbMHI59mVD_lKL6mKo_E0_pt05Ha5FrwtVTxidh1NIwMdUHFkUYE3L5YbJ6yqDpq_t-cNuXF4tbkFxqz7hEfNZ05T0Bf100OW4dOkVOMNVa/s320/20230408_120903.jpg" width="240" /></a></div><p></p><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjywfs2Y5iJsXXq-dw0eosazTNStcvEbyzNYUb1AHytV6YqBvN_1Oi4wIUzbJoZ3YD4U2x3Y-wGn_-jhdbj_7W1uc-JaqxfJlw4KZ0ZiQCwUZ57IG22DkfFdyXlv-xbalR22ROxL_U7K81R6beAbS_Z35zgaroz9Pr-P3va9lHke0Qvli-Ny8pUGFC5/s4032/20230408_142007.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjywfs2Y5iJsXXq-dw0eosazTNStcvEbyzNYUb1AHytV6YqBvN_1Oi4wIUzbJoZ3YD4U2x3Y-wGn_-jhdbj_7W1uc-JaqxfJlw4KZ0ZiQCwUZ57IG22DkfFdyXlv-xbalR22ROxL_U7K81R6beAbS_Z35zgaroz9Pr-P3va9lHke0Qvli-Ny8pUGFC5/s320/20230408_142007.jpg" width="240" /></a></div><p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgR4_t53pRqgkRwFUx2JJ0feFTgtyPKKMpm541EbbMfcGDAhkMa4amNehHZIpTcS19oUaa6H9nEX0dHQLQ_kpTTa24eDNAN3J2itg3rUHcismnTWipXqtMvx8QLVqYhxJWYzZmRmzjK8AkZR070f6UyPrOedyqidpJXsgzy0SYo85EFQD0HQONTiqPi/s4032/20230408_115427.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgR4_t53pRqgkRwFUx2JJ0feFTgtyPKKMpm541EbbMfcGDAhkMa4amNehHZIpTcS19oUaa6H9nEX0dHQLQ_kpTTa24eDNAN3J2itg3rUHcismnTWipXqtMvx8QLVqYhxJWYzZmRmzjK8AkZR070f6UyPrOedyqidpJXsgzy0SYo85EFQD0HQONTiqPi/s320/20230408_115427.jpg" width="320" /></a></div> <p></p><p>At first, I tried fancy ways of using the paper on the board (cutting out grooves, etc), because the markings on top need to go face down on the other board, or we'd end up with a mirrored board. I tried folding and cutting the slots with the scissors.</p><p></p><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5fzSsLam3Y6d-p-jX-CXq2hpjsYqxlu7fyH9TWlSpKAHOPXGJiy3jtWe1-hYASe41wXBjxeMHCFF37zdi3oZHhinmWQDYudWTevzaK_UpCaLrUhxL6joXdxfFvlrlTk8W2TbJNz0by-MyhtMHjpFx-5xfY-uw5eyOhEsQ7Zi7Z1Yqh_7GkFp4zhfa/s4032/20230408_115436.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5fzSsLam3Y6d-p-jX-CXq2hpjsYqxlu7fyH9TWlSpKAHOPXGJiy3jtWe1-hYASe41wXBjxeMHCFF37zdi3oZHhinmWQDYudWTevzaK_UpCaLrUhxL6joXdxfFvlrlTk8W2TbJNz0by-MyhtMHjpFx-5xfY-uw5eyOhEsQ7Zi7Z1Yqh_7GkFp4zhfa/s320/20230408_115436.jpg" width="320" /></a></div> <div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg01eF3i_B6CdbSqTyDhDqvKoG43PqHopUCgo75q45PxpCLWDAIZuh1kEn1r3VKjR08FCqB3hnGbSY8OwJY8W5tcppbXbikEbzXWgjh3n8J69cWyoYMBlFh3YGLu3f9jWYq3jv8j8nhoOdw2qPFekMKzDSo-QDkIbNBAOGuSMtNT8Vjtop0DGhryr52/s4032/20230408_115431.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg01eF3i_B6CdbSqTyDhDqvKoG43PqHopUCgo75q45PxpCLWDAIZuh1kEn1r3VKjR08FCqB3hnGbSY8OwJY8W5tcppbXbikEbzXWgjh3n8J69cWyoYMBlFh3YGLu3f9jWYq3jv8j8nhoOdw2qPFekMKzDSo-QDkIbNBAOGuSMtNT8Vjtop0DGhryr52/s320/20230408_115431.jpg" width="320" /></a></div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWo_RMCW5sV6FynmjwZZB3A2bSqEYJPP30QvsN6cOU1YJhsdcvhNkdev4TLbIvwnkNXczL8kJFf7D6HAm1H6BsFO8XiI0EsG7xsg8FWPDa1RFZXKn7blJXSHxVtlaPifu6LM2uuLEBCqR11TKEk5AAd6N7LRbutuMSvpy6iQZZwDkzgY-421gzydGZ/s4032/20230408_115431.jpg" style="margin-left: 1em; margin-right: 1em;"></a><p></p><p>But ultimately, I found it easier to simply fold along the markings, then use a pencil to mark the board, and a straight edge to complete the lines.</p><p></p><p>The next phase was to drill the panel latching hardware. Starting with the front panel pins, I needed a vertical (parallel) hole. Worried about how to do this, I settled on using a square to hold it perpendicular to the drill press table.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMcNHjXXR0lkfpd5vW5eVUu5hnWp28y9z-NZM6T33x2S0OE4UNoxB_Ng7e1KQK2BexgJ_njAbrXbPE_6x1r-E56ZnQqo1ozqbmEapK9_ttxgn3y-EY3XvNwJJmTwQeNeohqCHftOVWYStRi9VXux16mZqqkLuf2iZfh-qYWytg-XQUQ0KtwbOEI2l1/s4032/20230408_144830.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMcNHjXXR0lkfpd5vW5eVUu5hnWp28y9z-NZM6T33x2S0OE4UNoxB_Ng7e1KQK2BexgJ_njAbrXbPE_6x1r-E56ZnQqo1ozqbmEapK9_ttxgn3y-EY3XvNwJJmTwQeNeohqCHftOVWYStRi9VXux16mZqqkLuf2iZfh-qYWytg-XQUQ0KtwbOEI2l1/s320/20230408_144830.jpg" width="240" /></a></div><p></p><p>While I could install the two internal panels, I thought it would be the perfect time to fill the cracks in the box joints and seal the boxes up. I dutifully taped everything up, and kept worrying about filling those gaps cut in for the drawer slides. It took me a night thinking things through before I realized I could lay the box on it's back, open the side seals in order to pour epoxy into those gaps, and let them fill the cracks. It would allow me to fill up to the back of the boxes and not fill in any of the drawer slide groves. <br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixGLxdnCMfXRQ6cOlDh96Ywb0FM1hWEtY5cWC_IwLXVrCjWkUG_hSzeHht8EsdokddoXVFXgIo0swOvW_YKbJ_rPnXsMP6QWErLt0S8bHlP6ZXKk3OJdymDxYl9OAdqFWYYeu83TBt-11poVGLMJZ9TUz-jbjknUUFoUmEVt-h4GtgXLga_ZIkAJXH/s4032/20230602_192748.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixGLxdnCMfXRQ6cOlDh96Ywb0FM1hWEtY5cWC_IwLXVrCjWkUG_hSzeHht8EsdokddoXVFXgIo0swOvW_YKbJ_rPnXsMP6QWErLt0S8bHlP6ZXKk3OJdymDxYl9OAdqFWYYeu83TBt-11poVGLMJZ9TUz-jbjknUUFoUmEVt-h4GtgXLga_ZIkAJXH/s320/20230602_192748.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmB3li2XWUgCviEOLZwCj2QLHwiBSVMvQpWSCSksx2b-qssooknHwBOg7pqCmxH-lRcuEGR5K_4ZRDOu0CVm4WcAltpJE6PvW25dv7w7d_veFdL040WldrjdSMPf8gJWQOJIoO1FgAEjBMpnmCT91P54cHsYtU7m-BGeN4ExWQVyJRPeoAi4cskCvi/s4032/20230602_192755.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmB3li2XWUgCviEOLZwCj2QLHwiBSVMvQpWSCSksx2b-qssooknHwBOg7pqCmxH-lRcuEGR5K_4ZRDOu0CVm4WcAltpJE6PvW25dv7w7d_veFdL040WldrjdSMPf8gJWQOJIoO1FgAEjBMpnmCT91P54cHsYtU7m-BGeN4ExWQVyJRPeoAi4cskCvi/s320/20230602_192755.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNteFzzd3bTP9_f3s44vZpxTLc6AuEXuA37atmuv0hIIunl3q6hH3rDPw3uu0pjeNCxMvDVQ5CwdOmC-M0snMyorHugAbc80U38Ac7FjKPMGOGO9b62boQrYZ0tJWviwlGQLeh6g7yeuRJSQDcVAOCG92zKsRYLPB66LtSVY3lVm3Xb8ciDJ-4uMCE/s4032/20230603_081737.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNteFzzd3bTP9_f3s44vZpxTLc6AuEXuA37atmuv0hIIunl3q6hH3rDPw3uu0pjeNCxMvDVQ5CwdOmC-M0snMyorHugAbc80U38Ac7FjKPMGOGO9b62boQrYZ0tJWviwlGQLeh6g7yeuRJSQDcVAOCG92zKsRYLPB66LtSVY3lVm3Xb8ciDJ-4uMCE/s320/20230603_081737.jpg" width="240" /></a></div><br />I needed to take my time on this. Filling from the sides and letting it nearly set up would allow me to pour another little bit and get things to seal up faster as things cured. (This was the perfect time to fill the laser-engraving on the front door to match - I did a little mica powder, and a lot of clear, so it could have an interesting effect.)<p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaV7fUnXkkbfkEEKoPXRN8FScestQkm_W6-3cDRQTFxB7927P4z-wdPG97MwqaXkerjfREP7uEWcjpvADrA3-cg0ysLjVld1vcOmsMpUokvM3AxewEuZkalLqUT24nO-LRsPxBp5FvUwBE2ejMn8Lk04uMtCZfmO1mVRVClnO8EhAh7jIfT-l3KCbm/s4032/20230602_192758.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaV7fUnXkkbfkEEKoPXRN8FScestQkm_W6-3cDRQTFxB7927P4z-wdPG97MwqaXkerjfREP7uEWcjpvADrA3-cg0ysLjVld1vcOmsMpUokvM3AxewEuZkalLqUT24nO-LRsPxBp5FvUwBE2ejMn8Lk04uMtCZfmO1mVRVClnO8EhAh7jIfT-l3KCbm/s320/20230602_192758.jpg" width="320" /></a></div><p></p><p>There was a <b><i>lot</i></b> of interrupted epoxy pours. I was using a "deep pour" epoxy made to work with thicker things such as lathe blanks, river tables, and similar things where you need a lot of thickness. This wasn't because of thickness, but simply because this is both "thin" (e.g. it is very viscous and liquid and can fill cracks easily) as well as long curing. That alone should allow me to fill all the voids, but it does take a great deal of time to build a suitable base and sealed edges. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGuRUFVdNsRdUlhrTBuG2mOru17XOE9Pid3inLPSRa4_8EDei2TkazwPeaeezvbfjOZwkAw0h0m4rhayY-Aj-yrAeiQTo7DeljbOCuKDF7eEeOlzABSZl1VrqMwVebKfgZZvWag3O-mv1xGfchbPOIuGkhK1jgbzMqNMtVBTVr8VEv14QonHkfHq9D/s4032/20230609_160141.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGuRUFVdNsRdUlhrTBuG2mOru17XOE9Pid3inLPSRa4_8EDei2TkazwPeaeezvbfjOZwkAw0h0m4rhayY-Aj-yrAeiQTo7DeljbOCuKDF7eEeOlzABSZl1VrqMwVebKfgZZvWag3O-mv1xGfchbPOIuGkhK1jgbzMqNMtVBTVr8VEv14QonHkfHq9D/s320/20230609_160141.jpg" width="320" /></a></div><p></p><p>Two boxes have have the majority of the voids and cracks filled at this point, so I let them sit for a day or two. Once I was absolutely sure the epoxy had cured, it was time to sand it back down to flush with the wood surfaces again.</p><p>The logos in the front doors came out fantastic, though the silver is a little dark. I'm not sure what will be needed there. The gold turned out to be two separate hues of gold - one a little more orange gold (or "antique"), the other being a bright "queens" gold.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCGVjfqdGWLcwZyWWNp9xiJbYrT3u0X0EOls7Xgly_pC_OLRILH_k1j0I_u8kFejzUXTbwZOVg3avfXh-O5jwngeOdafgaMnIs0I3CLYHetB6Z5fSo1UDvv2DrSsfuELeWhMa7uIrHuXcy3UnrXcADi1E3ZNykAUAn5YgD58LIMP-PG0oD0dXtEPHBmZg/s4032/20230719_135655.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCGVjfqdGWLcwZyWWNp9xiJbYrT3u0X0EOls7Xgly_pC_OLRILH_k1j0I_u8kFejzUXTbwZOVg3avfXh-O5jwngeOdafgaMnIs0I3CLYHetB6Z5fSo1UDvv2DrSsfuELeWhMa7uIrHuXcy3UnrXcADi1E3ZNykAUAn5YgD58LIMP-PG0oD0dXtEPHBmZg/s320/20230719_135655.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWiSWWuovFYRxwBlMXrUgFXzUUYAvX2UITiidZqxY0F6xiYP9EMlBrNOHtXbxqBwVhdJkati8TgTFZz7wo4JEeD73b_vONnkYOJkGi5G1TeFpTI-rBfwhY-y49nBtdv_6vf03ux-a-DpDxu283h7ZXUCim25colSY6x2Ms9_PjcfwHMog1ctJLY7ifFEM/s4032/20230719_135704.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWiSWWuovFYRxwBlMXrUgFXzUUYAvX2UITiidZqxY0F6xiYP9EMlBrNOHtXbxqBwVhdJkati8TgTFZz7wo4JEeD73b_vONnkYOJkGi5G1TeFpTI-rBfwhY-y49nBtdv_6vf03ux-a-DpDxu283h7ZXUCim25colSY6x2Ms9_PjcfwHMog1ctJLY7ifFEM/s320/20230719_135704.jpg" width="240" /></a></div><p></p><p>There were some areas where I had quite the overfill, because I'd rather make sure we got it everywhere. I used the tablesaw to trim that off, a grinder to remove large volumes quickly, and then the sander to get it back to where it should be.</p><p>The inside was the most painful - I needed a small sander with a corner. I used a Black and Decker "mouse", and that seemed to let me get into the cracks. These little sanders come to a point on the tip, allowing you to get into the corners.</p><p>Once that was complete, I had to cut 66 small "boards" that were 0.232" thick (to fit into the grooves), 0.263" tall (to protrude as drawer slides), and 6" long (one chest, my "scrap" one, had only 4.875" of space for them, since it was adjusted later because I scrapped a board). There are three tool chests, each with 11 drawers (that makes 33), and since these require one on each side, 33 gets doubled. That was fun. All of those were then glued into place.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFuludZ2omYiIIOwf1wONr79G2Y_syVWB3bfHsCbyvTfwbyogO1uBjY4S1INl036uLKD4_V67_w1tTID39ggTzNx77iEtjs6OFQUxYr0RMHn46lhS9c0CqEQFJr7ipdETMXAwlO6Mk3sooft9qZhu3hMU112khmi3ZRjUPVjgY4oEc1tDXvqngyMguf4w/s4032/20231014_180844.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFuludZ2omYiIIOwf1wONr79G2Y_syVWB3bfHsCbyvTfwbyogO1uBjY4S1INl036uLKD4_V67_w1tTID39ggTzNx77iEtjs6OFQUxYr0RMHn46lhS9c0CqEQFJr7ipdETMXAwlO6Mk3sooft9qZhu3hMU112khmi3ZRjUPVjgY4oEc1tDXvqngyMguf4w/s320/20231014_180844.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbHJhq_gLUDYzx-Q4XPkiorq24rLsWWe7eRxd-B2IRCHIQbpsfaYBX4me-WuT7rZFVKYtOFC8MLvvZWGhvivZFm_nyDXHpMU9ag-rgAW47fcd-XDDFOiYKhyKRw1zbEJCroyHeYnZzjFFIY1FffjyuQ4QsJ5kh7h9rY3yveF1mLgLmLVB7BpPhF4E3e1Y/s4032/20231015_130826.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbHJhq_gLUDYzx-Q4XPkiorq24rLsWWe7eRxd-B2IRCHIQbpsfaYBX4me-WuT7rZFVKYtOFC8MLvvZWGhvivZFm_nyDXHpMU9ag-rgAW47fcd-XDDFOiYKhyKRw1zbEJCroyHeYnZzjFFIY1FffjyuQ4QsJ5kh7h9rY3yveF1mLgLmLVB7BpPhF4E3e1Y/s320/20231015_130826.jpg" width="320" /></a></div><p></p><p>Once dried, the inner vertical boards will need to be sanded and have my crooked lines filled with epoxy to match the carcasses, then I can perform the final fitment and glue those in.</p><p>Before I do that, though, I have to drill the holes to house the front panel locking pins. As I write this, there are a multitude of ways to accomplish a long, parallel hole. Keep in mind that I didn't think of a better way until I was through two of the three chests, so here we go.<br /></p><p>First, I have a drill press table that was trammed in to within 0.002" over 16", so I knew I had accuracy for that one. I took this to the drill press to bore the face lengthwise the pins. Here's hoping I'm right and that this works.</p><p>This was one operation that took time. First, if I had any angle instead of parallelism on that front facing bin panel, I'd likely pop out the back. Second, the drill bit was a longer one (12" long) on a 1/4" bore to fit the springs and pins. This had to be as perfect as I can, and ended up being the longest set up operation I've ever done. It took me an hour for each hole (two for each tool chest). But, I can rest assured that I am as good as I can be.</p><p>One additional gotcha was my drill press only has 3" of range, and these panels are anywhere from 3" to 4" (not all tool chests are exactly the same size). So, I had to drill this in stages. Painful, really, but I made it.</p><p>If you are using the Gerstner pin hardware, the entire bore has to be 1/4" in diameter to house the spring, and the ends are 0.3125" (5/16") for the caps, at least 0.260" deep. So, drill out with the long 1/4" bit was the first step.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTIw9gsBegLcPSsuUtTJQlLzzeOxUKmYKvQ8-dJ1Or6VWvoCUciqr7GPsZ9lkywH9MwxpIqh9i3WsOICvcZuIsmfqaI-wjO8g8ZDbdjjkO29y6LezyX6C6I7T1uCZTmqUvL4U64wO8gkKNbYOf1RmlkgItqUOIVPqnpR483qBlM1egqxjlIAtrmSsKjd0/s4032/20231028_125857.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTIw9gsBegLcPSsuUtTJQlLzzeOxUKmYKvQ8-dJ1Or6VWvoCUciqr7GPsZ9lkywH9MwxpIqh9i3WsOICvcZuIsmfqaI-wjO8g8ZDbdjjkO29y6LezyX6C6I7T1uCZTmqUvL4U64wO8gkKNbYOf1RmlkgItqUOIVPqnpR483qBlM1egqxjlIAtrmSsKjd0/s320/20231028_125857.jpg" width="320" /></a></div><p>Drilling had to be in stages, of course.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTcsvYlZpQXRO5n_Cc8q5tK7V4J6vE1B9wrHYouAUV_ynZq3WDgmRowWeJf0BB4VrQE3x-zeuM_amBKJeAMnidyAOvBFActFMY6KdCv7IUb8rF08Uv5sZDgWOk8VMukF8OfLeURd3p9G7ArqPzvUjm2MkJEQZAsx8TaQHOhXJuzFWIIioG2e0Oc6ePcPQ/s4032/20231028_132422.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTcsvYlZpQXRO5n_Cc8q5tK7V4J6vE1B9wrHYouAUV_ynZq3WDgmRowWeJf0BB4VrQE3x-zeuM_amBKJeAMnidyAOvBFActFMY6KdCv7IUb8rF08Uv5sZDgWOk8VMukF8OfLeURd3p9G7ArqPzvUjm2MkJEQZAsx8TaQHOhXJuzFWIIioG2e0Oc6ePcPQ/s320/20231028_132422.jpg" width="240" /></a></div><p></p><p>Then, I could finish the drill with a nice, grabby 5/16", 135 degree jobber drill to do a better job of self centering than the brad point bits along that 1/4" bore. I thought about a drill bit grinder for a 1/4" counter sync, and just decided to wing it. We'll see in the future if I scrapped all of these in one fell swoop.<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdsBTJ1CgJBrq57XigWZX-Qr1M5uWI1EWQ-XObFFaOMhUQVrcPTwz1CYmk-k7bh9R_dktOWmv3u7acW4B8gnWEkH5vmxg81X6-_AWo1igKwtZ2LPHHdi-xCzoZ91UuiC3AqkPIFGCNMsdmMxGyPiebafY47B_uWKEl3463SDAxvyHM42DchMLgAEJALvw/s4032/20231028_133810.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdsBTJ1CgJBrq57XigWZX-Qr1M5uWI1EWQ-XObFFaOMhUQVrcPTwz1CYmk-k7bh9R_dktOWmv3u7acW4B8gnWEkH5vmxg81X6-_AWo1igKwtZ2LPHHdi-xCzoZ91UuiC3AqkPIFGCNMsdmMxGyPiebafY47B_uWKEl3463SDAxvyHM42DchMLgAEJALvw/s320/20231028_133810.jpg" width="240" /></a></div><p></p><p>After two of the three chests drilled, I was posting over on the machinists forum, and someone pointed out a Craftsman "PortAlign" - an old portable jig used to drill precise holes. Right there, the lightbulb went off in my head and screamed something about me being an idiot and spending hours on getting things aligned for the drill press, when all I had to do was use a stupid doweling jig! So, let's do it.<br /></p><p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3IiythBFIPbM3RaRtGPvMFyz3TI4VJBdw3PbxjEE1KJEbafH3g-ClW9ZmU026s4LY7j7-h7RNVDhPZoIAtMZS1p93FWCZ8ihol4xc98HubkvO1Sm6CeaSnu9SJUfs7NNILOETzFH-962zpbtsK4Dh53aM3-yLcHzhNkaOJ0BI4iGc0p1Z6VR8Y5rBFtg/s4032/20231214_165105.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3IiythBFIPbM3RaRtGPvMFyz3TI4VJBdw3PbxjEE1KJEbafH3g-ClW9ZmU026s4LY7j7-h7RNVDhPZoIAtMZS1p93FWCZ8ihol4xc98HubkvO1Sm6CeaSnu9SJUfs7NNILOETzFH-962zpbtsK4Dh53aM3-yLcHzhNkaOJ0BI4iGc0p1Z6VR8Y5rBFtg/s320/20231214_165105.jpg" width="240" /></a></div> <p></p><p>I used a jig that had easily replaceable pins for the hole sizes I needed (1/4" for the through pin bore, and 5/16" for the brass end bushings that keeps the spring and pin in place once installed. All told, this took me so long in comparison to the drill press method, I was crying (it was 15 minutes for getting the jig set up, drilling the first hole, swapping the bushing, and drilling the second hole to depth, then repeating for the other hole. A quick flip of the chest to finish the underside 5/16" bore to 0.265" on both of those, and it was done. 15 minutes... is WAY faster than a few hours per each hole working on alignments.</p><p>How on <b><i>earth</i></b> did I miss that as an option?<br /></p><p>The pin drilling is done. Phew! I had to use the short hand drill for the underside, and as long as I did it okay, I should be good. Before I can install the inside draw walls, I had to build a new tool. I went as far as drilling and tapping two ends, 1/4"-28 for a fine thread adjustment (one left-handed thread, the other right) to make a new machinist "jack" that was long enough to make the sides parallel.</p><p>I struggled with the right handed thread as the stainless bar became work-hardened in the middle of it. It still fit what I needed, and I could flip an end around to adjust to a different size. But it was at this point that I realized that 1/4"-20 (course, not fine) threaded rod and some long nuts would have been sufficient. So, a quick trip to the big box store (because they had it in stock and I was impatient), and I cut a threaded rod in two pieces and cleaned up the threads on the cut.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvQ_hUmWbzgcVQKt5OxXAubvirWqUq09Ybuxve4rU2fe5-Z3YIglM9f-xT9qBr9Usp_mQPC1zygKxp01Iqx5s73_2whv1xSYENL7G1pXDaGlcY4S9jg-bv3v6ceoGGP0Gm1O5eyc6J0nI-P330jkHtZcs9gAFhIlCg6q5K_GnjPeI6QAJZ0YJGCEI_Gm0/s4032/20231104_092741.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvQ_hUmWbzgcVQKt5OxXAubvirWqUq09Ybuxve4rU2fe5-Z3YIglM9f-xT9qBr9Usp_mQPC1zygKxp01Iqx5s73_2whv1xSYENL7G1pXDaGlcY4S9jg-bv3v6ceoGGP0Gm1O5eyc6J0nI-P330jkHtZcs9gAFhIlCg6q5K_GnjPeI6QAJZ0YJGCEI_Gm0/s320/20231104_092741.jpg" width="240" /></a></div><p></p><p>With those tools created, I could trim the boards for the inside, and use these crude, long machinist jacks to ensure parallelism of the walls. First, it was a matter of getting dimensions for the vertical. This included the entire vertical height, as well as the distance from the bottom (or the top) to the first drawer slide, just so I could make sure they were even. Making notes :</p><p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIIQDwyrVBPTGNhvDLt_GvACPIzMvUDUeZnFjxh5UGWUS6jMWkbUjzziviuNeBMmfth7bJhW04hICStma8yYCSAtPj082G7vVPhBuQuoX0vUgvN0joGSUrRZyFFjHaj1cHteMPVx-aqCf1yOcOjoDRYRcti_5a5ymXyXXpSgwwUZVRvdnI3EW4K9U2MFY/s4032/20231209_105116.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIIQDwyrVBPTGNhvDLt_GvACPIzMvUDUeZnFjxh5UGWUS6jMWkbUjzziviuNeBMmfth7bJhW04hICStma8yYCSAtPj082G7vVPhBuQuoX0vUgvN0joGSUrRZyFFjHaj1cHteMPVx-aqCf1yOcOjoDRYRcti_5a5ymXyXXpSgwwUZVRvdnI3EW4K9U2MFY/s320/20231209_105116.jpg" width="240" /></a></div><p></p><p>Then, trim them the last few thousandths of an inch to fit. Let's glue those in place.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgE_HLC3xzLgPhEby-L13vhc7_IkV88flLR4Y9p6wTM-PBIFeXNJmi0GFLUfNkJGG9rb_-fNpCSSjjPUiPhQBlpCijkCiOpWDWK_5aBLpB0liy3ThSs3-6le7A4O-62T50AB9vwoCdGvcvFWB7a7jJJlfbCLo3BJc315jukoBLM5felzl1qx38o2V6uc5U/s4032/20231104_132918.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgE_HLC3xzLgPhEby-L13vhc7_IkV88flLR4Y9p6wTM-PBIFeXNJmi0GFLUfNkJGG9rb_-fNpCSSjjPUiPhQBlpCijkCiOpWDWK_5aBLpB0liy3ThSs3-6le7A4O-62T50AB9vwoCdGvcvFWB7a7jJJlfbCLo3BJc315jukoBLM5felzl1qx38o2V6uc5U/s320/20231104_132918.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4Q1aiX09NBYBDpL3Dp_vshBbu8DCBMGYXwsawxn18LPDobL6y4QZU7WvZfgxpvzVyTu9EJu5zJT6H1lt93xnfZU7gWynyzY8fD3hwdQvyI8ql-lRpNH2Wi1VEo1Jmm3R7nIPDGNe-6utKkZhZvfH3tGh0gJolrSEBAlb1J_W-v1Sok7GMC35qXhk_SVM/s4032/20231104_132922.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4Q1aiX09NBYBDpL3Dp_vshBbu8DCBMGYXwsawxn18LPDobL6y4QZU7WvZfgxpvzVyTu9EJu5zJT6H1lt93xnfZU7gWynyzY8fD3hwdQvyI8ql-lRpNH2Wi1VEo1Jmm3R7nIPDGNe-6utKkZhZvfH3tGh0gJolrSEBAlb1J_W-v1Sok7GMC35qXhk_SVM/s320/20231104_132922.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIr02gmKf28ApqbXjEpNb9Cy9Dg5ozvvlXGoL6ep-nL3KjT40WSIDiucrxdBrIJ6xidmOClRn676jSI-PA2oenVsnRja8CcOnCRIgKXLtwKMki42AcXxg1_zLZMzmQ8mo4QzgrslmrLPr1129ZVuGYhIysPHCHdJ3yYdBc2sgBbGqt6NY6d9tJ8NSzb_A/s4032/20231104_132925.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIr02gmKf28ApqbXjEpNb9Cy9Dg5ozvvlXGoL6ep-nL3KjT40WSIDiucrxdBrIJ6xidmOClRn676jSI-PA2oenVsnRja8CcOnCRIgKXLtwKMki42AcXxg1_zLZMzmQ8mo4QzgrslmrLPr1129ZVuGYhIysPHCHdJ3yYdBc2sgBbGqt6NY6d9tJ8NSzb_A/s320/20231104_132925.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhth9tHzxQ1dgzZBnznzHxOhddXbx29SoY0jG4UryeFTIntSg7d2CCB1kYq-jAxrb5VczGloSeqJcE8DrRb6fotMV-1oG7tcvwwgL5jsPV3rp__LbK3W1WifGyEMDs5f-krtnO4rvCPcIsZ3PujzJlpJ1L7uhGk0l2gXYKgYlAy10j5GS-RlouZk4A59h0/s4032/20231104_132932.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhth9tHzxQ1dgzZBnznzHxOhddXbx29SoY0jG4UryeFTIntSg7d2CCB1kYq-jAxrb5VczGloSeqJcE8DrRb6fotMV-1oG7tcvwwgL5jsPV3rp__LbK3W1WifGyEMDs5f-krtnO4rvCPcIsZ3PujzJlpJ1L7uhGk0l2gXYKgYlAy10j5GS-RlouZk4A59h0/s320/20231104_132932.jpg" width="240" /></a></div><p></p><p>I glued the final strut in place, and let it sit for a day. The clamps were removed :</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilITWpneCVMziZ9CWKmYpEhpKIYvUahHaqDeknZMLbTUUPJQmlV3nZZpMjB_aDUEbZqAWrXprcu-LehTczWOgXhKezuccn6ft1-yoqgRxCRwbPh85YY8OJf_53MDtfP90TU2wXZtELGDE2Z6tRzev2WeeYrii48nk5Ov-BG1nH4pV7tf24RMonMMAl8b4/s4032/20231106_082016.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilITWpneCVMziZ9CWKmYpEhpKIYvUahHaqDeknZMLbTUUPJQmlV3nZZpMjB_aDUEbZqAWrXprcu-LehTczWOgXhKezuccn6ft1-yoqgRxCRwbPh85YY8OJf_53MDtfP90TU2wXZtELGDE2Z6tRzev2WeeYrii48nk5Ov-BG1nH4pV7tf24RMonMMAl8b4/s320/20231106_082016.jpg" width="320" /></a></div><p></p><p>I fed them through the router to curve the corners (I should have gotten chrome/nickel corner protectors that were 1/4" radius, but I had mistakenly gotten 1/2" radius).</p><p>I did also have to do the final fitment for the front panels, but that went relatively decent. The process did tell me my table saw sled is 0.8 degrees out of square, so that is an issue for a future fix. In the mean time, panels have been trimmed.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgExpCIu-jT4_O0h2N4DopkkZH8h44zQok1WES1kMHKZl8uX9d2LqayF4t1NGCr_p_BrK__LiuT2cfY-pMawF3JxQh04dBsZ5zLGaIKuW2oSTgUmLSQl8FLqensgZODPkTFVSxGyuzi_fVlEDF26zX0cUQAZ80IXgGWuoQl4FrsTPLzBFgNCgrPV-mZy9A/s3264/20231109_121423.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgExpCIu-jT4_O0h2N4DopkkZH8h44zQok1WES1kMHKZl8uX9d2LqayF4t1NGCr_p_BrK__LiuT2cfY-pMawF3JxQh04dBsZ5zLGaIKuW2oSTgUmLSQl8FLqensgZODPkTFVSxGyuzi_fVlEDF26zX0cUQAZ80IXgGWuoQl4FrsTPLzBFgNCgrPV-mZy9A/s320/20231109_121423.jpg" width="320" /></a></div><p></p><p></p><p>I spent a few hours sanding to 800-grit (perhaps too fine for lacquer?), and then sprayed the insides of the top bin on both, as well as one side of the front panel. This was so I could keep it consistent on everything else. It was three coats on this first phase (30 minutes apart).</p><p> It looks like the gold epoxy actually jumps out once coated. The darker, "character" walnut seems to pop with the gold. (Remember, it's not black walnut, this is a combination of sapwood walnut and outer walnut, so it has an extreme grain to it - and it is absolutely gorgeous.)<br /></p><p><br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGjjLAg19r-wNESpqmwPhPHVRI4vbshCNrkBLnhQFGe8hgjNwuGbkCLmUUmCD3XYOLNGBkqWyBYbUr8tHoDBTodSoTalu7QMcKQjMgrZyiFyem0vE1jo6FKbuR9cNAFxJ2xeD9G4XZXb3v0rL3KBY7uto7VzlM5tQ5wxH6_pvroU3BMKLUvCoktqTIrzI/s4032/20231111_130418.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGjjLAg19r-wNESpqmwPhPHVRI4vbshCNrkBLnhQFGe8hgjNwuGbkCLmUUmCD3XYOLNGBkqWyBYbUr8tHoDBTodSoTalu7QMcKQjMgrZyiFyem0vE1jo6FKbuR9cNAFxJ2xeD9G4XZXb3v0rL3KBY7uto7VzlM5tQ5wxH6_pvroU3BMKLUvCoktqTIrzI/s320/20231111_130418.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrrvCssvB3NYcsp6liaMq2EfElF_c_ct33l8kTbFsSjtqHclDHL7UWRCET3TRR_KPlOGgwELlMhtJ2vL62Pq93Vau3Bv2LhC1bYTCG_46py7EW6DNrYS1MPhroZkAJvh3rHyq8pCWqU9Ci_pFaCBr7XCCXiuRWZFHIDgJeU3xNMNIluwQ2jcAftYyGIzM/s4032/20231111_130415.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrrvCssvB3NYcsp6liaMq2EfElF_c_ct33l8kTbFsSjtqHclDHL7UWRCET3TRR_KPlOGgwELlMhtJ2vL62Pq93Vau3Bv2LhC1bYTCG_46py7EW6DNrYS1MPhroZkAJvh3rHyq8pCWqU9Ci_pFaCBr7XCCXiuRWZFHIDgJeU3xNMNIluwQ2jcAftYyGIzM/s320/20231111_130415.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0Y0unOwsUxf8Pi6wyDNPyTJPIoKnD7cS7nGZ7oYHheU0F7HrNCF9NdjFw5-8ZaJfp2uDSkULL9i9dFu4RLckL_DdQVxRh3le7-t3wW3J77cBgak6BKXqVkX623Twz5tbKlOvZ_VXkIRrKBTL4SRrfq-IVI-YN8H6yqhH06oaYqpu7D7H8BE1sbuzIMXg/s4032/20231111_130406.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0Y0unOwsUxf8Pi6wyDNPyTJPIoKnD7cS7nGZ7oYHheU0F7HrNCF9NdjFw5-8ZaJfp2uDSkULL9i9dFu4RLckL_DdQVxRh3le7-t3wW3J77cBgak6BKXqVkX623Twz5tbKlOvZ_VXkIRrKBTL4SRrfq-IVI-YN8H6yqhH06oaYqpu7D7H8BE1sbuzIMXg/s320/20231111_130406.jpg" width="240" /></a></div><p></p><p></p><p>The silver epoxy, on the other hand, seemed to turn black.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEie70urrLtEZmxl3oc2uE3Np2ar_8vaR5pmkUI0AvgxvPCR58eFnDvmCTCiJ4_8XVlMs5jiGpTlLG5639-h5vcaLp-OimuF8t_sdwIhISVvsMVBeqBhU_iriPYzddpK5bgq1tds992KrdcHG_h3mujvwbiQxJDrk8rX_qDUYMFPgErzqAd6COxiDoXtORM/s4032/20231111_130451.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEie70urrLtEZmxl3oc2uE3Np2ar_8vaR5pmkUI0AvgxvPCR58eFnDvmCTCiJ4_8XVlMs5jiGpTlLG5639-h5vcaLp-OimuF8t_sdwIhISVvsMVBeqBhU_iriPYzddpK5bgq1tds992KrdcHG_h3mujvwbiQxJDrk8rX_qDUYMFPgErzqAd6COxiDoXtORM/s320/20231111_130451.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhe4xeV72jlpXSdZOLQrbSwKix-cmOjupFvLMRov1WW7MF32rKsmRIoG1Vgk2q02Yf2qUY5kic7WRuDCWUv9PIb1-0ma9-17S3mplAQ-cIcHeoIHMbhk6mxZ97xj1xEZ5NW1oPj1rtPktKNclyOYPUPHjGBSs5h55BkqG_w66qmOg8QASTJ292tfkuAfj0/s4032/20231111_130454.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhe4xeV72jlpXSdZOLQrbSwKix-cmOjupFvLMRov1WW7MF32rKsmRIoG1Vgk2q02Yf2qUY5kic7WRuDCWUv9PIb1-0ma9-17S3mplAQ-cIcHeoIHMbhk6mxZ97xj1xEZ5NW1oPj1rtPktKNclyOYPUPHjGBSs5h55BkqG_w66qmOg8QASTJ292tfkuAfj0/s320/20231111_130454.jpg" width="320" /></a></div><p></p><p>This sat for a weekend, and the following Monday, I shot the final outside coats (three coats at 30 minutes a part). I let it sit for a day or two, and then I installed the hardware. This was a make-or-break point - either I was successful up to here, or I could turn this into a junk heap fairly quickly.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXvoSwwEN6Krntjqqe5vceafN8KovPDmLCkVjvzk7n5byrKLPDahyphenhyphenvaIjOMfEGcweNlLkxOCVIZj8qaP_YqUgGk7DQ4R-KEPcXzWFJWyCS5mC1FFdV9O8MieMQh0MTCesg2u7uNQWOACfRTMr84Wq8YzUDB5NysHNjOkLOUTZ7m3JpGJAAxK-NhxSsXIE/s4032/20231113_142212.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXvoSwwEN6Krntjqqe5vceafN8KovPDmLCkVjvzk7n5byrKLPDahyphenhyphenvaIjOMfEGcweNlLkxOCVIZj8qaP_YqUgGk7DQ4R-KEPcXzWFJWyCS5mC1FFdV9O8MieMQh0MTCesg2u7uNQWOACfRTMr84Wq8YzUDB5NysHNjOkLOUTZ7m3JpGJAAxK-NhxSsXIE/s320/20231113_142212.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNUU-dC3vqQvCPB8JukGsk3otpLItsiLdiBnjZoi9m6S0FN0saYg93_wJZAOjMSOvU9uvGzSwYLLJPg_mo30IenXAHI2F6PXqPt6cM2dtux65-tUXmYBv4aczjqkyQkwIFYe2kKRA-mAp49YqnFhwwlbog5fn1nk9K2iw0skaVkIYrI7w2YPb1TQ_9758/s4032/20231113_142217.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNUU-dC3vqQvCPB8JukGsk3otpLItsiLdiBnjZoi9m6S0FN0saYg93_wJZAOjMSOvU9uvGzSwYLLJPg_mo30IenXAHI2F6PXqPt6cM2dtux65-tUXmYBv4aczjqkyQkwIFYe2kKRA-mAp49YqnFhwwlbog5fn1nk9K2iw0skaVkIYrI7w2YPb1TQ_9758/s320/20231113_142217.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6Eu-hM6c1mI4zIjJRAU8hNDnLcToWMKXRT7XhJvBlFTNHVHO8JGyTZYPIH7rcdLphp8g2RwW4_NSxMefp63OcyUK88EqhOaezXTZxlIAlFGpwvrwhiMrfAwlu0XY98s8dzyqNx3sdc7QTRCryzR21KaSQcDFMoVYLRilHJ89w_PPPHmO5uuCDIdPV990/s4032/20231113_142232.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6Eu-hM6c1mI4zIjJRAU8hNDnLcToWMKXRT7XhJvBlFTNHVHO8JGyTZYPIH7rcdLphp8g2RwW4_NSxMefp63OcyUK88EqhOaezXTZxlIAlFGpwvrwhiMrfAwlu0XY98s8dzyqNx3sdc7QTRCryzR21KaSQcDFMoVYLRilHJ89w_PPPHmO5uuCDIdPV990/s320/20231113_142232.jpg" width="320" /></a></div><p></p><p>Again, the dark and the gold seem to just pop.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhv0p-iYETa33hZbPEv3nSMHovH4Bw0C8ExGipnikkN4S6S_A3MKjMXpKRl-wmgUM3jKXXvFFxftxExhg0q8n9dtjdvfmG_fdcgAWXHa6fEGpDhatzcYMxoTq6dbgSwTwNHLeTXpHr9VQj-AdIt4GefTHWMj976ZdcZrI3RSrEIsTYAq4V0AP3ugHr942Q/s4032/20231113_142223.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhv0p-iYETa33hZbPEv3nSMHovH4Bw0C8ExGipnikkN4S6S_A3MKjMXpKRl-wmgUM3jKXXvFFxftxExhg0q8n9dtjdvfmG_fdcgAWXHa6fEGpDhatzcYMxoTq6dbgSwTwNHLeTXpHr9VQj-AdIt4GefTHWMj976ZdcZrI3RSrEIsTYAq4V0AP3ugHr942Q/s320/20231113_142223.jpg" width="320" /></a></div><p>This sat for a few days (even though the lacquer was dry in 30 minutes, I just felt like I needed to let it sit a little longer). Now for the hardware. First, installing the corner protectors and the hinges.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0OQUSzARJ8KCikuzklplpoNnmz3eeSq49zZw3XjxH6qDjqTgP-pUxxyTz1K6gUq-VqpptrU2X1uxAxN7r61XiAXYe_awMXfaCxB7oZENi19e2Y_BcwEWQA8OeTWuFqImmyRPIWSNK9YptZxdweWI8qXpveW4l2LlOClkmC9AVd9V-e2zmKOkYlYdw7kk/s4032/20231113_155805.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0OQUSzARJ8KCikuzklplpoNnmz3eeSq49zZw3XjxH6qDjqTgP-pUxxyTz1K6gUq-VqpptrU2X1uxAxN7r61XiAXYe_awMXfaCxB7oZENi19e2Y_BcwEWQA8OeTWuFqImmyRPIWSNK9YptZxdweWI8qXpveW4l2LlOClkmC9AVd9V-e2zmKOkYlYdw7kk/s320/20231113_155805.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnZ7mGD1p-dGgRjbrutYNsPGE3Z3pOpf1bxXkP6lpd53GU4i6RNHD1kX53FzpKpctjaJZxL7GLctRHZkwg8tL7x8DiiLyXq3K08wrBaXuaF5_47Sc69HU3auh8-C1f-696vPABcjSLhPvJ1IRHaftFm6tiwLu5ChZR1DAxQeU-VkZL66Qm7aUo_5gpFHk/s4032/20231113_155818.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnZ7mGD1p-dGgRjbrutYNsPGE3Z3pOpf1bxXkP6lpd53GU4i6RNHD1kX53FzpKpctjaJZxL7GLctRHZkwg8tL7x8DiiLyXq3K08wrBaXuaF5_47Sc69HU3auh8-C1f-696vPABcjSLhPvJ1IRHaftFm6tiwLu5ChZR1DAxQeU-VkZL66Qm7aUo_5gpFHk/s320/20231113_155818.jpg" width="320" /></a></div><p></p><p>Next, I needed to get the front panel plungers installed. These came from Gerstner, since I knew they had a system that worked. The kit is one half of what you need - e.g. a single plunger, spring, one grommet for the panel, and two brass bushings - I had picked up a few kits when I knew it was for one side only, so two per box. I glued in the top bushing, let it set up for a few hours, and then glued in the other side. On one box, I did have to chuck the plunger up into the lathe and trim it down 0.432" because of the size, but they are currently glued up and setting overnight so that I have a solid base to start the latches and handles.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUy-GVQ4PLvCl1Ir5-MmW1_Br1eKf8Qikxen3r2lV4h7f6bhzEgeVaNIngjos7yuhpwOdslt6Z847SIO04ic4AO0KKEFJa13eR52mPyiLxQE7OpDFZuhyphenhyphenqeDpWNpDgOyOt1gXIW6PtI_ZRAZaW0maoqvYuGNmuN9u_eYkd7s1sF6LkNf-1hvPHxKPqvMY/s4032/20231115_170719.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUy-GVQ4PLvCl1Ir5-MmW1_Br1eKf8Qikxen3r2lV4h7f6bhzEgeVaNIngjos7yuhpwOdslt6Z847SIO04ic4AO0KKEFJa13eR52mPyiLxQE7OpDFZuhyphenhyphenqeDpWNpDgOyOt1gXIW6PtI_ZRAZaW0maoqvYuGNmuN9u_eYkd7s1sF6LkNf-1hvPHxKPqvMY/s320/20231115_170719.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYZBJNA_KEBv1HSh6tBWdunoSeCmUoWtwB65fvHRKGlpH-IqIajttwjpzR6Aoku0Hi8kPHcmVMYk1CMSL-tNV4e_HkZdH9agEPDSajk8oX-wzhq9lFI3d5mauf5Jm7c9DSTp2pwDDdXH-OUSDQHeaBBQvsOMFKnNCoKBdZAZeeWiN5qJbXbCvGyd9wbrA/s4032/20231115_170732.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYZBJNA_KEBv1HSh6tBWdunoSeCmUoWtwB65fvHRKGlpH-IqIajttwjpzR6Aoku0Hi8kPHcmVMYk1CMSL-tNV4e_HkZdH9agEPDSajk8oX-wzhq9lFI3d5mauf5Jm7c9DSTp2pwDDdXH-OUSDQHeaBBQvsOMFKnNCoKBdZAZeeWiN5qJbXbCvGyd9wbrA/s320/20231115_170732.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg506ItbJaLxTPN-v5XovHeVzmWxcao-hG4jq57Ab_FKjpm9c13qxVtecdFi1wjcy1yRR3udUT36iYcmkvOKNK5dUBUFPfuqt17evsRK9BFUSWIhJ4vSGsYr5x-0nUciUGr7-eKpeRuGgA8yENaybG3H0kv0vB-jgcmWxeMEb1pvnrRx5B5UrKEO0gCEms/s4032/20231115_170746.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg506ItbJaLxTPN-v5XovHeVzmWxcao-hG4jq57Ab_FKjpm9c13qxVtecdFi1wjcy1yRR3udUT36iYcmkvOKNK5dUBUFPfuqt17evsRK9BFUSWIhJ4vSGsYr5x-0nUciUGr7-eKpeRuGgA8yENaybG3H0kv0vB-jgcmWxeMEb1pvnrRx5B5UrKEO0gCEms/s320/20231115_170746.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFsAlgKLSI2V8iLM0wqa1QzdoL5BDNmO94lPvh1AALRpjKumfiQr_t0WRNSEyfrQ7RJxb4-Tyjck9_PUZhPmXbYvr9LWBagjl6uGW6wGxH4S9vvMEReSs5gHFoHBzZtzHOThOlqqFhgpheN_cO7lwTbrBu8zmYgwRR90himeWyKNMnupJE0Hck0zyh4nQ/s4032/20231115_170806.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFsAlgKLSI2V8iLM0wqa1QzdoL5BDNmO94lPvh1AALRpjKumfiQr_t0WRNSEyfrQ7RJxb4-Tyjck9_PUZhPmXbYvr9LWBagjl6uGW6wGxH4S9vvMEReSs5gHFoHBzZtzHOThOlqqFhgpheN_cO7lwTbrBu8zmYgwRR90himeWyKNMnupJE0Hck0zyh4nQ/s320/20231115_170806.jpg" width="320" /></a></div><p>The interesting thing on those plungers is that the lid surface is simply a carpet tack placed in the right spot. Gerstner did well with what they had - I was thinking I might have to make some brass plates, but finding the tacks in the kits was a good thing.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4deFbOWgjO1H-h6g6fpQxX3pw-zZGcxv8a1BIeg5QMUm40pqFglwAHeY-h_LxRFJ_8NO19muZBcdz4o4OYK0YLXpxD6jQZphYKShZ0YWI312lTftNR7oaJ8BISK0GXpPGZlxxWFgfyJYDhCjw_9h5A-Rw5oGLpBDDae7JUL3I-018lQbSFkHMAyKTwBg/s4032/20231116_085641.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4deFbOWgjO1H-h6g6fpQxX3pw-zZGcxv8a1BIeg5QMUm40pqFglwAHeY-h_LxRFJ_8NO19muZBcdz4o4OYK0YLXpxD6jQZphYKShZ0YWI312lTftNR7oaJ8BISK0GXpPGZlxxWFgfyJYDhCjw_9h5A-Rw5oGLpBDDae7JUL3I-018lQbSFkHMAyKTwBg/s320/20231116_085641.jpg" width="320" /></a></div><p></p><p>Next comes the latches and locks. I debated on installing a key on the brass one. I'm still undecided, but the latches are all in place.</p><p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipcy5YdbknGrB1I36Y7ne4I1vEIasMb8krDMVd-7nt067JQ7yHm2J_Loo9Jnd25yVeb9_UdIHpY3_SaopZZyhB9PziU5f4Sa_xoqtpKJaiRDK9-55tcQAW_AiXIUVxCLVcdQ7zQ9mesgsFR0dONYcoNjEfsaFbhzR3I0xn3vobNCYDqRA1jeDZik7_i_I/s4032/20231116_164740.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipcy5YdbknGrB1I36Y7ne4I1vEIasMb8krDMVd-7nt067JQ7yHm2J_Loo9Jnd25yVeb9_UdIHpY3_SaopZZyhB9PziU5f4Sa_xoqtpKJaiRDK9-55tcQAW_AiXIUVxCLVcdQ7zQ9mesgsFR0dONYcoNjEfsaFbhzR3I0xn3vobNCYDqRA1jeDZik7_i_I/s320/20231116_164740.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgD301ANX9Cd0Kskl_wYtJLOMxEADF4cnQR6ET0QT8HBCpFEtosMgSSZxnL8JSRNx-L3W-HDlYkf3EjP6rYMKa9afSyKUHTyuszovgXGzhWlbKruJC53Ox4yrCLUDGUjHdmuJrHhBfl7BwQPNXCa6qhyphenhyphenUucsPBj3yJZB0avq3RFHk-m41BIRB5BmaNZyxM/s4032/20231116_164702.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgD301ANX9Cd0Kskl_wYtJLOMxEADF4cnQR6ET0QT8HBCpFEtosMgSSZxnL8JSRNx-L3W-HDlYkf3EjP6rYMKa9afSyKUHTyuszovgXGzhWlbKruJC53Ox4yrCLUDGUjHdmuJrHhBfl7BwQPNXCa6qhyphenhyphenUucsPBj3yJZB0avq3RFHk-m41BIRB5BmaNZyxM/s320/20231116_164702.jpg" width="320" /></a></div><p></p><p>I must say, these are looking fantastic. The front panels were simply set in place for the photos. Before I could call these done, the panels needed to have the hole drilled and the brass grommet installed, as well as the lower hinge hardware for the panel. I was dreading the panel installation. It turns out that the installation is documented on <a href="https://www.youtube.com/watch?v=cw2pvniLe_Q" target="_blank">youtube by Gerstner</a>. So, it's off to the drill press to drill the tops, install the hinge plates into the chest, and the hinge pins onto the panels.</p><p>First, in go the chest hinge plates so we know how thick to make the panel hinges. Unsurprisingly, it's just appropriately sized tacks that hold it all in place. Once that is done, install the pins in the bottoms of the front panels that go into those and the panels are the right size (those are drilled out with a #22 drill bit for a tight fit). I did toss some wood glue in to set up the depth on the pins into the front panel.</p><p>The final step is to install the plunger grommets into the top of the panels. The reason why we do the bottom hinges first is so that we can open the lid, close the panel, and give a slight rap on the pins with a hammer, indenting the top of the front panel with where those go. Drill them out (I went with an 11/32" diameter brad point bit about 0.040" deep to allow them to be flush with the top, followed by the 7/32" about 0.410" deep). Then, a little glue to "bed" them into place, pop them in with a light ball peen hammer (the rounded nose allows the grommets to be installed without damaging surrounding finish).</p><p>Phew! It was time for a photo op - these have been a long time coming!<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgDH-EkY9qB8bUw57qJDlb9-roTrqu-2bKzVRzqUmi33wZkBzSltByZjGTosrfkPZnLJfkoR3DCpfsIQbgG2zO7cWvYghxOKH0T1dnaGXHRiEkE_grbgHPk9-3_e-yKPZN-O062tSbCpA-oOszVgstrD0Gi0xjM1xz7X9Tt0N1CGdjcLFiMyJohg3A_uE/s4032/20231117_134950.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgDH-EkY9qB8bUw57qJDlb9-roTrqu-2bKzVRzqUmi33wZkBzSltByZjGTosrfkPZnLJfkoR3DCpfsIQbgG2zO7cWvYghxOKH0T1dnaGXHRiEkE_grbgHPk9-3_e-yKPZN-O062tSbCpA-oOszVgstrD0Gi0xjM1xz7X9Tt0N1CGdjcLFiMyJohg3A_uE/s320/20231117_134950.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtDzWwvXMEMqOtI-uOJwURIXZ-FuOGgyve-LytDTjqyL9zWj8IbmUhXB98ySDBZlu0zNyFsMQsK5N6qqEXjpzDww2mKOIXzB4aTkFZFPclItoh1ghFlcuk5xOSaPWx5OgnWnW_qcRxt9utYZKep7nuGjUF_Dtx1aQthtJt-YmITnzv0aske6GJk0usBZg/s4032/20231117_135204.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtDzWwvXMEMqOtI-uOJwURIXZ-FuOGgyve-LytDTjqyL9zWj8IbmUhXB98ySDBZlu0zNyFsMQsK5N6qqEXjpzDww2mKOIXzB4aTkFZFPclItoh1ghFlcuk5xOSaPWx5OgnWnW_qcRxt9utYZKep7nuGjUF_Dtx1aQthtJt-YmITnzv0aske6GJk0usBZg/s320/20231117_135204.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTYiSKl7daGfaqco8oYlZ_e9cJJa4SdH-EqfGley1HyLf59pmjsdONjUrWRc6hoogaSl1DayAc9D4QMSX_BlH3DwnhAfmnP79OGYAGc3D1AOB1qjKruFyESEd5qkkMVQudTGXQ7SUJTZjbL2UKbTyaMa3eKqFjdKW5QUCdnEUf6eO4dcu-9WJCrDKxzc0/s4032/20231117_135222.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTYiSKl7daGfaqco8oYlZ_e9cJJa4SdH-EqfGley1HyLf59pmjsdONjUrWRc6hoogaSl1DayAc9D4QMSX_BlH3DwnhAfmnP79OGYAGc3D1AOB1qjKruFyESEd5qkkMVQudTGXQ7SUJTZjbL2UKbTyaMa3eKqFjdKW5QUCdnEUf6eO4dcu-9WJCrDKxzc0/s320/20231117_135222.jpg" width="320" /></a></div><p></p><p>And all three :</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMkn7XWMVvybL5VNCZeQbn-t3hq0Oi4rU9oSnEj97F0lC8oGbqVVqyQyZfMNbyMIOtO7XMmaLfgo29yCoxQHSbp1NHk188ICYnm8DlRhE9iaf4gLTyJGG_hIsAwuyD8QChHKlq0HmlNYqUrIx4bnFpMOL6-DZbLm269JmSOyqoK4lsohoIV1U_Gt_95-c/s4032/20231220_162216.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMkn7XWMVvybL5VNCZeQbn-t3hq0Oi4rU9oSnEj97F0lC8oGbqVVqyQyZfMNbyMIOtO7XMmaLfgo29yCoxQHSbp1NHk188ICYnm8DlRhE9iaf4gLTyJGG_hIsAwuyD8QChHKlq0HmlNYqUrIx4bnFpMOL6-DZbLm269JmSOyqoK4lsohoIV1U_Gt_95-c/s320/20231220_162216.jpg" width="320" /></a></div><p></p><p>Really, this
has been a fantastic project. However, I have learned one thing - if
you want a high quality, wooden tool chest, what Gerstner charges for
one is <b><i>well worth it</i></b>. The time I have put in (at a standard consultant
rate of $70/hour) calculates to about $7,020 (not counting the cost of the hardware or wood,
either). Considering you can get the <a href="https://gerstnerusa.com/shop/2610-chest/" target="_blank">Gerstner pro-series (the big one) for $2,495</a> (US), the only thing you get by making your own is being able to
say you made it yourself, and Gerstner does sell <a href="https://gerstnerusa.com/shop/2609-mastercraftsman-chest-diy-kit/">kits to put together your own that include everything for even less</a> (about $1200 US - I don't know if sanding will be required, or what you'd need to do to complete them). If you have to go cheap, consider the <a href="http://www.silverhawk.net/2020/01/gerstner-vs-windsor-design-harbor.html" target="_blank">Harbor Freight "Windsor Designs"</a> chest as it is a fraction of the price. Sure, it doesn't have the same fine sanding and finish on it, and it's not quite the same size or drawer count, but it will do the job. In fact, with the push to digital on the Machinery's Handbook, it turns out that Gerstner no longer sells one that can hold a hard copy of the machinist's bible, so the drawer orientation may not even be an issue.<br /></p><p>Really, these custom-made chests are keepsakes. They are going to be farmed out to people I know with some specific uses (one was made with more gap between the front panel and the drawers in order to house additional and custom wood panels for what he does, another one is to house some of my fishing tools (rod making, fly tying kinds of things), and the third one is going to someone who has started the dangerous dive into metrology.</p><p><i>Now</i> I have to make 33 customized drawers. <b><i>Ugh</i></b>.<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-22160390132161142592023-11-13T10:50:00.000-08:002023-11-13T10:50:42.741-08:00New Chest - Found a Gerstner O52 and It's Base<p> Whelp - all that work building the tool chests out of walnut, and someone posted a tool chest on the local classifieds listing, for $650. I thought, that's a great price.</p><p>It turns out, the chest was unused. The seller was a retired machinist who purchased the chest a while back when he was preparing to retire. Instead of using them, they sat (in the original shipping boxes). He realized he wasn't using them after a long time, and sold them to me... for less than the asking price of $650. It was a steal.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZlA1IsLdriJM9pdkADsoPRq3ESqzZWAsnnJuHha6lJiAfGluqyoznfHsJ3JtWy0ZWs7KmfJE2Pdu93ll7oooUJVn7GSmA_8mxeYqOTzGgbqqRUxuvTa8hvbubGGr1nRenhAD7zKN-iOOk13F3awB_STQYCIGHQ3uxMq6ZFIaifbsqNHxYDrUQUiSacOs/s4032/20231101_101707.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZlA1IsLdriJM9pdkADsoPRq3ESqzZWAsnnJuHha6lJiAfGluqyoznfHsJ3JtWy0ZWs7KmfJE2Pdu93ll7oooUJVn7GSmA_8mxeYqOTzGgbqqRUxuvTa8hvbubGGr1nRenhAD7zKN-iOOk13F3awB_STQYCIGHQ3uxMq6ZFIaifbsqNHxYDrUQUiSacOs/s320/20231101_101707.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmDxxt-vSP1h7ggu-zZGsKDC1vmwBaLhaUXZU_jyFenml8iCDT5llSGL_kNf3Pg7xKvsDNhVFygIRqYoCiVa4xB53IC21qwyl2jEVfIsg1lKM0u8MGPgkkxUpzfMZA-OSAghgzXP3sdkiFYdFNBpDXZnlMD34yzuFKqOyLjk_Peq_LnfFqFSrNrhaQfVU/s4032/20231101_101729.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmDxxt-vSP1h7ggu-zZGsKDC1vmwBaLhaUXZU_jyFenml8iCDT5llSGL_kNf3Pg7xKvsDNhVFygIRqYoCiVa4xB53IC21qwyl2jEVfIsg1lKM0u8MGPgkkxUpzfMZA-OSAghgzXP3sdkiFYdFNBpDXZnlMD34yzuFKqOyLjk_Peq_LnfFqFSrNrhaQfVU/s320/20231101_101729.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrcnpGjCTe08W3lJGte6uljalyvCeWZfZy2N_kE0R9icyQzlvtBK3XM_Y2GJSGxuz43OEMYGuuRZy_wc9dSIPqWV8wn4HAffYcBmc7eRfUcnI-aMssKVfefogHZmHWmTqptA0Fg7NIRouHFK6WLvPW53uyzdCGz5FFh-3JYBFsNstcwYqO563w-5y3rdw/s4032/20231101_101852.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrcnpGjCTe08W3lJGte6uljalyvCeWZfZy2N_kE0R9icyQzlvtBK3XM_Y2GJSGxuz43OEMYGuuRZy_wc9dSIPqWV8wn4HAffYcBmc7eRfUcnI-aMssKVfefogHZmHWmTqptA0Fg7NIRouHFK6WLvPW53uyzdCGz5FFh-3JYBFsNstcwYqO563w-5y3rdw/s320/20231101_101852.jpg" width="320" /></a></div><p></p><p>Now I am the proud owner of a new tool chest, models O52 and O62. They wait to become a Christmas present from my wife to me [she gets to pick something from the stash, and it's going to be what I want].<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-51274787115961556612023-09-30T14:58:00.004-07:002023-09-30T14:58:38.342-07:00Plate and Light - Installed!<p> Finally, after all that effort (both the kind that had results and the kind that didn't result in anything that was really needed), I have the place installed on the car!</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZp2tCt7wEgfqDWSgLtUThxUko6QZW60nHktdg2FWsPtPhHCjW7sqeBb1mOkZSDWtIuMokWwmlXJTdEk5lk3TiRDA0BPbGbEkbB4teeIwNFkOM82JYX3xysxTL-1wq9Xadn36N_tfrke8WgxXjDZItlKivfxZC9SIFRNMnLfMtk7ilhpFn4cFM38VV0BQ/s4032/20230930_154135.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZp2tCt7wEgfqDWSgLtUThxUko6QZW60nHktdg2FWsPtPhHCjW7sqeBb1mOkZSDWtIuMokWwmlXJTdEk5lk3TiRDA0BPbGbEkbB4teeIwNFkOM82JYX3xysxTL-1wq9Xadn36N_tfrke8WgxXjDZItlKivfxZC9SIFRNMnLfMtk7ilhpFn4cFM38VV0BQ/s320/20230930_154135.jpg" width="240" /></a></div><p></p><p>Now I can legally drive!<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-70305618710257097092023-09-30T14:29:00.001-07:002023-09-30T14:29:10.776-07:00More License Plate Work - Light Mount<p> I started digging around getting the license plate light installed, and in the assembly manual, there is this little gem :</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEDVynOedIdUmLLWH31-XwvVYD1gZndz0WsGFnJUxlkLU8IrVGUXlDEz1ebYNdfLOb2Xxyaup9b8utBizu29DML1WsB5mMODXAx_TXac3KttLKJKe1aa3nuXOqP8f7bhvZXiQWiZe1K6fgDfK89GStIXEWIslbkBZFN-x4Ua78esrTTu2XE6s4dfdEDS4/s946/1977-corvette_assembly-license_plate_light.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="589" data-original-width="946" height="199" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEDVynOedIdUmLLWH31-XwvVYD1gZndz0WsGFnJUxlkLU8IrVGUXlDEz1ebYNdfLOb2Xxyaup9b8utBizu29DML1WsB5mMODXAx_TXac3KttLKJKe1aa3nuXOqP8f7bhvZXiQWiZe1K6fgDfK89GStIXEWIslbkBZFN-x4Ua78esrTTu2XE6s4dfdEDS4/s320/1977-corvette_assembly-license_plate_light.png" width="320" /></a></div><p></p><p>It doesn't say much about how it got into position, and my memory is fading, so I cannot answer how this little bracket is installed. With having to create the mounting bracket underneath, I'm starting to think I now have to custom build a bracket to fit this aftermarket bumper cover. Okay, I'm going to treat this like we did the gasket, and create a paper template, print to make sure it fits, then print and glue to some angle iron that I can use to mount this thing up. I'm hoping I don't have to remake the bracket, but we'll see.</p><p>First, it's time to grab a photo and take some dimensions.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFAI9LJ4Kv1XASzKhLAmpDA5CT09Nl6poQ0Zvdp0lIBWTFJXLymgEJMgZ0KILMepO0iXZHDHzvhBeHGGU8FrlXMq1JO3QiYvNMxWcqd4QWH5DJOz_XShW05TqmBBxFSpRSO9j_KXoKUdoHkjVR1EV3yExnEQ-Fab3btw5_qiQd_Ji00xwQd3Um-zCe1N8/s2004/20230815_104715.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1068" data-original-width="2004" height="171" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFAI9LJ4Kv1XASzKhLAmpDA5CT09Nl6poQ0Zvdp0lIBWTFJXLymgEJMgZ0KILMepO0iXZHDHzvhBeHGGU8FrlXMq1JO3QiYvNMxWcqd4QWH5DJOz_XShW05TqmBBxFSpRSO9j_KXoKUdoHkjVR1EV3yExnEQ-Fab3btw5_qiQd_Ji00xwQd3Um-zCe1N8/s320/20230815_104715.jpg" width="320" /></a></div><p></p><p>With this, I fed this first into GIMP (the open source photo editing software), and "unskewed" it (rotating and altering how the image sites to simulate a perpendicular photo - symmetry is key). Next, I open up Inkscape (open source Scalable Vector Graphics editor), and proceed to trace the image.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCySuMIRT6jZ_vxNm3v6vdrWWzps5eXP9PTx-gXEifT9Q7XnfPhNv-Zd-OJ3xyYM2PppdVk6I33U4j0ZL5o5OrGwTux5h-x7cvIT_bzJih22pInlX77hCiQYbYodzJvm1WQue1O_UWUr2QoNrAm88Sk7-ew4jz-v6bZBCZySqI5v5nM5sUNkoWsiXFOSo/s1068/inkscape-license_plate.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="742" data-original-width="1068" height="222" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCySuMIRT6jZ_vxNm3v6vdrWWzps5eXP9PTx-gXEifT9Q7XnfPhNv-Zd-OJ3xyYM2PppdVk6I33U4j0ZL5o5OrGwTux5h-x7cvIT_bzJih22pInlX77hCiQYbYodzJvm1WQue1O_UWUr2QoNrAm88Sk7-ew4jz-v6bZBCZySqI5v5nM5sUNkoWsiXFOSo/s320/inkscape-license_plate.png" width="320" /></a></div><p></p><p>Once mapped out, it's time to make sure we got the size right.Select everything, and then make sure, using the measuring tool.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_ouE0lfkXJ-JuKDWxVWT6YsrTFVT6jKa9HnQV1S46QMS2Z311Koc4DDagmhzhLd9AtNz0t9BQ4VBuxJ1FXjL5CPHkoqYquUnOXdL3PWgjIwf-S6r0fL9fvzT4ha5fiQYEZrHOPKP0h-H6a91nuDhbRwF5Wn0R9nO3YF0yRFE4XBeiAPGTwdjBNtcboD0/s1041/inkscape-license_plate-with_measurements.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="708" data-original-width="1041" height="218" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_ouE0lfkXJ-JuKDWxVWT6YsrTFVT6jKa9HnQV1S46QMS2Z311Koc4DDagmhzhLd9AtNz0t9BQ4VBuxJ1FXjL5CPHkoqYquUnOXdL3PWgjIwf-S6r0fL9fvzT4ha5fiQYEZrHOPKP0h-H6a91nuDhbRwF5Wn0R9nO3YF0yRFE4XBeiAPGTwdjBNtcboD0/s320/inkscape-license_plate-with_measurements.png" width="320" /></a></div><p></p><p>With accurate measurements, it's time to perform the object math - subtracting the pieces to get exactly what we want. </p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcQrS2T2rZB-fibpCm6xGYXoOCGPzJeO4tks5yazbEVQCO0nnCa-E7vxyX3SGJFVWhlrDqhrqc0z4ahCtoMD2ltZ0a4AqBwsnnKN0rOw8H_MPPnV-kxtTduE0vBwRGL1iBfBr9leAdgp4_RRAljBSOCqOTSfUwdIxTExjcZ8OKrkWvtXLQDMnXibTQu_g/s1081/inkscape-license_plate-final_shape.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="528" data-original-width="1081" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcQrS2T2rZB-fibpCm6xGYXoOCGPzJeO4tks5yazbEVQCO0nnCa-E7vxyX3SGJFVWhlrDqhrqc0z4ahCtoMD2ltZ0a4AqBwsnnKN0rOw8H_MPPnV-kxtTduE0vBwRGL1iBfBr9leAdgp4_RRAljBSOCqOTSfUwdIxTExjcZ8OKrkWvtXLQDMnXibTQu_g/s320/inkscape-license_plate-final_shape.png" width="320" /></a></div><p></p><p>Finally! We can now print this out, cut it, and test fit it. (Note, I'm too lazy to get out the vinyl cutter and cut the part out automatically - so it's going to be a hand-cut, using the age old method of scissors.)</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4vemTCn2JsanOWORJogBEC4vbibjRwBjzS9Obm9vMMCMybVIcQrobpdBZjlO61g-Nnybp9bIOQviboW-7VBxWNL8EBpGpMnEQ1qEIQCCZHwW8ftOchYqrccx6rdADn34WTGjnaSvcWJQnEoEs1P7l89bOm0zehVhmdRVGP_9YSerftC76CcizA_QLueY/s1771/20230815_121300.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1677" data-original-width="1771" height="303" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4vemTCn2JsanOWORJogBEC4vbibjRwBjzS9Obm9vMMCMybVIcQrobpdBZjlO61g-Nnybp9bIOQviboW-7VBxWNL8EBpGpMnEQ1qEIQCCZHwW8ftOchYqrccx6rdADn34WTGjnaSvcWJQnEoEs1P7l89bOm0zehVhmdRVGP_9YSerftC76CcizA_QLueY/s320/20230815_121300.jpg" width="320" /></a></div><p></p><p>The test fit perfectly. Now I can print out another one, glue it to whatever will back this up, cut and machine it out. That will complete the rear bumper, or anything from the doors back except for the sound system.</p><p>It was around this time that I realized no one carries a bracket, no one has a bracket for sale from old cars, and the Assembly sheets from the factory show no bracket at all. Really? I went through all of that for nothing?</p><p>Yup. Good exercise, though. Now to install the plate.<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-3271798172579512252023-09-29T17:14:00.007-07:002023-09-30T14:59:26.573-07:00C3 - License Plate and Lights<p>As I've dug in further to my car, trying to get license plates installed, I'm finding I just can't get parts. Machining the license plate holder was one thing, but now I have to make a light bracket, plus I have to figure out the screws for the lower plate, but I don't want to purchase them in order to make the custom brass ones. Here we go. Let's throw in the assembly manual diagrams :</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUqe-fKS0o4j-omqEFnWg0_jvJUFB3FFYY7K0r-zqTLV7zuCdi1ejMuHqwlaXlOkKpYFhusa9rc1GuBZvJ3KH0_eYYzQnLAbEPCSUQ7-hQKrnw7tZhAfzzzgCHea3op3mENTrlJYbzkZpuwDXFUMIiY1TlJev1PLS6gTa53L0wVyxwZRx1FP2_Dc0k3X0/s1414/license_bracket-aim-light_screws.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="867" data-original-width="1414" height="196" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUqe-fKS0o4j-omqEFnWg0_jvJUFB3FFYY7K0r-zqTLV7zuCdi1ejMuHqwlaXlOkKpYFhusa9rc1GuBZvJ3KH0_eYYzQnLAbEPCSUQ7-hQKrnw7tZhAfzzzgCHea3op3mENTrlJYbzkZpuwDXFUMIiY1TlJev1PLS6gTa53L0wVyxwZRx1FP2_Dc0k3X0/s320/license_bracket-aim-light_screws.png" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgU3tcp1Fw2UwnFuDNsseJe91_I05aTZ37NntPTlcOiTY0G07b8BYxia5zkcSDKvZhrnjUBNBn4CqLvMgFjLjxgDyJDTeF2IhZTLNLUKoijCq6UDlJ90XhD1ihdPmgbCl1QaJi5hweMKpXJ1M1umtj5zE3oYJGwecEON0rv1jtGToftsYQ8BRqP-XwJEJ4/s1434/license_bracket-aim-lower_brace.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="705" data-original-width="1434" height="157" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgU3tcp1Fw2UwnFuDNsseJe91_I05aTZ37NntPTlcOiTY0G07b8BYxia5zkcSDKvZhrnjUBNBn4CqLvMgFjLjxgDyJDTeF2IhZTLNLUKoijCq6UDlJ90XhD1ihdPmgbCl1QaJi5hweMKpXJ1M1umtj5zE3oYJGwecEON0rv1jtGToftsYQ8BRqP-XwJEJ4/s320/license_bracket-aim-lower_brace.png" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpSX7KO_r-Lloes2fyJrTxI5aWF-s-MyZm1lhO_V7xFFtDmiGOJvQZgys6CNX3wxxF10KJETpM4IdJ0GXioGtDXbI3uZGUxbLfMxxl-H_5FwfwMB7XmFjxGpn58Ccw-eSZwTkty0X8ISS3VWAYtjznh_yy5bXTUNWSdIgw89vrhIxRbdgbm_gsbW3EQls/s1422/license_bracket-aim-rear_screws.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="857" data-original-width="1422" height="193" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpSX7KO_r-Lloes2fyJrTxI5aWF-s-MyZm1lhO_V7xFFtDmiGOJvQZgys6CNX3wxxF10KJETpM4IdJ0GXioGtDXbI3uZGUxbLfMxxl-H_5FwfwMB7XmFjxGpn58Ccw-eSZwTkty0X8ISS3VWAYtjznh_yy5bXTUNWSdIgw89vrhIxRbdgbm_gsbW3EQls/s320/license_bracket-aim-rear_screws.png" width="320" /></a></div><p>In the first diagram (page "407"), the screws are #2, or part number 3974037, for the license plate light bezel mounting.</p><p>In the second diagram (page "473"), I'm looking at #3 (part number #3907444) for the plastic mounting nut (the bracket [#7] is part # 339142).</p><p></p><p>First, lets hit the lower screws for the plate fastening. Identifying the screws shouldn't be too difficult, as the plastic sockets do not come threaded for a specific example. It should be as easy as identifying the largest through hole diameter (call it the largest minor diameter), and also the largest entry point diameter. From those two measurements, I should be able to deduce the screw size using screw dimensions.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEio7DG4sipfEXK-dkSkwrHksA_XMCusk9ttsy-ANJDY1YbAbqwGF1hkZldDxLIi75QznAcmC_X9dHBkAa7A148oHULK2KSuiMHni4S5HnaEVhQmU4AT3bqEFHT595lzOPgIghZn3f8tZrbAgqNvNplI3V05e6F9xLIJaRmnVKJWJy3UUhhV2wK_v2y0Ox8/s4032/20230929_173213.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEio7DG4sipfEXK-dkSkwrHksA_XMCusk9ttsy-ANJDY1YbAbqwGF1hkZldDxLIi75QznAcmC_X9dHBkAa7A148oHULK2KSuiMHni4S5HnaEVhQmU4AT3bqEFHT595lzOPgIghZn3f8tZrbAgqNvNplI3V05e6F9xLIJaRmnVKJWJy3UUhhV2wK_v2y0Ox8/s320/20230929_173213.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEik0VYWuWcaIwajFVK3laZK3uwzqaSeHfZCHlbu39BmGXbHPfV-9Ed0GaEX8Zmf9oXu0CdAM35CZafUTmLlTi57u0zBy0QXiM88Qf4zaHvVDoOYVYWy4FTqg4Yzzz6ef0h4DbZJycXyNr1tRJQIeqCBX8_EUV4H-SSmY1OytiXPjdg-G7o4WEJ7FSiNe0A/s4032/20230929_173313.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEik0VYWuWcaIwajFVK3laZK3uwzqaSeHfZCHlbu39BmGXbHPfV-9Ed0GaEX8Zmf9oXu0CdAM35CZafUTmLlTi57u0zBy0QXiM88Qf4zaHvVDoOYVYWy4FTqg4Yzzz6ef0h4DbZJycXyNr1tRJQIeqCBX8_EUV4H-SSmY1OytiXPjdg-G7o4WEJ7FSiNe0A/s320/20230929_173313.jpg" width="240" /></a></div><p></p><p>The largest hole was 0.193". The small end was 0.128" in diameter.</p><p>It was at that time I stupidly realized the package that had been left unopened HAD THE STUPID SCREWS!</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgJ4yYDHxL33SpBgZG-b0SPUnQPHCaJWIu2n1h4w1eYgCEN5yFESCveRZC4QnA2dDkquSGPtyT__jajxGiGBXNwhiRnIiimaKXACJmvW0XnCGlRVvMOewlzs7wollqziSeGS6KJaJipYWWQRzmTMw4IFrY5lXVfLsVzOeo6en09ppDKgWEDP-N3dmpxPw/s4032/20230929_173357.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgJ4yYDHxL33SpBgZG-b0SPUnQPHCaJWIu2n1h4w1eYgCEN5yFESCveRZC4QnA2dDkquSGPtyT__jajxGiGBXNwhiRnIiimaKXACJmvW0XnCGlRVvMOewlzs7wollqziSeGS6KJaJipYWWQRzmTMw4IFrY5lXVfLsVzOeo6en09ppDKgWEDP-N3dmpxPw/s320/20230929_173357.jpg" width="240" /></a></div><p>The screws had an outside diameter of 0.240", and a thread pitch of 14. The depth isn't much, because these are essentially wood screws, but I have a sneaky suspicion that any 1/4" screw would fit. It also tells me the threads can be 25% larger than the hole, and I expect a course thread would be just perfect, so a 1/4"-20 will be fine.<br /></p><p>This allows me to use the above criteria in calculating the next screws for the license plate light. Let's measure things up and see what things show as.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYZXeTAl60ry2g0iH-MYpPevUgYkYvRNdAA9Jr48Xbyx-VsEhu7gYalC5MHpUoc_vmotg3wGjkzWMO0GQeSNbhiOPYMqok8vxQlpgFnxkHzQO2_Dw_LHQlkmkjDxzm8kMoYbdup_Kr1Q8M59ZnFvXoecsf-BVZ1y8oVGUzLE7ymoPEFZykpUWruWD1w_I/s4032/20230929_173701.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYZXeTAl60ry2g0iH-MYpPevUgYkYvRNdAA9Jr48Xbyx-VsEhu7gYalC5MHpUoc_vmotg3wGjkzWMO0GQeSNbhiOPYMqok8vxQlpgFnxkHzQO2_Dw_LHQlkmkjDxzm8kMoYbdup_Kr1Q8M59ZnFvXoecsf-BVZ1y8oVGUzLE7ymoPEFZykpUWruWD1w_I/s320/20230929_173701.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkZzjTs3kW2-ECxcEckobDMz1-G69GaFUfCEoLLOpgAPtAmhbegnm8rNmiaHjj3UB0BZYaOVWCW7n2gRAKEsbNXT3r4pXmlcOu_7BMfhEq6NQr4sy7bk4_EhhRxvL4_DhUpma3uT61z6ZFMoVNIzMuQS3Zp5y46kLtKOQSGdQjzLnQE5spn8jOY0SH_bw/s4032/20230929_173812.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkZzjTs3kW2-ECxcEckobDMz1-G69GaFUfCEoLLOpgAPtAmhbegnm8rNmiaHjj3UB0BZYaOVWCW7n2gRAKEsbNXT3r4pXmlcOu_7BMfhEq6NQr4sy7bk4_EhhRxvL4_DhUpma3uT61z6ZFMoVNIzMuQS3Zp5y46kLtKOQSGdQjzLnQE5spn8jOY0SH_bw/s320/20230929_173812.jpg" width="320" /></a></div><p>The largest fit diameter did not go all the way through, at 0.139". The largest that <b><i>did</i></b> go through was 0.133" diameter. Looking at the Machinery's Handbook, to see what matches :</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_Cy-Mxsgw45Ic-DiKJGrKOc8OGUm6yIGMxPfYrEgxNdRJs8bWSowUUOrW9Ys8XqUBXDi2LqMuv1Nagd2Qc7g-hOXAkqsfbPfcgqyiuwoo3WTpMXGzdfDmmr6P-sQUy6yKnowWBpqlroHp9Ea3qxKYYb9ywVygz5O9ksJLNkTxg4R7M_WKRVILrFES1EI/s4032/20230929_175951.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_Cy-Mxsgw45Ic-DiKJGrKOc8OGUm6yIGMxPfYrEgxNdRJs8bWSowUUOrW9Ys8XqUBXDi2LqMuv1Nagd2Qc7g-hOXAkqsfbPfcgqyiuwoo3WTpMXGzdfDmmr6P-sQUy6yKnowWBpqlroHp9Ea3qxKYYb9ywVygz5O9ksJLNkTxg4R7M_WKRVILrFES1EI/s320/20230929_175951.jpg" width="320" /></a></div><p></p><p>With a minor diameter that cannot exceed 0.139" or 0.133", and a scan of the table, we find the maximum's minor diameter of a #10 screw is a 0.1376". The #10 screw in my mind is a wee bit too big, so it is smaller than that.</p><p>The major diameter of the screw has to be at least 0.133" in order to engage the hole with the threads at all, and that means #5 (major diameter between 0.1172" and 0.1240") will absolutely not engage the hole.</p><p>That leaves a #6 and a #8 for the most common sizes (I am not going to do a #7 or a #9 - they are too odd). With the ranges of a #6 between 0.1293" and 0.1369", it is on the "barely" side. That leaves only a #8 screw, with a max 0.1553" and 0.1629". Course threads would mean a #8-32 screw, or a #8 wood screw.<br /></p><p>Okay, screws identified! I had the upper screws for the plate made already in a previous post, so it's the same basic process. First, turn down just a little length for the smaller light screws (#8-32's), and use a die to cut the threads (yes, I could thread it on the lathe, but I don't want to have to re-tract, and line up, and this way I know I'm not bending a long slender part).</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjU_KvDBiAfJMOKSRmg48cXM81vfT-EU9z6VKm3EugGHajmAJHgfJ2US5V3pEv12tMO_0gWzyOyKhJzezZjO17QE3w_vqNsnlvzJCt14pxUtsOtRkV8_YRKXu90G6M4qllBYqtz2gR6evB1hloFr8vZbn82x5AdqfX2lzhNGI18zPAGcBz0lDMei2j7nTc/s4032/20230930_092604.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjU_KvDBiAfJMOKSRmg48cXM81vfT-EU9z6VKm3EugGHajmAJHgfJ2US5V3pEv12tMO_0gWzyOyKhJzezZjO17QE3w_vqNsnlvzJCt14pxUtsOtRkV8_YRKXu90G6M4qllBYqtz2gR6evB1hloFr8vZbn82x5AdqfX2lzhNGI18zPAGcBz0lDMei2j7nTc/s320/20230930_092604.jpg" width="320" /></a></div><p></p><p>At that point, i can turn down the next section of the screw, and the die keeps the thread perfect.</p><p>The final screws, the wood-screw-like, lower bolts that had the angled thread on the tip, was going to be fun. I did not want to try turning an additional, tapered thread on this point because the complexity was something I did not opt to choose, so I turned a pointed tip and then threaded anyway. Note that I am well aware that the quick change gearbox, set up for 20 thread per inch, is right on the money. I do not need to repeat this on these screws (I'd already validated on the previous ones), but I've found that marking up the part before turning gives me a good visualization of when I am deep enough to break out the threading die for 1/4"-20 to ensure a perfect thread.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj85TcImeM4Bf0k39zhDfEjNVEsYXqUXJhgr3OjCQawbWJFfOW3dojrsINwg0ANRDWdHr1m2gu3IC57ic0SSWuzzupZxv6iZoo0Jmn97oN3_kamgTsAzX2JlQvUahuBgKUtNyzr4ixiegI_pQ6gXB5XoDJiceSnteClWkt4aIVIrvEX8jOMNxIadkw3Hho/s4032/20230930_101451.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj85TcImeM4Bf0k39zhDfEjNVEsYXqUXJhgr3OjCQawbWJFfOW3dojrsINwg0ANRDWdHr1m2gu3IC57ic0SSWuzzupZxv6iZoo0Jmn97oN3_kamgTsAzX2JlQvUahuBgKUtNyzr4ixiegI_pQ6gXB5XoDJiceSnteClWkt4aIVIrvEX8jOMNxIadkw3Hho/s320/20230930_101451.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtvBr6lhj7tf4zG3BtRwuUlgMm_6Yu7qKkznQ5Ym2TByJlpiFSs9JfJC-QtcCYiggKLwHzfuUI5hx0-Y6gSxpIgNfDVUuQalNqZUu3G9FcyzvNTXSxEx6Nqe19u_COm7tGY51LUdQbXVx5QO1tDHhtNSHVfvGNLF7S7x0yVfljH2qew8gcBMsugpPnm1w/s4032/20230930_101900.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtvBr6lhj7tf4zG3BtRwuUlgMm_6Yu7qKkznQ5Ym2TByJlpiFSs9JfJC-QtcCYiggKLwHzfuUI5hx0-Y6gSxpIgNfDVUuQalNqZUu3G9FcyzvNTXSxEx6Nqe19u_COm7tGY51LUdQbXVx5QO1tDHhtNSHVfvGNLF7S7x0yVfljH2qew8gcBMsugpPnm1w/s320/20230930_101900.jpg" width="320" /></a></div><p>Now I have all six screws ready to go.</p><p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgh3StKstxkt-UvgSc_sdxiWrK9s9mQnmMw-CSxMs9BTu2LAm9-rkgki73goPwbkAIxEY93HIO5W-IT6GdrVBNfwZkgE936gpMntPkpbqek73lsGkk3Sr6Eu6AUty7gbffpF9XjU1PoqEnj-Np89Vx37W6rSnXpehtIIGmmW0IEsq-USZP7_QMWlOFM3ME/s4032/20230930_142036.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgh3StKstxkt-UvgSc_sdxiWrK9s9mQnmMw-CSxMs9BTu2LAm9-rkgki73goPwbkAIxEY93HIO5W-IT6GdrVBNfwZkgE936gpMntPkpbqek73lsGkk3Sr6Eu6AUty7gbffpF9XjU1PoqEnj-Np89Vx37W6rSnXpehtIIGmmW0IEsq-USZP7_QMWlOFM3ME/s320/20230930_142036.jpg" width="320" /></a></div><p></p><p>I just need to install the plate light, then the lower bracket (maybe I will have time in the next evening or two).<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-29084272722752520172023-09-27T14:00:00.004-07:002023-09-27T14:00:31.382-07:00Custom License Plate Screws<p>After finishing the rotary broach, and having a 5/32" broach ready to go (the size of hex for my other 1/4"-20 socket machine screws), I was ready to rumble on my machine screws.</p><p>I first tried to make it head first so I could punch the hex hole in it.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilg4mDTnaUDOB19obE2-K7iQZBV6nnW2lfJKXvntn9Yt49H8Le6eGjkYe3hyzD_aYoZP5sqEK3XA4GuhAEy39JOe889Ekx7i6Xkf_qT1aZYqJM1_GZCbhPuGPgLkZMewp0m_-BV0Hj2dDx0TLiunka5uao8sSjWbfI1dsV_VoDL9lg3izFs90M8cvZtAw/s4032/20230926_151459.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilg4mDTnaUDOB19obE2-K7iQZBV6nnW2lfJKXvntn9Yt49H8Le6eGjkYe3hyzD_aYoZP5sqEK3XA4GuhAEy39JOe889Ekx7i6Xkf_qT1aZYqJM1_GZCbhPuGPgLkZMewp0m_-BV0Hj2dDx0TLiunka5uao8sSjWbfI1dsV_VoDL9lg3izFs90M8cvZtAw/s320/20230926_151459.jpg" width="320" /></a></div><br />While this worked in getting the basic profile, getting the thread in there would have absolutely wasted brass material. Additionally, once threaded, and parted, I had a bad bolt - it didn't even seat into the washer, indicating that I had the angle completely off that I'd measured. I could not check the fit of the screw while in the part was still in the lathe. (The angle was measured as a 90-degree bevel. Apparently, even though I did my best, I did not get it proper.)<p></p><p>I did this twice before I realized I was wasting more material because I could not test it, and concentric surface on the other side was inconsequential.<br /></p><p>Third try is the charm. I used some aluminum and realized that all I need to do is get the angle less than the washer so that the upper edge would seat. I just wanted it close enough. Truth be told, it is nearly half way between 45 and 60 degrees, but since 60 degrees would have given me the outside seat, I went with that with the tool squared up.<br /></p><p>On my next try, I opted to reverse the construction - turn the outside diameter (0.600", then cut the 60-degree, large chamfer for the bottom of the head to the 1/4" diameter, then thread it on).<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNDPKya1oou58Ye7-l4OOoxLTePVzRW0QXrAzCDA-NB6MyQgXnq_YkaP28e30gEekNhskjvUV93gGk5yd5nvDbuYg-vi2dvdiO1xaKdrQ_XWyQvBc6Dcx9Ysl7heh3vKX1QDJ1x3rLu0Xc2HJKD1WfUJX2DZUWBXR51E678XZkT0O4osPO_18EhFLHbqA/s4032/20230927_124445.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNDPKya1oou58Ye7-l4OOoxLTePVzRW0QXrAzCDA-NB6MyQgXnq_YkaP28e30gEekNhskjvUV93gGk5yd5nvDbuYg-vi2dvdiO1xaKdrQ_XWyQvBc6Dcx9Ysl7heh3vKX1QDJ1x3rLu0Xc2HJKD1WfUJX2DZUWBXR51E678XZkT0O4osPO_18EhFLHbqA/s320/20230927_124445.jpg" width="320" /></a></div><p>Once that was ready, it was time to part it off.<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0wRj1dkLpSaNGSe69dMIIzb1RvEXDYpXVcRVweVcSp8Hxtv3qUbCfxNVBqHlJ8oliAN7zvtXy4PCMP_uUgmtlLAWclbtbP6OQN4Led0w3SIibu1VOrDODi9iZ_-ycCEhUOZrvBCyOxIo-lqirfSPLjbvJf6vyj1QthbL7ZMlyyDOEKgDYCbEwfTVdAEQ/s4032/20230927_130110.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0wRj1dkLpSaNGSe69dMIIzb1RvEXDYpXVcRVweVcSp8Hxtv3qUbCfxNVBqHlJ8oliAN7zvtXy4PCMP_uUgmtlLAWclbtbP6OQN4Led0w3SIibu1VOrDODi9iZ_-ycCEhUOZrvBCyOxIo-lqirfSPLjbvJf6vyj1QthbL7ZMlyyDOEKgDYCbEwfTVdAEQ/s320/20230927_130110.jpg" width="320" /></a></div><br />Now, I have two bolts, with no way to grip them yet. I used a chunk of 9/16 aluminum bar stock and drilled and tapped it to 1/4"-20. I then cut a number of slots into it so that I could chuck this little tiny bar into the lathe to get "close enough" on the concentric nature of these bolts.<p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhP9G0Qs8d8o_GYI-rt9f6IOKVXBwkE5Hlzk3QU-WEJaAG0uRwg1tv2A5c_y8NZNylWfHeEQ6Ig9kAyNQ3CnhyphenhyphengmGmsnOV23UqgKZiWcU7mCL-_1lfuFAXamGBNk-NeEsf4PQamUyy_dfxoPUSPvvsd4iMVfpu7H2AkTiLPAz7dzeIhGW7A0RntAzVhZnI/s4032/20230927_130344.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhP9G0Qs8d8o_GYI-rt9f6IOKVXBwkE5Hlzk3QU-WEJaAG0uRwg1tv2A5c_y8NZNylWfHeEQ6Ig9kAyNQ3CnhyphenhyphengmGmsnOV23UqgKZiWcU7mCL-_1lfuFAXamGBNk-NeEsf4PQamUyy_dfxoPUSPvvsd4iMVfpu7H2AkTiLPAz7dzeIhGW7A0RntAzVhZnI/s320/20230927_130344.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhb1DEXpQPohH_-xluJmFkgZathFpmk7YOMfd_Sd6PmlmsT586RmvaVJEfql7nc9rmUYeMt8PtuR4qqME1CZlsAfme0e19QynwErf84Aep3P-DDXtHwB51fVgGe8EFbck-ZDmtIpr5K_lGs6-DTgz9X2kjCejQ6ztUy-lwkPelnp0Pi7XMNax92dGp3iMM/s4032/20230927_130226.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhb1DEXpQPohH_-xluJmFkgZathFpmk7YOMfd_Sd6PmlmsT586RmvaVJEfql7nc9rmUYeMt8PtuR4qqME1CZlsAfme0e19QynwErf84Aep3P-DDXtHwB51fVgGe8EFbck-ZDmtIpr5K_lGs6-DTgz9X2kjCejQ6ztUy-lwkPelnp0Pi7XMNax92dGp3iMM/s320/20230927_130226.jpg" width="320" /></a></div><p></p><p>In the previous photos, I had not yet cut two other slots (not all the way through) on the chucking nut in order to properly grip the screws. Set in the chuck after the cuts, I proceeded to drill a 5/32" hole as a start, re-chamfer the entry point on the drill, then broach it through.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkMJL6HRCnm2joTNfuBTQI7Hu1msOpYFf0hRRciyoLyIQO4DkR3tPnew_0sFdPlXsKeeDOIGMCaadv4sYoRIg2qkwOn92XNs58RsfQJM8Hw6-6rLSTK60-o0VLPCKf8MpPDiW5X5_FVejkmSsZL2-QKwm8jW4KTWxYrWWWIqYxk5JTYIVd-Hz-qEwOkwo/s4032/20230927_132534.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkMJL6HRCnm2joTNfuBTQI7Hu1msOpYFf0hRRciyoLyIQO4DkR3tPnew_0sFdPlXsKeeDOIGMCaadv4sYoRIg2qkwOn92XNs58RsfQJM8Hw6-6rLSTK60-o0VLPCKf8MpPDiW5X5_FVejkmSsZL2-QKwm8jW4KTWxYrWWWIqYxk5JTYIVd-Hz-qEwOkwo/s320/20230927_132534.jpg" width="320" /></a></div><p></p><p>And that is now two license plate bolts complete. I need to fabricate the light bracket and install the lower plate before I can install these, but two more parts have been completed.<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-14266579492517910012023-09-09T15:30:00.003-07:002023-09-09T16:50:16.267-07:00Fancy Hex-Shaped Drill Bits<p> On one of my projects (the drafting kit), I had a beam compass that I needed to increase the radii on. I bought a rod to match what it had, and then promptly realized I needed to drill a hex-shaped hole lengthwise. Nearly any machinist who has been around for a while (I have to say nearly, because it took me a long time to find this out) will be familiar with tools to cut holes in shapes that are not round. These tools are called "rotary broaches", and they can get pricey (e.g. the bit itself comes in cheaply around <a href="https://www.polygonsolutions.com/rotary-broaches/hex-rotary-broaches/hexagon-rotary-broaches-half-inch-shank/" target="_blank">$61 from some random supplier</a> found on the ol' Internet).<br /></p><p>So, I found a <a href="https://www.hemingwaykits.com/HK2570" target="_blank">build-it-yourself rotary broach kit</a> and ordered it from Hemingway Kits. It uses a designation for "FCMS" (or something similar), which is essentially "cold rolled steel".<br /></p><p>The tools required for this are a milling machine (the Harbor Freight special will do), and a lathe, along with an M3x0.5 tap. <br /></p><p>First is to face, bore and turn the locking lug. Then thread it (the measured drawings have measurements in metric and imperial, so it was threaded at 52 TPI).</p><p>Once done, make the shank. It is essentially a part made on the lathe, but the mill is used to cut a flat groove 4mm wide for alignment.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjVLWOLc7TGQ7xB4sGkB1XmiPfVS1qJHGJ-PxWG9O37Rjj8A4GuYfFHln49MoaWJQCoUtw8Pc1GWANrQ67cIoBpcqGPOoecjhxHVdC9ck_eSZuVukcUMmvZnL5rEEhlufyQAgt6HA0aU2ThmCNzln0yfVPgf65Zfa-KI4bHUoyUlevhElWXvUI7owQovY/s4032/20230710_182240.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjVLWOLc7TGQ7xB4sGkB1XmiPfVS1qJHGJ-PxWG9O37Rjj8A4GuYfFHln49MoaWJQCoUtw8Pc1GWANrQ67cIoBpcqGPOoecjhxHVdC9ck_eSZuVukcUMmvZnL5rEEhlufyQAgt6HA0aU2ThmCNzln0yfVPgf65Zfa-KI4bHUoyUlevhElWXvUI7owQovY/s320/20230710_182240.jpg" width="320" /></a></div><br />Next comes the body - face it, bore it (different sizes to different depths, then turn the outside of it (this is exact). Once this is done, you will need to cut an internal thread to match your locking lug.<p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuMSA1dr1eh0cLUcLFDCJfsIu2wvmXdtSKiUoV5nVH0qLViSbNHBiRmgEcvkxiv467zw9pRU8AB31zABfkwRyrru7log8BD_zdTZBCbWSvqCLACcbBbIuE2LIgD380oq9jbqG5lw3dQ1T8M5pkv5S13HjPprZzq_zXELudDnORuo8LDJXDkplO5fNRUHs/s4032/20230708_163819.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuMSA1dr1eh0cLUcLFDCJfsIu2wvmXdtSKiUoV5nVH0qLViSbNHBiRmgEcvkxiv467zw9pRU8AB31zABfkwRyrru7log8BD_zdTZBCbWSvqCLACcbBbIuE2LIgD380oq9jbqG5lw3dQ1T8M5pkv5S13HjPprZzq_zXELudDnORuo8LDJXDkplO5fNRUHs/s320/20230708_163819.jpg" width="240" /></a></div><p></p><p>This comes after the lug itself because you want a good, secure fit, and the locking lug can be used to ensure you don't cut threads too deeply on the inside. In other words, you will fit this to your lug. Once done, the part is parted (no pun intended) off, and taken to the milling machine where it is set up at a 1-degree angle. I used a collet block to hold it, so I set a 0.017" lift 1" from one side to give me exactly a 1-degree angle.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiA50aaT3LjILH6uvF5fqUXvSz7N1v4qn5D5mmRjkMsr31kLFYql98ZWcGwXXI-eyCKkQ092g-jG1J8mUpJmh4LU3ibEBwhuR0itiXBU3d43nM-pPX3BOy5K4hBkCtnic932hldzRoM9n8Q6RGBivBrOrcynexHYVtP3bfhvSZvXmIWCEBs3zBj5Ka0FHI/s4032/20230711_084934.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiA50aaT3LjILH6uvF5fqUXvSz7N1v4qn5D5mmRjkMsr31kLFYql98ZWcGwXXI-eyCKkQ092g-jG1J8mUpJmh4LU3ibEBwhuR0itiXBU3d43nM-pPX3BOy5K4hBkCtnic932hldzRoM9n8Q6RGBivBrOrcynexHYVtP3bfhvSZvXmIWCEBs3zBj5Ka0FHI/s320/20230711_084934.jpg" width="320" /></a></div><br />Then the back (parted area) is milled flat there, and then a boss is completed flat along that angle to match the groove in the shank. You have to drill the two holes to bolt the shank and the body together, and then you can tap those holes. I milled small flats on the sides on opposite ends using the boss as a horizontal index. Those two flats allowed me to get a solid grip on the body when threading. Hint - use tapping fluid with an M3 tap. It makes it much easier.<br /><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_UVDSqmZ_0DgGSo6X_DsLyAiXZdYYzArmuZy54jllYyoFmQLsoT6fUYHnj34_UC4FMhxCn5Qy_Y7hF3JGiSjV0MzfSnksxBXecrSVVNwk6jq5MXbl9FA2Y5LdfbbBq0mL2Gis3js5Pu88lRaGCQLQJemCc9a_A97MSTTjG8xMOON-Dy4qWEEaMmBoqGI/s4032/20230717_073746.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_UVDSqmZ_0DgGSo6X_DsLyAiXZdYYzArmuZy54jllYyoFmQLsoT6fUYHnj34_UC4FMhxCn5Qy_Y7hF3JGiSjV0MzfSnksxBXecrSVVNwk6jq5MXbl9FA2Y5LdfbbBq0mL2Gis3js5Pu88lRaGCQLQJemCc9a_A97MSTTjG8xMOON-Dy4qWEEaMmBoqGI/s320/20230717_073746.jpg" width="240" /></a></div><p></p><p>You might notice the appearance of the aluminum bar with pins and a hole - I quickly realized in a previous step (when fitting the locking lug to the body) that I needed a spanner wrench to match, so I whipped one up. <br /></p><p>The next part required is the broach's "spindle". This is the part that actually holds the rotary broach itself. Following the specs, I slapped it together. Now, I know I am supposed to wait until I have an actual broach, because angles and math, but I wanted this complete. Here is the parts, followed by assembly.<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEsxHYw1e-6sBQxmvHUW5TSpT2Alj3P7tsnZkKy64sNLX-zIS8fQIpDWcFOOBPG4kA8PhRkJ6WVnl3OJzbE0HrAaHcsxrUlAsVnq2-IOrva67Bbs7H21CrZ5WqXyellvsAjFfBAaKkMiq3wH_C3q8okZdqkXM-xkLqBKsE1NQWfX8pqB12PS8swwddNEA/s4032/20230824_165117.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEsxHYw1e-6sBQxmvHUW5TSpT2Alj3P7tsnZkKy64sNLX-zIS8fQIpDWcFOOBPG4kA8PhRkJ6WVnl3OJzbE0HrAaHcsxrUlAsVnq2-IOrva67Bbs7H21CrZ5WqXyellvsAjFfBAaKkMiq3wH_C3q8okZdqkXM-xkLqBKsE1NQWfX8pqB12PS8swwddNEA/s320/20230824_165117.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioZ8EKLQ8gpWoBO5TuoMBXvy_sBbFdcIxL07r6fs9Hc_gAkdhwHMyzJpcjRqNRONI6-vKkN0Mlod-pT6z-_-rg2DRqGc1km8BvQknrDOL6xaEyEtZXQ1UqnbRr_kPfMfr_r_ULCUK7WhVuAVya1jh5Cx2kMx7yJa1PY3m0n6VO1zN_VIKZgLVRUPmiAMg/s4032/20230825_100620.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioZ8EKLQ8gpWoBO5TuoMBXvy_sBbFdcIxL07r6fs9Hc_gAkdhwHMyzJpcjRqNRONI6-vKkN0Mlod-pT6z-_-rg2DRqGc1km8BvQknrDOL6xaEyEtZXQ1UqnbRr_kPfMfr_r_ULCUK7WhVuAVya1jh5Cx2kMx7yJa1PY3m0n6VO1zN_VIKZgLVRUPmiAMg/s320/20230825_100620.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdbebYU_OgUBk-OiupzrBjjmLyzeMK8TfkHVROD2RqMgcjwbw3AHcy3zVwKfC8K8RsZRxydCYB_a3Op9MTCsre5OC5CpH1vtlGfsHLamb_HikNl3kI2TTLWrObajPNRMu_6Cm6nID8NATzHups7gBKe0tBWVYtaVSZ4tAYvE_uFptSpFprRnkWn1AU-Rs/s4032/20230825_101038.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdbebYU_OgUBk-OiupzrBjjmLyzeMK8TfkHVROD2RqMgcjwbw3AHcy3zVwKfC8K8RsZRxydCYB_a3Op9MTCsre5OC5CpH1vtlGfsHLamb_HikNl3kI2TTLWrObajPNRMu_6Cm6nID8NATzHups7gBKe0tBWVYtaVSZ4tAYvE_uFptSpFprRnkWn1AU-Rs/s320/20230825_101038.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuC5M9_eLgRLCGgx3nRedOofO20SUng9n2_5jQOdc83hgootForKOQ2CRzoIKQpTsDCTPOG3Y_u94m7aHKE3T3yPaGCMLcNpfRqfT7FF17kKr92SgiozIZTEbNcY4_bq1X1dj4kCvenw-znAFTEDqQ5ztbVl4kufbBRt83f1RwvMpYvfDepuL9bHCFrmg/s4032/20230825_112735.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuC5M9_eLgRLCGgx3nRedOofO20SUng9n2_5jQOdc83hgootForKOQ2CRzoIKQpTsDCTPOG3Y_u94m7aHKE3T3yPaGCMLcNpfRqfT7FF17kKr92SgiozIZTEbNcY4_bq1X1dj4kCvenw-znAFTEDqQ5ztbVl4kufbBRt83f1RwvMpYvfDepuL9bHCFrmg/s320/20230825_112735.jpg" width="240" /></a></div><p></p><p>After the spindle, I measured, and re-did the math for how long broaches are going to be based on the angles of everything. After recalculations (and making tools along the way to measure how far I am when I am really close to the lathe spindle), I whipped a broach up. Quite fun using a hex collet block in the mill at an angle. It was a bit sketchy - it was a tool makers vise, in a tilting vise. But, once I got the feel for taking cuts, it went pretty quickly. This is a 5/32" for what I assume to be a 1/4"-20 drive.<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtsvcCqqiC78emlT-b3mtu01aOogE4xkSeNLv88TzVbtWso3zrlcymSmesJqba_YkoQsbiUuc8H2MXDHGxcDa223EieB2xG-qSBBXSwaKLIsdh7Ynxj5EVWolzHBZH1MM-cE5mpTNsn8iDcpY9os4VLKwtdBV_cO50WstNCYurI5d1SFlB4zplEHXpvJw/s4032/20230909_153755.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtsvcCqqiC78emlT-b3mtu01aOogE4xkSeNLv88TzVbtWso3zrlcymSmesJqba_YkoQsbiUuc8H2MXDHGxcDa223EieB2xG-qSBBXSwaKLIsdh7Ynxj5EVWolzHBZH1MM-cE5mpTNsn8iDcpY9os4VLKwtdBV_cO50WstNCYurI5d1SFlB4zplEHXpvJw/s320/20230909_153755.jpg" width="320" /></a></div><p></p><p>Once shaped, I needed a slight cone. Most people seem to use a Dremel to grind, but I opted to chuck in a small hollowing wood carbide holder because of it's diameter, and then just used it like a normal tool in the South Bend.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXNzmIqFy-gFBtdy0mfCYiEK8l1UVdruAgDrFy964y_j7-OWXH1o9IN-1kfNEkShe36AoeHvnia3LwqI0JyB2B_pYC9xy0kpHduwIBQGkMVtotlXBChAdFAztvBH5HVN58o5icgofK442870C60wfGtChm0hQXbAFVMPK2d6TaLf_MViqAavfOCni70pA/s4032/20230909_154810.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXNzmIqFy-gFBtdy0mfCYiEK8l1UVdruAgDrFy964y_j7-OWXH1o9IN-1kfNEkShe36AoeHvnia3LwqI0JyB2B_pYC9xy0kpHduwIBQGkMVtotlXBChAdFAztvBH5HVN58o5icgofK442870C60wfGtChm0hQXbAFVMPK2d6TaLf_MViqAavfOCni70pA/s320/20230909_154810.jpg" width="320" /></a></div><p></p><p>With that, all I need to do is harden the broach and then I can start making car parts again! I grabbed some brick and a torch, and a jar filled with ice water, and heated it up to red hot (actually, orange hot). Then just a quick dunk, agitating (shaking it to prevent steam from creating too much of a barrier) it the whole time until it is cool to the touch.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZU5KCuxPsfTeiKkfUeMDxXtIG-XY04C19zw0c9djjl_O0eVl1OiLy3Os5iuxppfKyajwdc9dhmn-_n8Wmh7JF-UDLW_Pq8XBEn56F5mATtM0TiJ-zeu5IUL_Q6wHHGlJGNrasAuoBkuJ2Q4Iu4e_in6UUTC9fTdOEzZVOk7WOBRwPyluIB1hZZGVPSOg/s4032/20230909_174123.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZU5KCuxPsfTeiKkfUeMDxXtIG-XY04C19zw0c9djjl_O0eVl1OiLy3Os5iuxppfKyajwdc9dhmn-_n8Wmh7JF-UDLW_Pq8XBEn56F5mATtM0TiJ-zeu5IUL_Q6wHHGlJGNrasAuoBkuJ2Q4Iu4e_in6UUTC9fTdOEzZVOk7WOBRwPyluIB1hZZGVPSOg/s320/20230909_174123.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEpj3ibbKaxjHOtKFbp5QSR1wyF5EKNJ9Adrvjz70H_u98IE6uhP2cwcXdW4w_IkFS3qVLX1e5Zh3R5sBte9eOoE6gNfT-G_FdqjDI6vK-6Ek95qpiIRCvJQo-_4Gkzoo_cBCpqo1u0qlTR0kyUv84KOxAMl9aC5UdWhr1UE1xesSX-7cdGskLqEpiys0/s4032/20230909_174134.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEpj3ibbKaxjHOtKFbp5QSR1wyF5EKNJ9Adrvjz70H_u98IE6uhP2cwcXdW4w_IkFS3qVLX1e5Zh3R5sBte9eOoE6gNfT-G_FdqjDI6vK-6Ek95qpiIRCvJQo-_4Gkzoo_cBCpqo1u0qlTR0kyUv84KOxAMl9aC5UdWhr1UE1xesSX-7cdGskLqEpiys0/s320/20230909_174134.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnT6b7XTDlZ5kEy7tHTH5hTbIr9UMs17On7QV5lY26uyN88ddJ93RNMiL9ER9ZcEkNtn9fiSSTgXQGJkla4aXUtiW6veYX8v20uza8ncU-hvKs1rZBGqbxsCzFG8HKxzJAlHh8KTMGKfCFXARxsXUdx9yoyA3oR-T4Rsl9TP_Zgzmj4UaiJgISWgDdIJY/s4032/20230909_174320.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnT6b7XTDlZ5kEy7tHTH5hTbIr9UMs17On7QV5lY26uyN88ddJ93RNMiL9ER9ZcEkNtn9fiSSTgXQGJkla4aXUtiW6veYX8v20uza8ncU-hvKs1rZBGqbxsCzFG8HKxzJAlHh8KTMGKfCFXARxsXUdx9yoyA3oR-T4Rsl9TP_Zgzmj4UaiJgISWgDdIJY/s320/20230909_174320.jpg" width="320" /></a></div><p></p><p>I scraped it against some aluminum, and it definitely scored it. This thing is, in theory, ready to rumble. I will to a test cut just to make sure this is going to work before I proceed, but this tool is DONE!<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-74920779701281125452023-09-09T13:00:00.002-07:002023-09-09T15:18:55.962-07:00Dial Indicator Adapters for the South Bend<p>I've been working on a rotary broach kit from Hemingway. As I started the phase of making the first broach, I encountered a bit of a problem. The collet set I'm using requires me to get fairly close to the headstock, and the micrometer doesn't actually fit in the space I have to subsist in.</p><p>I need a new way to measure.</p><p>I grabbed some cut-off chunks (and "scrap parts") I had laying around and built two of them. One of them connects to the V-ways like we normally see, but the other one uses two 1/4"-20 holes right above the gear box. This would allow me to offset a dial indicator much farther away. I had a gits oiler right there, so I needed to mill around it.<br /></p><p>First was getting the parts to square. Then, machining out a slope and the v on the moveable indicator holder. I then drilled and tapped 1/4"-20 holes in two directions for the dial indicators (specifically so I could orient the dial indicators as either facing upward or facing outward), and cut grooves so that the indicators can nestle down in and be secure. At that point, I drilled (and counter bored) a 3/8"-16 through hole in the middle, and machined the bottom clamping jaw out of a scrap bin part.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcXlccrNJ7nVSEP_8Pia3NpFP8vy3ekTgHr_S4Jb1c1Zp2n4ScmbzolZPa1GrdSUeL58DMSyPhduL7rzFA5HHrHWfA_BZiDcO1rV_tVk7aLR3Dp_fxMGVLcID-H0qM-Z_s6cMW-giAkAjOKDCGhlZeo8nR4Xdh76wkfraJ2ejhJolVWJ2JFzrzbcUEgII/s4032/20230909_125632.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcXlccrNJ7nVSEP_8Pia3NpFP8vy3ekTgHr_S4Jb1c1Zp2n4ScmbzolZPa1GrdSUeL58DMSyPhduL7rzFA5HHrHWfA_BZiDcO1rV_tVk7aLR3Dp_fxMGVLcID-H0qM-Z_s6cMW-giAkAjOKDCGhlZeo8nR4Xdh76wkfraJ2ejhJolVWJ2JFzrzbcUEgII/s320/20230909_125632.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLpGFpBwVSaK9hFgyn6aVJLHxCj4wLUNqkrJZMNCFoUgy6Pse6QHopVcH6-t4_uX90t0gZujG0L-esXoXOOiaN9cuCwdpcyi_7HIbPyKvQ-X97vbHdCYNBVZH6OIXXjoJZej9wK08krFPp-lkFhazGjrdMLRrO_UAAhqU-p0V4LglIMRxX1Ei9kK8Rwo8/s4032/20230909_125713.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLpGFpBwVSaK9hFgyn6aVJLHxCj4wLUNqkrJZMNCFoUgy6Pse6QHopVcH6-t4_uX90t0gZujG0L-esXoXOOiaN9cuCwdpcyi_7HIbPyKvQ-X97vbHdCYNBVZH6OIXXjoJZej9wK08krFPp-lkFhazGjrdMLRrO_UAAhqU-p0V4LglIMRxX1Ei9kK8Rwo8/s320/20230909_125713.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvgZYLn612GuYzVnE9RRKHkNMLmfZf8SUBWatkLdHrz5IQ63LLn0zFZBJbMBTtyrJi5jzmv7jjAboJu8WtIEb-EsZbwi8DUVFoo4vf9ZFl95c6hjaeZw0y-udq7c6ML81-uju-NFNI2iD-exKhnXk0_Z4lBIWQYOQFMJU3XdnemTkD7CyzoJB_5OAEoiM/s4032/20230909_125747.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvgZYLn612GuYzVnE9RRKHkNMLmfZf8SUBWatkLdHrz5IQ63LLn0zFZBJbMBTtyrJi5jzmv7jjAboJu8WtIEb-EsZbwi8DUVFoo4vf9ZFl95c6hjaeZw0y-udq7c6ML81-uju-NFNI2iD-exKhnXk0_Z4lBIWQYOQFMJU3XdnemTkD7CyzoJB_5OAEoiM/s320/20230909_125747.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8yGo5fXEnKYefmlCXr4MOviCqoN3dVEoUe-wZ7q08ccps0I63GnBJIz95UrOkeOp-3MFuJu-kla8ZtrMVXlaNfv92OSNc6pUi5d0FMqMES6_k5cidCHx6elMceEG_kWmScrfbYCBc5OqP7lcY-uUxsCY2_j2CCQC8dNLCTQfXCj0IPQjO61vlDX6cMHw/s4032/20230909_125822.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8yGo5fXEnKYefmlCXr4MOviCqoN3dVEoUe-wZ7q08ccps0I63GnBJIz95UrOkeOp-3MFuJu-kla8ZtrMVXlaNfv92OSNc6pUi5d0FMqMES6_k5cidCHx6elMceEG_kWmScrfbYCBc5OqP7lcY-uUxsCY2_j2CCQC8dNLCTQfXCj0IPQjO61vlDX6cMHw/s320/20230909_125822.jpg" width="240" /></a></div><p></p><p>Once that one was complete, I ran a cut-off block through the mill to square it up as well as notch for the gits, and used transfer screws to set the drill points for this new block. I did have to make a few tweaks, but I also drilled and tapped two 1/4"-20 holes to hold the dial indicator. This dial indicator was only going to face upward. Here they are without the indicators attached.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguyQ8Z_PbtU6BEa_6DzwkXkKicKWJgXeXMdjxa_s_a9qhUg5U_53lCCzSwlxTRnNy9nDn47-F8P9fITZj7xJ-y9uiJ3-_7KSkpKRSTjsd8AKnuEpWzuutXgj1ObXXnZYWPVzIn0mN98jSAFWLwWiHaf4nPDQboSehXtzBhEKT98vFjdSfpNemqc6JzVfw/s4032/20230909_130129.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguyQ8Z_PbtU6BEa_6DzwkXkKicKWJgXeXMdjxa_s_a9qhUg5U_53lCCzSwlxTRnNy9nDn47-F8P9fITZj7xJ-y9uiJ3-_7KSkpKRSTjsd8AKnuEpWzuutXgj1ObXXnZYWPVzIn0mN98jSAFWLwWiHaf4nPDQboSehXtzBhEKT98vFjdSfpNemqc6JzVfw/s320/20230909_130129.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMeKtdW9NTBL-v_gyoPj9hJhrewjr2agYOfl8t2BIbm1irwrmXuzDg93R4UCAKsGsAdUvdNhzXcZAI5OV9KeOHf8w_LTcP1s5u8Yv6C8m1wO0Og50Mz93jqRZ4Dio8hWj0NsBySze71M4ADxsY-jRGqa2T3vwvvLT9Blzd56mOKqWjKvbv3WHOhCeF-QI/s4032/20230909_130135.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMeKtdW9NTBL-v_gyoPj9hJhrewjr2agYOfl8t2BIbm1irwrmXuzDg93R4UCAKsGsAdUvdNhzXcZAI5OV9KeOHf8w_LTcP1s5u8Yv6C8m1wO0Og50Mz93jqRZ4Dio8hWj0NsBySze71M4ADxsY-jRGqa2T3vwvvLT9Blzd56mOKqWjKvbv3WHOhCeF-QI/s320/20230909_130135.jpg" width="320" /></a></div><p></p><p>Here they are with dial indicators on them.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnr-lytOV0wsMBBoh13NJw3Cx9C7bwzWzG2SMmcX1qJOw0NShIpq7u-w-3QU70VZweNRMRC3CBVTcEubBqvzUHKnh6v-ozNwBIOIJL2d5dH2y2RqVDgcZ0uU_ym9a3OWzOc8lvJMeAC_VGzeVEMokBDuujH_aZn3vMpq0s0rqFriv0R7IH8Yn2xfMzSG0/s4032/20230909_130242.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnr-lytOV0wsMBBoh13NJw3Cx9C7bwzWzG2SMmcX1qJOw0NShIpq7u-w-3QU70VZweNRMRC3CBVTcEubBqvzUHKnh6v-ozNwBIOIJL2d5dH2y2RqVDgcZ0uU_ym9a3OWzOc8lvJMeAC_VGzeVEMokBDuujH_aZn3vMpq0s0rqFriv0R7IH8Yn2xfMzSG0/s320/20230909_130242.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbqfunj9PEef1v94qqwwmNCv3UhHeYXI9-UeMb4eLN2rDGeZRxCUd_YQPxYvLmqFEaNZcC_dzrGb-1sXqLnEqoGp3rpsGcHRjJrJK27u0RODkNchswiAp5P4keF9fvf3DPsM0yria5nZQLykssXOsTjdg1Pjd1-LicbYYZwPkVfOT-xvZQDNcVjNBHHQo/s4032/20230909_130246.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbqfunj9PEef1v94qqwwmNCv3UhHeYXI9-UeMb4eLN2rDGeZRxCUd_YQPxYvLmqFEaNZcC_dzrGb-1sXqLnEqoGp3rpsGcHRjJrJK27u0RODkNchswiAp5P4keF9fvf3DPsM0yria5nZQLykssXOsTjdg1Pjd1-LicbYYZwPkVfOT-xvZQDNcVjNBHHQo/s320/20230909_130246.jpg" width="320" /></a></div><p></p><p>These will be absolutely sufficient for my next steps on the broach - cutting the broaches to exact length. Here is the micrometer attachment, showing the length (which is how much it obstructed the carriage movement).</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEia6suKN5X796CzIP-qntjuzMU12LU3gct01XSIPShLZst0Yf0iaGY3JzSx-XJSP9zm0VUTogzYJGofknvriLIAnqK3Y9KSpUg5Gxn7zaYJ8BAKo_vZHMsNhAch5pfrq0QPBL30zug5J_korzrcp9_NWxexREr8WWF3aPZdCUlmJu--sO0tyWmuoQyFYCw/s4032/20230909_161111.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEia6suKN5X796CzIP-qntjuzMU12LU3gct01XSIPShLZst0Yf0iaGY3JzSx-XJSP9zm0VUTogzYJGofknvriLIAnqK3Y9KSpUg5Gxn7zaYJ8BAKo_vZHMsNhAch5pfrq0QPBL30zug5J_korzrcp9_NWxexREr8WWF3aPZdCUlmJu--sO0tyWmuoQyFYCw/s320/20230909_161111.jpg" width="320" /></a></div><p>This is a win, and allowed me to continue on the broach project.<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-85734117024896379362023-08-13T19:26:00.002-07:002023-08-14T18:55:41.365-07:00Why We Machine<p> I was attempting to get the license plate installed, and realized that the paint shop didn't get the bumper cover in the right place. There was a full 5/8" between the cover and the brace that the plates attach to, and I honestly think the paint shop lost a part that was there to make up the difference. Alas, it didn't matter, and I could not find official parts that would fit.</p><p>While the average mechanic would slap a bunch of washers in there (a farm boy would grab the duct tape and bailing wire), I didn't want things to come loose and fall off if the plates were ever changed. Plus, the holes for bracket were at the wrong places, so, it was time to make a bracket.</p><p>I grabbed some 3/8" aluminum bar stock, and some 1/8" think bar stock. On one side, I measured 0.680" (less, of course, the thickness of the bumper cover, bringing that one down to 0.610"), and the other side was 0.645, bringing that measurement down to 0.575"), so with the 1/2" of bar stock (and mill scale), I had to make up the difference in shim stock because I didn't want to break out the mill.</p><p>With the 3/8" bar stock, I drilled a 1/4" hole to match the thread, and then needed a 1/4"-20 transfer screw for the other side - <i>which I didn't have</i> [sigh]. But, I <b>did</b> have a 1/4"-20 threaded rod. I chucked it up in a collet, put a 120 degree chamfer on one end and parted it off, and used an angle grinder (precision!) to put a gap on each side. This gave me a makeshift transfer screw that only needed to be used once.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDVHZf4pnfSHXEvusGAA1PIa2Oh6BBcP57WvASNRBahxCkGRNBALBC3-mE4gciaGKDyqsb0NhvNwgkrsROmfA46012GnBHa4WrYffA02nHxysfRjNe9Hbz-nX6n1PVG_KDZcT8-VWw-nEcsZsyWvs4mwu16717Vo3sQAfy0oGPI3XOu0SrQsK_jq_n2Bw/s4032/20230813_200806.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDVHZf4pnfSHXEvusGAA1PIa2Oh6BBcP57WvASNRBahxCkGRNBALBC3-mE4gciaGKDyqsb0NhvNwgkrsROmfA46012GnBHa4WrYffA02nHxysfRjNe9Hbz-nX6n1PVG_KDZcT8-VWw-nEcsZsyWvs4mwu16717Vo3sQAfy0oGPI3XOu0SrQsK_jq_n2Bw/s320/20230813_200806.jpg" width="320" /></a></div><p></p><p>I threaded it in with my long, narrow needle-nosed pliers, threaded the other end of the block, and gave it a whack. Then I could drill out to cover that bolt. That longer, 3/8" bar stock could then get installed temporarily while figuring out the license plate position, and marking those holes.</p><p>Once those were laid out, I used two pieces of the 1/8" bar stock and marked through holes and put in #6-32 holes to lock those pieces together, and then simply made brass shims to make up the difference in depth (0.070" on one end, and 0.110" on the other), and then locked the shims, 3/8" bar stock, and 1/8" bar stock into one longer piece. The machinist in me cried that I didn't break out my mill to get a good finish and get the whole thing within +/-0.002", while the mechanic in me kept complaining that shooting for +/- 0.010" was too much accuracy. Turns out, I hit -0.003" and that was satisfactory, even if the finish wasn't satisfactory.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCSEaSyr95VSlLnpkbh8IY0xYDADcf1Vxz-gcCLc3JFP4JhsSufc_M9uONus2iUGYVRjM1Vsc95nHA3DSD0j0zdy0q4W-dWuF0AM2eozp9aqSJfYtRiXwBm8-eHFyylUAupwNcUbeViYV0s5EijnFbebCec903ZEBvuBG8VXEFKARi_J2wzaauVa63ous/s4032/20230814_193929.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCSEaSyr95VSlLnpkbh8IY0xYDADcf1Vxz-gcCLc3JFP4JhsSufc_M9uONus2iUGYVRjM1Vsc95nHA3DSD0j0zdy0q4W-dWuF0AM2eozp9aqSJfYtRiXwBm8-eHFyylUAupwNcUbeViYV0s5EijnFbebCec903ZEBvuBG8VXEFKARi_J2wzaauVa63ous/s320/20230814_193929.jpg" width="240" /></a></div><p></p><p>A quick install, and the plate is ready, save the bottom bracket (still waiting on real, reproduction parts).<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRj_kAEQ_1dbROZj2qXleJrzoAeWUS8wfSqYkQv9K8ua-F1KGoE7SCl22iJC6Z2oTW3_o2FzTDKKsTaAVpyqjoIS91Xs-wOcFnJfOfHOCCn0Dh_fbd_z6xjAyabzi7CbVbgcbUOvCO5mOyzxuVQSbVYhaR_ezza2yWvVzeN39KhU-uJTyGzRnTmfr_oow/s4032/20230812_203209.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRj_kAEQ_1dbROZj2qXleJrzoAeWUS8wfSqYkQv9K8ua-F1KGoE7SCl22iJC6Z2oTW3_o2FzTDKKsTaAVpyqjoIS91Xs-wOcFnJfOfHOCCn0Dh_fbd_z6xjAyabzi7CbVbgcbUOvCO5mOyzxuVQSbVYhaR_ezza2yWvVzeN39KhU-uJTyGzRnTmfr_oow/s320/20230812_203209.jpg" width="240" /></a></div><p></p>Viola! I had the plate installed, for the first time in 18 years! And all because I had the tools to make tools to make a brace that I could not find! I am wondering if I need to go with brass socket head screws and a brass frame to bring out that gold metallic paint.<br />Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-69617359497084173162023-07-17T13:46:00.001-07:002023-07-17T13:46:07.089-07:00Acrylic Boxes<p> I had some boxes I needed made. Knowing I had a laser cutter, I did a fast google search and found <a href="https://en.makercase.com/#/">MakerCase</a> (see note in a few paragraphs in italics). I quickly downloaded a custom-sized box with box joints, and slapped it through the paces. It couldn't cut deep enough, and repeated attempts failed to stay lined up.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR8QMJB02fxbijw1BSrky5B7KPuLph8wrZNBHzZubxl-sVikavcDzsaMfdjXgFTRaP72uOBATqf0QknfZrDYivVkLadUW6_uUF1LcVtTlDb1zZrde8tDUk2Zl3sws4SZ8PIYEBVEUEHPDEIwTcIScS5k1I2JTvwMAn0SqyQ_tLDqhcSldDshoJu76Z3A8/s4032/20230701_151742.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR8QMJB02fxbijw1BSrky5B7KPuLph8wrZNBHzZubxl-sVikavcDzsaMfdjXgFTRaP72uOBATqf0QknfZrDYivVkLadUW6_uUF1LcVtTlDb1zZrde8tDUk2Zl3sws4SZ8PIYEBVEUEHPDEIwTcIScS5k1I2JTvwMAn0SqyQ_tLDqhcSldDshoJu76Z3A8/s320/20230701_151742.jpg" width="320" /></a></div><br /> I then realized that a $50 sheet of acrylic was a pittance less than a package from <a href="https://sendcutsend.com/" target="_blank">SendCutSend</a> in acrylic. So, off the DWG's were sent, and processing/mailing times were waited.<p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirQNB5BuR8QhvtwQF1Wez_MVVG-HiDMNR8gr1E1Y9TnVG6Qkezw1SkqXZqQKGJMuY0cTyArzyMqciFQwCscGT3aqoUkYSx5_CZz770k0zNASZZoDv38_E_x2CViGgpCdmPvXtLs8ho83QiZ96ay5Ybip8Ff6HQAuxcEbUeFDCaWuH9RVQummGUdSHtKu0/s4032/20230711_214055.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirQNB5BuR8QhvtwQF1Wez_MVVG-HiDMNR8gr1E1Y9TnVG6Qkezw1SkqXZqQKGJMuY0cTyArzyMqciFQwCscGT3aqoUkYSx5_CZz770k0zNASZZoDv38_E_x2CViGgpCdmPvXtLs8ho83QiZ96ay5Ybip8Ff6HQAuxcEbUeFDCaWuH9RVQummGUdSHtKu0/s320/20230711_214055.jpg" width="240" /></a></div><p></p><p><b><i>Apparently, the MakerCase file is on the outside of the cut line. This
means that the box joint cuts will have a minimal overlap. </i></b> I corrected
this using a file on the joints to fit it, so make sure you fit it up
BEFORE you glue it.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIAxMyun0XBpHB33yotZCp07vFno-rGpbY671Fb_jaOg5GaR_Qi7uG2Q3-Lv2fAwu6gYT6zbj_2oy794GLlWcTu8BGxYPboopTkYVwguNfPy_C4CFf1KGLJmCp-ej4TzcVWjDK1qoD5i50YYHPSn7S1uEXNrWBl5EbQaOIEn8826M_Vi3mt_Y79_62bwk/s622/20230711_2140505-anotated.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="451" data-original-width="622" height="232" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIAxMyun0XBpHB33yotZCp07vFno-rGpbY671Fb_jaOg5GaR_Qi7uG2Q3-Lv2fAwu6gYT6zbj_2oy794GLlWcTu8BGxYPboopTkYVwguNfPy_C4CFf1KGLJmCp-ej4TzcVWjDK1qoD5i50YYHPSn7S1uEXNrWBl5EbQaOIEn8826M_Vi3mt_Y79_62bwk/s320/20230711_2140505-anotated.jpg" width="320" /></a></div><p></p><p>I tried to purchase a thin acrylic adhesive, but that got lost in the mail somewhere, so I ended up using e6000 cement from a local hardware supply chain.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7Vr_oXtvvUHEDe7xJvtgp58XjXY1JZSP6sdn13XoKPf_0KSQYIeAMQn8Zg6_NGeZGnBHOrBM3Wq8UT-NzX6BSG6b3RpjzvHiucDn_ElGb9sPZAP-aou3urbvRHGVKZXTFU7uvf2s_dO2J1dJ1wez_hcsF8exXb5wzZMz_33r2Z6Wz8C9JszYD8CCl93A/s4032/20230713_082629.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7Vr_oXtvvUHEDe7xJvtgp58XjXY1JZSP6sdn13XoKPf_0KSQYIeAMQn8Zg6_NGeZGnBHOrBM3Wq8UT-NzX6BSG6b3RpjzvHiucDn_ElGb9sPZAP-aou3urbvRHGVKZXTFU7uvf2s_dO2J1dJ1wez_hcsF8exXb5wzZMz_33r2Z6Wz8C9JszYD8CCl93A/s320/20230713_082629.jpg" width="320" /></a></div><p></p><p>This cement is terrible - it immediately starts to congeal, so be aware that long cuts (like I had on my box) will start setting up before to finish applying the cement. It is also very stringy - so it will be messy.</p><p></p><p>It should be noted that it is still a workable option for fast prototyping, or for custom one-off boxes.<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-87602134796019789992023-07-17T12:59:00.004-07:002023-07-17T13:27:27.124-07:00The Puck Stops Here - Hockey Pens from Penn State Ind<p>I have some family members who are very much hockey nuts. My sister is a rabid fan for the Minnesota Wild - and a while back I found out that Penn State Industries manufactured a <a href="https://www.pennstateind.com/mm5/merchant.mvc?Screen=SEARCH&q=hockey" target="_blank">hockey pen turning kit</a>. I had to make some - so I bought <a href="https://www.pennstateind.com/store/PKHOCKSS.html" target="_blank">the three-pack</a> (a chrome, gold, and gunmetal). The gold went to a St. Louis Blues color scheme (blue and gold), I made an Edmonton Oilers' (Royal Navy and Orange) (#041E42 blue and #FF4C00 orange) using the gunmetal, and the chrome went to Minnesota.</p><p>Considering that I couldn't find good pen blanks for Minnesota colors, or Edmonton's, I had to use a pen blank mold kit and resins.</p><ul style="text-align: left;"><li>For Edmonton, I used the "<a href="https://www.amazon.com/gp/product/B09XN7XXVT/" target="_blank">AOI HI BLUE</a>" and "<a href="https://www.amazon.com/gp/product/B08726X3QY/" target="_blank">TIGER</a>" mica powders, the "Eye Candy" brand.</li><li>For St. Louis, the same "<a href="https://www.amazon.com/gp/product/B09XN7XXVT/" target="_blank">AOI HI BLUE</a>" and <a href="https://www.amazon.com/gp/product/B078GTYHP6/" target="_blank">"Queens Gold" by Stardust</a> (nearly any bright gold metallic mica powder will do nicely), and.</li><li>For the Wild, it was an "<a href="https://www.amazon.com/gp/product/B07B8K1PVP/" target="_blank">Imperial Jade</a>" (again, "Eye Candy"), <a href="https://www.amazon.com/gp/product/B087G8MRVT/" target="_blank">Red (QC9118 by "Seisso")</a>, and <a href="https://www.amazon.com/gp/product/B09GR3FJ6Y/" target="_blank">Meyspring's "Stirling Lining"</a> silver metallic powder.</li></ul><p>Each was cast using Alumilite's Amazong Deep Pour resin epoxy (avaiable from <a href="https://www.amazon.com/Pack-Alumilite-Amazing-Turning-Epoxy/dp/B0BSSL64VH/" target="_blank">Amazon in a 4 pack</a> or from your local <a href="https://www.hobbylobby.com/Crafts-Hobbies/Clay-Molding-Sculpting/Casting-Resin/High-Gloss-Deep-Pour-Turning-Epoxy/p/81019056" target="_blank">Hobby Lobby</a>) because of the long drying time. Please note that exothermic reactions on Epoxy will cause it to mix while it cures, so you will not get good color borders between different epoxies if you use the long-cure stuff like I did. Each one was allowed to cure for a week in desert heat, even though the cure time is "72 hours". This is because the "cure" isn't always perfectly hard.<br /></p><p><b><i>*Note* - make sure you spray mold release/silicon spray into your mold for each one to make the release easier!</i></b> <br /></p><p>The mold I used is a "Lizard Blanks" 1"x1"x6" mold. I can't find a link to the specific mold kit on Amazon, but you should be able to <a href="https://www.woodcraft.com/products/lizard-blank-1-x-1-x-6-gen-2-oversized-pen-blank-resin-casting-mold" target="_blank">find one at your local woodcraft store</a>, or order it from them directly. Other blank molds may do nicely - I don't know. Even a 3/4"x3/4" might suffice for you.</p><p>Anyway, after pouring and curing (I poured all colors at the same time into the mold, hoping for clearly defined colors, but ran into exothermic mixing), I pulled the blanks out, drilled and barreled them, and subsquently turned them like any other pen kit.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFdN5WaCxQoLBDA4GK-1BBtZkP_e9UhNoDMtS8T28tnlpyfYUsR4ZT31K-Fvi7hiv3OJ69kx1K7cqsC5Pp6alX5tpyw2G8MPHqgYb1f9tm73innOKOR3nFdsN7WJcrvbPp73JcP7WEsqPYYrNv_OOblvMnmCLT3OQa4hs0SpB2wHP2hO0tLhaqJ5PdQHE/s4032/20230717_135519.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFdN5WaCxQoLBDA4GK-1BBtZkP_e9UhNoDMtS8T28tnlpyfYUsR4ZT31K-Fvi7hiv3OJ69kx1K7cqsC5Pp6alX5tpyw2G8MPHqgYb1f9tm73innOKOR3nFdsN7WJcrvbPp73JcP7WEsqPYYrNv_OOblvMnmCLT3OQa4hs0SpB2wHP2hO0tLhaqJ5PdQHE/s320/20230717_135519.jpg" width="240" /></a></div><p>Minnesota is on the left, St. Louis in the middle, and Edmonton is on the right. I think they turned out great, though I am not going to make a habit of making these.<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-15832195873489507652023-07-06T16:50:00.005-07:002023-07-06T16:50:40.363-07:00AXA Lathe Tool Holders<p> I hated having my tools just laying around. Some folks sell tool holders on eBay that have been 3D printed, and you can even download the patterns from <a href="https://www.thingiverse.com/thing:4684486" target="_blank">thingiverse and print your own</a>. I was too lazy to set up the 3D printer, so I ordered some 3/8" thick x 2" wide Delrin (which is nice - as an oil-based plastic, I expect it to last longer than ABS, and be "slippery" on the tool holders), and then milled at a 30 degree angle to get the 60 degree taper, and kept flipping them until I had them fit nicely.</p><p>Now, it should be noted that I used a mill, a torch, and a heat-set soldering iron. But, you can make these very simply by using only a saw to cut the 30 degree angles. You don't even need to bend them - you can use angle iron to hold them at 90 degrees. Essentially, you can make these using the 3/8"x2" delrin, and only a bandsaw and screw driver.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_7-UfLj9PauVAbqeVIqwpC2t0VTYy7X_uoVUu61MwxFz5NQWDLrXY6bcjbimEZbpn1YUbH6dt6TjUfI-5pGATgVeFBHkshw4yBySNcP4468RlWSD489LqjTqaltTLoi4HGfZg-Rbwjkv0n-G6Y6P2p3e1WhfdQXWfIJ11pAPVjrXl2JtHuPlaLYu5cM4/s4032/20230704_065234.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_7-UfLj9PauVAbqeVIqwpC2t0VTYy7X_uoVUu61MwxFz5NQWDLrXY6bcjbimEZbpn1YUbH6dt6TjUfI-5pGATgVeFBHkshw4yBySNcP4468RlWSD489LqjTqaltTLoi4HGfZg-Rbwjkv0n-G6Y6P2p3e1WhfdQXWfIJ11pAPVjrXl2JtHuPlaLYu5cM4/s320/20230704_065234.jpg" width="240" /></a></div><p></p><p>Once created, I laid them out on a board set to drawer slides to make it easy to get access, and bolted them to the board.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihVFVeoZVTwzuJbdWsrnX8ZDgUjXpgSLm_UaR-XC4Q4tjLndqQ5s3xU_fU9Fc3OBLWXdXZCK1M9ik4ud3Kko0zwxeWVv3DLXOi-XcDAkVi8t1AvzyPdZB9CLEWaDP5lIUL4R5Wvp3i0HV6lWsSeM5dC3D_bE4W7fPzPvzdZEuJ_WauFUQnBsr1hAi5xF0/s4032/20230704_073603.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihVFVeoZVTwzuJbdWsrnX8ZDgUjXpgSLm_UaR-XC4Q4tjLndqQ5s3xU_fU9Fc3OBLWXdXZCK1M9ik4ud3Kko0zwxeWVv3DLXOi-XcDAkVi8t1AvzyPdZB9CLEWaDP5lIUL4R5Wvp3i0HV6lWsSeM5dC3D_bE4W7fPzPvzdZEuJ_WauFUQnBsr1hAi5xF0/s320/20230704_073603.jpg" width="240" /></a></div><p></p><p>I'm pleased with the result of having all of my AXA tool holders easily accessible!<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-8938022125767944092023-03-15T11:14:00.003-07:002023-03-15T11:14:26.419-07:00Hackers-R-Us - Openprovider.com<p> A few days ago, I read a Cybersecurity blog post about <a href="https://krebsonsecurity.com/2023/03/sued-by-meta-freenom-halts-domain-registrations/" target="_blank">trusting Freenom</a>, a domain registrar that handles .cf, .ga, .gq, .ml, and .tk TLD's (top level domains). Suddenly, we have an account that receives a message :<br /></p>
<ul><pre><code>
284892930
We recently contacted you to inform that our verification system can't verif your payment in MyVerizon-your app.
please update payment information manually to avoid limitations on your_service.
cphrc.org/?o&Vz0N6ZvH
</code></pre></ul>
<p>This message comes through the registrar, openprovider.com, not freenom, and appears to fully be a phishing attempt for mobile account take over (cphrc.org <br /></p>
<ul><pre><code>
user@workstation:~$ whois cphrc.org|grep -i registrar:
Registrar: Hosting Concepts B.V. d/b/a Registrar.eu
user@workstation:~$
</code></pre></ul>
<p>The registration appears to be done through a third party registrar with an .eu top-level domain, and that indicates this domain came through Europe. A European registration trying to handle a United States mobile account is not just a red flag, but an impossible-to-pass hurdle for me. The standard abuse forms have been filled out in order to shut it down quickly.<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-39860205309416898332023-03-12T17:04:00.005-07:002023-03-12T17:04:43.710-07:00Trying a Trailer Toolkit<p> Tsk, tsk, tsk! As soon as you get a new tool, you start really playing with it to see how useful it can be. Enter the laser "engraver". I ordered some thin sheets of ABS (and some 1/4" for backing), and used the laser to cut out some thin profiles, and to mark the thicker stuff. Then, I bolted it together.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis9CObJEoHpEYpIC3r-qogP1eFQNXkTByK1ZjlE35yBfAo_jF4jWQnE6mdHLHjFiNkFkPfCh_Bqry5WTgu3MOjp4D2Xp5iGGTkpJe-MYv5XUXqLj8WQyaLFuZYqaV7pr3cVqeZywq8cwdMg_x8igDoHoG0TMWD_kl_nT-E1EQxMRcABAnCnWATd3rZ/s4032/20230308_201037.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis9CObJEoHpEYpIC3r-qogP1eFQNXkTByK1ZjlE35yBfAo_jF4jWQnE6mdHLHjFiNkFkPfCh_Bqry5WTgu3MOjp4D2Xp5iGGTkpJe-MYv5XUXqLj8WQyaLFuZYqaV7pr3cVqeZywq8cwdMg_x8igDoHoG0TMWD_kl_nT-E1EQxMRcABAnCnWATd3rZ/s320/20230308_201037.jpg" width="240" /></a></div>The M3 threaded rod was trimmed to length (three were left longer than normal so that I could lock it together). I added some butyl rubber feet on the bottom to clear the M3 nuts on the bottom end so I didn't scratch anything up (epoxied to the ABS, and then a second layer applied with superglue).<br /><p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVCUFYE7qfy7225GLDpI8VWBm7Gzzt5bLQAh9wgvyhQAPPtIG2lykad5BW2qgivqP1xrqwyKgcS1kLXPnSMxWh7W-kWTT9DlT8rsr6-KKxdXZLn-2X2mSlz3kp6JlHQhoRe-h9a22nxWv3zBzF0VX9Q3UnOiRHIVqONj5wMUej2VthFHmvksfJ7Qr-/s4032/20230311_161503.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVCUFYE7qfy7225GLDpI8VWBm7Gzzt5bLQAh9wgvyhQAPPtIG2lykad5BW2qgivqP1xrqwyKgcS1kLXPnSMxWh7W-kWTT9DlT8rsr6-KKxdXZLn-2X2mSlz3kp6JlHQhoRe-h9a22nxWv3zBzF0VX9Q3UnOiRHIVqONj5wMUej2VthFHmvksfJ7Qr-/s320/20230311_161503.jpg" width="240" /></a></div><p></p><p>And closed, it holds it (even vertically) fairly well.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuzTC1xy6IaQtEbK27gxiAi_rFaEdNeTRBt4o616_NianuJwWGJS04nUM6ZrAqxrQ2h3WTUui8R7LAyFVcKzqmqTZen5JtbbU2y95isvgfLPKNXQZ5HmFPt5WPpJFbpPvf-NwaMZ2T0kqf7ZxzkCD_O1sO1bCS3jcjDC5sy-E00GC8XG7dVwyhTclE/s4032/20230311_161541.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuzTC1xy6IaQtEbK27gxiAi_rFaEdNeTRBt4o616_NianuJwWGJS04nUM6ZrAqxrQ2h3WTUui8R7LAyFVcKzqmqTZen5JtbbU2y95isvgfLPKNXQZ5HmFPt5WPpJFbpPvf-NwaMZ2T0kqf7ZxzkCD_O1sO1bCS3jcjDC5sy-E00GC8XG7dVwyhTclE/s320/20230311_161541.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifDaSZ5aIkAtaZcwephv1mjyOzlc0QGSnCX7BWGJdsviKoxDdoPdn41zCiJMSrx4t8XiAtDLdHsjKAIoP9Fhd2z0bnV_qzjkcSPWZuzdSy-QassIy_fOjn6c20XZdJGsTzimrU0SeRGXYPucay3H-ainp7p-HtlSUwz177YIzxCOmfUP51kkDhuQKL/s4032/20230311_161556.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifDaSZ5aIkAtaZcwephv1mjyOzlc0QGSnCX7BWGJdsviKoxDdoPdn41zCiJMSrx4t8XiAtDLdHsjKAIoP9Fhd2z0bnV_qzjkcSPWZuzdSy-QassIy_fOjn6c20XZdJGsTzimrU0SeRGXYPucay3H-ainp7p-HtlSUwz177YIzxCOmfUP51kkDhuQKL/s320/20230311_161556.jpg" width="320" /></a></div><p></p><p>You should know, I really needed an organizer for the custom tools that I would require for a trailer. The hitch is an E2 hitch, and everything for the temporary work on the trailer (except for lug nut sockets - I still need to get those) in an emergency is now easily accessible.</p><p>Thumb screws to finish it, and it fits perfectly and keeps it all together! I'll use a portable socket set (one of those cheap craftsman variants), and have the basic tools required.</p><p>So far, my tools :</p><ul style="text-align: left;"><li>1/2" Breaker bar</li><li>1/2" drive ratchet <br /></li><li>Adapters to allow 1/2" tools to work with smaller sockets (turning my 1/2" drive ratchet into a 1/4" and 3/8" drive)<br /></li><li>Screwdriver<br /></li><li>1/2" drive lug wrench</li><li>1/2" drive extension<br /></li><li><span style="color: #990000;">Screw driver bits</span></li><li><span style="color: #990000;">Lug nut sockets</span> (harbor freight has some really cool <a href="https://www.harborfreight.com/12-in-drive-impact-flip-socket-set-3-piece-62491.html?_br_psugg_q=lug+nut+socket+set" target="_blank">double-ended ones</a> that I already keep in the truck, and I'll get another set)<br /></li><li><span style="color: #990000;">Some battery chargers and cheap harbor freight cordless tools</span></li><li><span style="color: #990000;">Torque wrench </span><br /></li></ul><p>Nice!<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-79967305593381970452023-01-27T18:18:00.006-08:002023-02-23T09:33:19.665-08:00Using Laser Engraver, Plywood, and Poor Quality Control<p>I've had some rOtring drafting implements (pencil and pen) that I wanted to protect a little more than having them bounce around in a drawer all the time. It dawned on me that I have the resources I need for a custom kit box. I opened lightburn, and sketched out my pencils/pens and some old (albeit rusty) compasses that I'm going to clean up.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-ZSmmil_A5JobUW0nyC4XIIo41x74ce7HfcU5sQCoVCx999NVaWq3wEf9soKuOP7ZwH40jbPXVmym-Q6ZmDKqRKs3OUdmuwzLAxckwOiwOxqKXbqd8kiAA2ijS8gAkBS1uXHPjv9amMPbnkag1bbd80nkDdm7pJeZbQkFJE56MCuHoH-HeDsipaMK/s972/lightburn-drafting_kit.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="972" data-original-width="822" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-ZSmmil_A5JobUW0nyC4XIIo41x74ce7HfcU5sQCoVCx999NVaWq3wEf9soKuOP7ZwH40jbPXVmym-Q6ZmDKqRKs3OUdmuwzLAxckwOiwOxqKXbqd8kiAA2ijS8gAkBS1uXHPjv9amMPbnkag1bbd80nkDdm7pJeZbQkFJE56MCuHoH-HeDsipaMK/s320/lightburn-drafting_kit.png" width="271" /></a></div><p>The next step was to load this into the laser cutter and make a run at cutting this out. I used 1/4" plywood from some random store that had orange markings (Dome Hepot, I think is the name). I set it up, and cut three out (and two solid with just the outline). I started with a single pass at 20mm/s and 100% power, and counted the passes required to get through the material.</p><p> It took 15 passes at 20mm/s and 100% power to "get through" the plywood. So, I loaded the lightburn up again, and changed the cut to repeat 15 times, and started it off again.<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9r7r3LrQARlELfmAHkdsuIVVoXiEmJgA10TVqxDZ-HlOoZxwyQPqbXnFEiZimveS7QDReCMl3TZMa1z5UIhInl9oj7HApuRMeXNJy5fTxrMn8C1_mFYyNgnVokFDO3PEkBAdtVpbTuT15obbkihlLaDOo9yqzCWPEFJGOFEoIFWWaoCZgnvqZN1QL/s4032/20230126_091721.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9r7r3LrQARlELfmAHkdsuIVVoXiEmJgA10TVqxDZ-HlOoZxwyQPqbXnFEiZimveS7QDReCMl3TZMa1z5UIhInl9oj7HApuRMeXNJy5fTxrMn8C1_mFYyNgnVokFDO3PEkBAdtVpbTuT15obbkihlLaDOo9yqzCWPEFJGOFEoIFWWaoCZgnvqZN1QL/s320/20230126_091721.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDZYX_2UBigcmYUqQ_yWHf1mEnlB3gMd1beuPYOeGZfEm2pQ9xKwE3qlAoMv9BLmvhXbjHd8xUSgKihwIGEygdKGnkFJYk-L_gpMY5qaOQmp4XOrNXWTr-An-OT-p8PpgbzVb2clx3U4ZwiG3pgXd1LHLETaAMcEbas7vbKsynkJpXnAUjm-GLRwFt/s4032/20230126_091828.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDZYX_2UBigcmYUqQ_yWHf1mEnlB3gMd1beuPYOeGZfEm2pQ9xKwE3qlAoMv9BLmvhXbjHd8xUSgKihwIGEygdKGnkFJYk-L_gpMY5qaOQmp4XOrNXWTr-An-OT-p8PpgbzVb2clx3U4ZwiG3pgXd1LHLETaAMcEbas7vbKsynkJpXnAUjm-GLRwFt/s320/20230126_091828.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhow5aP-kb67WyEkVboRktsp6oX23AxPcA1YggLYSuS4puvW2qSsK-vEOCG1FSUWJmP-nvg7g2blKHTfoAmusoUxKoEJQPesjGjPhCjJLcr_5HDHf6a_MyheUW-OWP6NQBSesqdzaIzIBAS7Z9Rkudv-qSPSqC43YmkrlVodmp3_mdp49GDbO_7bYZQ/s4032/20230126_091845.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhow5aP-kb67WyEkVboRktsp6oX23AxPcA1YggLYSuS4puvW2qSsK-vEOCG1FSUWJmP-nvg7g2blKHTfoAmusoUxKoEJQPesjGjPhCjJLcr_5HDHf6a_MyheUW-OWP6NQBSesqdzaIzIBAS7Z9Rkudv-qSPSqC43YmkrlVodmp3_mdp49GDbO_7bYZQ/s320/20230126_091845.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDbAizbICHOpNvmQ5PsRhyXWPWBWPATT74fq24uKzWTUcij4_vdwdXIF9aipJL5UfCvzElPVjXmMtHLUmG-ONXlGkkHg8SNxh4acYwWeiqgetgDCarJ5w4R-yDrDBXwvs9MxuFgiwMOXlNw4S16OQOaAh4kQADW4AYY3Qqm0-XkIq7IHZ5zO-JJSlL/s4032/20230126_173257.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDbAizbICHOpNvmQ5PsRhyXWPWBWPATT74fq24uKzWTUcij4_vdwdXIF9aipJL5UfCvzElPVjXmMtHLUmG-ONXlGkkHg8SNxh4acYwWeiqgetgDCarJ5w4R-yDrDBXwvs9MxuFgiwMOXlNw4S16OQOaAh4kQADW4AYY3Qqm0-XkIq7IHZ5zO-JJSlL/s320/20230126_173257.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAFBdmZBX-6UHzk0d2RABL1l8NqwtdH8JornKZMS1IyDaos7vWAfQr4-Wwtq4q4KESDlKJLyJYXOkUc6CLMVjbSvBoxM1sJzn8hJCzOyV8vvJWO1sGTwRlPS4nzRoeifhd16kCG9o11McpoFdETbTiUd-EMpwXMwACP1m5C4waCnshBfC6x8p0L4iy/s4032/20230126_182235.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAFBdmZBX-6UHzk0d2RABL1l8NqwtdH8JornKZMS1IyDaos7vWAfQr4-Wwtq4q4KESDlKJLyJYXOkUc6CLMVjbSvBoxM1sJzn8hJCzOyV8vvJWO1sGTwRlPS4nzRoeifhd16kCG9o11McpoFdETbTiUd-EMpwXMwACP1m5C4waCnshBfC6x8p0L4iy/s320/20230126_182235.jpg" width="320" /></a></div><p></p><p>When I pulled everything off and flipped the board, I found that it did not cut all the way through in some places. Further check confirmed that the 1/4" plywood was shallow in some areas 1/32", and it was thick in some areas by 1/32". In other words, this material was up to 1/16" out of parallel.</p><p>[sigh].</p><p>Oh, the lack of quality control, all to make a buck. Next time, I'll just order some real wood from Amazon in 1/4". I think I'll have better luck.</p><p>...anyway...</p><p>After the irritation subsided enough for me to break out the hobby knife, I finished the final 1/16" cuts, and pulled the parts together. I glued two templates and the bottom together, and one template and the other panel together, and then loaded the "boards" under a portable tool set for the weight, and gave it a few hours to get up.</p><p>Once out, I just HAD to check it.<br /></p><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbW0srKMUVuALuDSmAxkXADRO97HopdJctRxjGR-iMd4EbxiYuQqFoHRrKikexRA1x4L8X6nop7xv-9pbEoeLocBebRZODLNOXf4gVaB4pIjM5iQHZAhKGBqIynihSExeojt8RieSaWLoCXwaN5PM8DkabOlcivoK3B_uitbA24uFyUI6i816mSqVQ/s4032/20230127_172548.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbW0srKMUVuALuDSmAxkXADRO97HopdJctRxjGR-iMd4EbxiYuQqFoHRrKikexRA1x4L8X6nop7xv-9pbEoeLocBebRZODLNOXf4gVaB4pIjM5iQHZAhKGBqIynihSExeojt8RieSaWLoCXwaN5PM8DkabOlcivoK3B_uitbA24uFyUI6i816mSqVQ/s320/20230127_172548.jpg" width="320" /></a></div><p>This will work. I used a 1/8" router round over bit to round the edges, did a quick sanding job, and threw stain (dark walnut) on the two halves of the clam shell, and gave it a coat of lacquer. I also took some dark blue felt for a machinists' tool chest and fed that through the laser engraver, too (two pieces - well, three in case I messed one up).<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEich5eG25E1AgI5bdo8kZJ5qg-MIERnGBDAOt1-W_70nd7PcCxAfuqBjLk1Zns2JWalZWCyYhmvgc6k9sDMRpEIWKrC2cXG07LYV6CxIPakWsJ1jOibzkTEGbP7iIBaL1jIJA9UwnbHKVoDLEPfgcxWPM5sOR13TZGzgct_-1F9WWke04uPM0G1vVfE/s3264/20230218_092054.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEich5eG25E1AgI5bdo8kZJ5qg-MIERnGBDAOt1-W_70nd7PcCxAfuqBjLk1Zns2JWalZWCyYhmvgc6k9sDMRpEIWKrC2cXG07LYV6CxIPakWsJ1jOibzkTEGbP7iIBaL1jIJA9UwnbHKVoDLEPfgcxWPM5sOR13TZGzgct_-1F9WWke04uPM0G1vVfE/s320/20230218_092054.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhG1adwoqUjUHMmfr3XJ7ZBbS1p-Jl5Ckl3KkhammBev6d4LvIpMi5Xr7ZNPjTgjtucQOBHpwZqiVfQAxWmCOFmhZIKTvZ7DWjXNBsk6INPUzK542I-rNQKJVJm4eO1iNYYLe53GfipvRi9vvvPOXYxq3YwN9_23ynBQAMEJUHaCngF2iqTh2_SX9CE/s3264/20230218_092149.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhG1adwoqUjUHMmfr3XJ7ZBbS1p-Jl5Ckl3KkhammBev6d4LvIpMi5Xr7ZNPjTgjtucQOBHpwZqiVfQAxWmCOFmhZIKTvZ7DWjXNBsk6INPUzK542I-rNQKJVJm4eO1iNYYLe53GfipvRi9vvvPOXYxq3YwN9_23ynBQAMEJUHaCngF2iqTh2_SX9CE/s320/20230218_092149.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQcyR5vBioTXDRjx8VaUzGmH0Urf-mVSWFAZl7jHJgzhvs93LI7sHDkQWovyjJk6tHZx-nkMcmi4jENDeVn7vL5MWs3yp_wRCdMHp7kE5AimESFEoK-VKAYYr-sVOUWC6TBGwOX5aca_CRPRUb9UzUJClskrmAUrH891gDyKDAG3ZHVGEuI5WmW-VX/s3264/20230218_092115.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQcyR5vBioTXDRjx8VaUzGmH0Urf-mVSWFAZl7jHJgzhvs93LI7sHDkQWovyjJk6tHZx-nkMcmi4jENDeVn7vL5MWs3yp_wRCdMHp7kE5AimESFEoK-VKAYYr-sVOUWC6TBGwOX5aca_CRPRUb9UzUJClskrmAUrH891gDyKDAG3ZHVGEuI5WmW-VX/s320/20230218_092115.jpg" width="240" /></a></div><p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1_XRf6lLppIhRtYzZd6rKMLdrhsDAQVUjHa1t2xmIm5D7OVIUTwGWAeT7mKoQU5d8Z9_eEoEy7DNQ4EbqRpF8HCTSwJFEcoGtknQ2I8Bz8QGGa8RvFu89MgOS4i3wVao9RHcLJwRyJvmNTdWPya95HMK9KqsV7hGdrBmUCnC_KBxAz6hsKh67sTJF/s3264/20230218_092729.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1_XRf6lLppIhRtYzZd6rKMLdrhsDAQVUjHa1t2xmIm5D7OVIUTwGWAeT7mKoQU5d8Z9_eEoEy7DNQ4EbqRpF8HCTSwJFEcoGtknQ2I8Bz8QGGa8RvFu89MgOS4i3wVao9RHcLJwRyJvmNTdWPya95HMK9KqsV7hGdrBmUCnC_KBxAz6hsKh67sTJF/s320/20230218_092729.jpg" width="320" /></a></div><p></p><p>With them looking pretty much perfect, it was time to glue them into place. I used 1/4"-20 hex nuts as spacers to allow weight to keep the felt down (my old Digital Fundamentals college text book, and my old welding text book as well, were about perfect sizes). I only did one piece per clam shell half in order to keep myself from getting too stressed, and added the weight/book, and waited before doing the other piece.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmqhdekjoa0gNVhdWIVeVql69vkTUy08RN1wVBhv6ZvQvkVe9r-7MjYwXMDP7dFrvEdo45K2Ix-i6Fl-UEyM8QrkPlLVTzPfmOtQJCJoznjqRoKTSlHBjNlz6WC4DfRzRqU5ognou1L_Q_gpfrXAINphb1oMT5n3AcJf1A5Or0EpN3ank7Zvog1Sec/s3028/20230218_094440.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1924" data-original-width="3028" height="203" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmqhdekjoa0gNVhdWIVeVql69vkTUy08RN1wVBhv6ZvQvkVe9r-7MjYwXMDP7dFrvEdo45K2Ix-i6Fl-UEyM8QrkPlLVTzPfmOtQJCJoznjqRoKTSlHBjNlz6WC4DfRzRqU5ognou1L_Q_gpfrXAINphb1oMT5n3AcJf1A5Or0EpN3ank7Zvog1Sec/s320/20230218_094440.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghNfOSyu2KyOW2kCNImdZDT5UNCXNh0Gk2YJ-f9Ig8WtEqppdgSNOObm7IvALPSrXI4OejLWXbPYPItxzFwHjY2GNNjAY0ByZ9wD52IDq6fS5hgSafBNWcbbRXI08s7QCI9W-fPAtK8hpekMned9lSG34G7ReYBBFgKpSRfH9t6C3aFR3e_htX5rwF/s3264/20230218_094450.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghNfOSyu2KyOW2kCNImdZDT5UNCXNh0Gk2YJ-f9Ig8WtEqppdgSNOObm7IvALPSrXI4OejLWXbPYPItxzFwHjY2GNNjAY0ByZ9wD52IDq6fS5hgSafBNWcbbRXI08s7QCI9W-fPAtK8hpekMned9lSG34G7ReYBBFgKpSRfH9t6C3aFR3e_htX5rwF/s320/20230218_094450.jpg" width="320" /></a></div><p></p><p>I tossed in the merchandise just to see how it looked :</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgk_b-xIUt_zFrkop_fETV-ETo1H-6Ehl6TG_BMdz4mQqqntIaQEzmveLtuP85o2Nyo1zgDJ0ADiP7ZBbOEZMqd7myvZcFA39mV11V21UyHUB4NYCS0ThJlMbwhrQ922G8yijRUMxzsCRMDgREs3H_1hswUsBxXpgEkt9ynDwU_qsVhJYFgAOSLkVNI/s3264/20230218_153217.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgk_b-xIUt_zFrkop_fETV-ETo1H-6Ehl6TG_BMdz4mQqqntIaQEzmveLtuP85o2Nyo1zgDJ0ADiP7ZBbOEZMqd7myvZcFA39mV11V21UyHUB4NYCS0ThJlMbwhrQ922G8yijRUMxzsCRMDgREs3H_1hswUsBxXpgEkt9ynDwU_qsVhJYFgAOSLkVNI/s320/20230218_153217.jpg" width="240" /></a></div><p></p><p>It will do nicely. I ordered some oiled bronze hinges and a small latch (for a jewelry box). I cut some space in using an X-acto knife for hinges, and then put it together.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglt7pGmdEdGeprew3Aol5c2u3sns_hAYTGvUD-trw7HKsCO373-kdxxn4qNF1aA7HwYaVge4fX2KeE91d91wCamFCSIBTcLh4b_b9MrQ-Zl0bdcFt6yH8XT0yp8yiLJ8gslAVoegNyQaSS04unJkvQ938x3dlhl9N9Ylz68I9zqbjhYSU6xJV25nZ6/s4032/20230223_100308.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglt7pGmdEdGeprew3Aol5c2u3sns_hAYTGvUD-trw7HKsCO373-kdxxn4qNF1aA7HwYaVge4fX2KeE91d91wCamFCSIBTcLh4b_b9MrQ-Zl0bdcFt6yH8XT0yp8yiLJ8gslAVoegNyQaSS04unJkvQ938x3dlhl9N9Ylz68I9zqbjhYSU6xJV25nZ6/s320/20230223_100308.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvzizY6eqafQv3OxGumeaaAdViGyApw6Jf8koSYdwYrjqY7K4KHlnNiMLvqsYyl2OElImGdeizsJAdr2A0I3AaZrbXz89P3SgCsz-yg3JaGftypL08QTR8aiRrAcCgiqahI2nMdhw_G2LgMQ_sYMZjLW70FjUu5lcEMeHAxLcJ9MoVulUDbq2g5FfK/s4032/20230223_100428.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvzizY6eqafQv3OxGumeaaAdViGyApw6Jf8koSYdwYrjqY7K4KHlnNiMLvqsYyl2OElImGdeizsJAdr2A0I3AaZrbXz89P3SgCsz-yg3JaGftypL08QTR8aiRrAcCgiqahI2nMdhw_G2LgMQ_sYMZjLW70FjUu5lcEMeHAxLcJ9MoVulUDbq2g5FfK/s320/20230223_100428.jpg" width="320" /></a></div><br /> I guess I have to clean those compasses next. I'm not sure the best way to proceed, maybe I'll take a stab at a rotary tumbler used for rock polishing, or maybe I'll actually put in the work to polish them using the wheels on the grinder. <p></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-48793260988194433852023-01-07T13:08:00.002-08:002023-01-07T13:08:51.121-08:00Laser Engravers, Resin, and Pen Turning Kits<p>Yet another project that has been on my back burner ever since I got the laser engraver/cutter was cutting a resin pen blank to make a custom, single instance pen blank for a buddy that loves working in his shop. It turns out he is a pretty crazy <a href="https://www.utah.edu/" target="_blank">University of Utah</a> nut, so I thought I'd use that logo as a test candidate. It's not even a precursor to the real project, this is more of a feasibility test.</p><p>So, I grabbed the SVG logo from <a href="https://en.wikipedia.org/wiki/File:Utah_Utes_-_U_logo.svg" target="_blank">Wikipedia</a>, and then imported it into LightBurn. This is a "round" thing (it's going to be turned on a lathe), so I had to use a rotary attachment. Here's the deal - I attempted to use a <a href="http://www.silverhawk.net/2022/11/conical-laser-engraving.html" target="_blank">rotary attachment that used wheels that were WAY to large</a> on engraving mugs - and it was a failure on the outcome. Seeing as how these pen blanks would not have a handle, I decided to try a different rotary attachment.</p><p>Granted, with my recent foray into rotary's and CNC, I was a little skeptical. I had to measure the roller diameter, and then used the step options to control the rotary from the engraver to determine how many steps to get a full 360-degree rotation. It is a 12mm roller diameter, and it was 40mm on the engraver to get the full rotation.<br /></p><p>With those numbers, I could plug them in to LightBurn, and then I could start to play with this new device.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmA0a_8VuqRFB66HeQY65FSOIELHHa0hNUfiLq7Wh8pmjwNRwC9qCYmG_F3exJGnLTg9OvAyAyISXMDHe1vLn80WznR0coEtoyzBRdHODn11A1MYsmH6439utFxGiz5C9usFWCoPyqldUDREvOElU4Kk3wZjx3fLXcrGI8Q12KdAQzHkcTvq4sNfvf/s569/rotary_settings.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="551" data-original-width="569" height="310" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmA0a_8VuqRFB66HeQY65FSOIELHHa0hNUfiLq7Wh8pmjwNRwC9qCYmG_F3exJGnLTg9OvAyAyISXMDHe1vLn80WznR0coEtoyzBRdHODn11A1MYsmH6439utFxGiz5C9usFWCoPyqldUDREvOElU4Kk3wZjx3fLXcrGI8Q12KdAQzHkcTvq4sNfvf/s320/rotary_settings.png" width="320" /></a></div><p></p><p>Once I had LightBurn configured, it ran pretty decently, actually. I slapped a piece of masking tape around one end of the round resin blank with a sharpie mark. This allowed me to run a "frame" or an outline of the cut parameters in order to ensure it did not wrap more than once around the blank. Once I knew it would fit, I could size the cut decently, and then start to play with cuts in resin. For this, I went back to the non-rotary set up with scrap pen blank cut offs and started to play with settings. I started out with a 100% power and a 20mm/s speed (default in LightBurn is 100mm/s at 20% power), and kept decreasing the speed and measuring depth with a feeler gauge.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihA1cLM_auBe_g-i3iji0JNox2TmBcUJeGdyP5_VeyNveHUNsgVoQjYke_9Se1RkXtUkb3IhTUj3YNcqImvkSyb8x1sl6oPnyqRT8nJZdFBx_LKqrHJfYGdBQROABdQwCn_mj5h5KUnl113wZ_10e7vOXHevi4rqtNcESe7fUdut3_QxNa28du0Dsu/s4032/20230107_093748.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihA1cLM_auBe_g-i3iji0JNox2TmBcUJeGdyP5_VeyNveHUNsgVoQjYke_9Se1RkXtUkb3IhTUj3YNcqImvkSyb8x1sl6oPnyqRT8nJZdFBx_LKqrHJfYGdBQROABdQwCn_mj5h5KUnl113wZ_10e7vOXHevi4rqtNcESe7fUdut3_QxNa28du0Dsu/s320/20230107_093748.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxPuxrshxiSvExnF0nxIuaM2qpt4dqqy3vv-Lm74uxmztLFaypEbuWWEnvzjmL0Q0Io8iceXwlZK14v3GO6dAFgPmKbBTLkue6bojSdW4EYoxNnrYi02LUR8HH0y-Tl5f2HWaqwfLoDbqrrxxxnC5D0lfJFx_C-082WDSuUa7DgIjVnUMJJzHQt_0q/s4032/20230107_100945.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxPuxrshxiSvExnF0nxIuaM2qpt4dqqy3vv-Lm74uxmztLFaypEbuWWEnvzjmL0Q0Io8iceXwlZK14v3GO6dAFgPmKbBTLkue6bojSdW4EYoxNnrYi02LUR8HH0y-Tl5f2HWaqwfLoDbqrrxxxnC5D0lfJFx_C-082WDSuUa7DgIjVnUMJJzHQt_0q/s320/20230107_100945.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEBK7hcRAzSuBG3aqwN1PuztzzNYzz26W1u_P9R9s_hKoEwZoJJT0UTCbi5ESOCuLGNowr27q8kGp_nMMDicvQoj6vtkrRYbRAm3ExfFSMoovyt2fCnLk97EBAoINTFEHL4CQsiK8FjpQweMCEb8oMytZx6uoIHtMDGn9-LsiRtgSlGUz_rarCIdIY/s4032/20230107_100947.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEBK7hcRAzSuBG3aqwN1PuztzzNYzz26W1u_P9R9s_hKoEwZoJJT0UTCbi5ESOCuLGNowr27q8kGp_nMMDicvQoj6vtkrRYbRAm3ExfFSMoovyt2fCnLk97EBAoINTFEHL4CQsiK8FjpQweMCEb8oMytZx6uoIHtMDGn9-LsiRtgSlGUz_rarCIdIY/s320/20230107_100947.jpg" width="320" /></a></div><p></p><p>With a 10w laser, resin seemed to cut at 0.060" depth using a 1mm/s speed at 100% power. I calculated how many cuts it would take to get 3/16" into a 3/4" round resin blank (1/4 of the way in, I did NOT want to cut past center, but needed to get close, and I could always run a second pass) as 6 cuts.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGUnxBZWMnZGipXpcYNNUZIIrgxqkvC0vaj5RrzUNTKcMtmjva-QwnU6lELS7WsfHFp1SPJFlUyJYwHDh9rUvaxT3An_SwlLmfEbW7LSBE79law5xji184h1brl8qAEcQd5CZ1jjSRQAOozjdunpy5o5sLM5avDm8ntIPbyLmU3BoGIG7ovpl6pqLU/s4032/20230107_101235.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGUnxBZWMnZGipXpcYNNUZIIrgxqkvC0vaj5RrzUNTKcMtmjva-QwnU6lELS7WsfHFp1SPJFlUyJYwHDh9rUvaxT3An_SwlLmfEbW7LSBE79law5xji184h1brl8qAEcQd5CZ1jjSRQAOozjdunpy5o5sLM5avDm8ntIPbyLmU3BoGIG7ovpl6pqLU/s320/20230107_101235.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhS7JSeXT7unhTsaWCggxBgW0kFDItm7QI56QAcHFi-xQZKzKRzJLAb6Ss-rtDIxLhxjTsPRgF3XEHJ1Qb9Rj7TDWpYfe9a7fIrLuc12Lvgi5WUPMUEWDv4YXkZ9EEXYrNI6oOnBs55EjRBUtmqXEodWA1OjSNCCrXy2mpap6rsxPO7YFb5aD0wjJWL/s4032/20230107_101419.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhS7JSeXT7unhTsaWCggxBgW0kFDItm7QI56QAcHFi-xQZKzKRzJLAb6Ss-rtDIxLhxjTsPRgF3XEHJ1Qb9Rj7TDWpYfe9a7fIrLuc12Lvgi5WUPMUEWDv4YXkZ9EEXYrNI6oOnBs55EjRBUtmqXEodWA1OjSNCCrXy2mpap6rsxPO7YFb5aD0wjJWL/s320/20230107_101419.jpg" width="240" /></a></div><p></p><p>I grabbed one of my blanks (I turned 2 round, just in case I hosed it up - queue your ominous music), and set it up to cut. I ran two passes and thought I needed to check it before doing the final four.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_9kFFNwIDNpJjc2Tn_z8W_im28IuUItht4twdDlJH0spL7mXQzHZllzv5gm85N6WiRR2YUGqZfxb0UidwcwYK6tSYhTTzzvplUQIkH-1QcBhkdVoSIxSNOj3vQlip-3x_6a9vwXH1F9NTaF17ylocIFlzx1xygUtQj4eCZzV0zww0ZMXakra9L62S/s4032/20230107_105600.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_9kFFNwIDNpJjc2Tn_z8W_im28IuUItht4twdDlJH0spL7mXQzHZllzv5gm85N6WiRR2YUGqZfxb0UidwcwYK6tSYhTTzzvplUQIkH-1QcBhkdVoSIxSNOj3vQlip-3x_6a9vwXH1F9NTaF17ylocIFlzx1xygUtQj4eCZzV0zww0ZMXakra9L62S/s320/20230107_105600.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNO-KDtJzQuMj8x0xwNkF9lx12M9HfRA_KywsXIj4fX9HGhmH1YlNMW2oy-te2ane8ivPY8CG8iL_IANpRRmwKojJbCCZxzQckR3YCXugu9W84XV-yioWMgEtqcZtS6k-VxHu_S4IPnBNYk6ReU_AAb_1NFVDJpYfg0QJYY14dnlNSXAjcXEGR31Av/s4032/20230107_102349.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNO-KDtJzQuMj8x0xwNkF9lx12M9HfRA_KywsXIj4fX9HGhmH1YlNMW2oy-te2ane8ivPY8CG8iL_IANpRRmwKojJbCCZxzQckR3YCXugu9W84XV-yioWMgEtqcZtS6k-VxHu_S4IPnBNYk6ReU_AAb_1NFVDJpYfg0QJYY14dnlNSXAjcXEGR31Av/s320/20230107_102349.jpg" width="320" /></a></div><br /><p></p><p>I <i>had lines on the wrong side of the blank</i>. I made an assumption that it simply got out of sync, e.g. the blank got stuck or skipped in a turn. I started cussing about having to make 6 passes if it got out of sync this badly with only 2, and started to re-think the process. As I added "fill" cuts, (I wanted a hatch pattern I could use to break pieces out) to this new process, and to get cross lines instead of burning it all out, I opened the cut/layer settings (double click the cut) and alter the lines-per-inch or the line interval. Apply those settings, and click on the display/monitor icon to see it increase (or decrease) the line spacing and make sure it looks good.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVQdUmaLv1WGb42v4w_XrnT-0lSWeXPN6bH1NsCwO9SVTUGS_C9iu8Gx5ily5Cd-8NIJwjAg3BKb2w2CpFO4hy9uaKOL8DLG6XJ39oLamL5FrhRAI7DvY9xK6oB53LJUr5b1NPYAc1DzvLNkZsUx_A21zzozmhl4nyEFSXbeG-gCoVzjb0U5AhX0Lp/s839/lightburn-hatch_fill_settings.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="393" data-original-width="839" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVQdUmaLv1WGb42v4w_XrnT-0lSWeXPN6bH1NsCwO9SVTUGS_C9iu8Gx5ily5Cd-8NIJwjAg3BKb2w2CpFO4hy9uaKOL8DLG6XJ39oLamL5FrhRAI7DvY9xK6oB53LJUr5b1NPYAc1DzvLNkZsUx_A21zzozmhl4nyEFSXbeG-gCoVzjb0U5AhX0Lp/s320/lightburn-hatch_fill_settings.png" width="320" /></a></div><p></p><p>It was at this point, my brain went geometrical, and I clued in. I grabbed the failure and held it up to the light, and.... yes, indeed... those added lines were simply coming TOO far through the blank - it was getting cut on the opposite side.<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqzWDgOI_EtDtWO71sim6i9lW-Sf5CBR0m8Kx3x45tjP_SuWh1xFRey4jlqg0Un-RD9vIN7qIRUrB3RxwYINY42FUhLd0L-6Xd6k-ksWoaUENj4i0727pWX6dTWi2BFZW8XlIzAXCb-L1Gq-yse8V3bUq_bP2FGId9SJ7S72lj0hT8MfD9t1k7gI-N/s4032/20230107_122126.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqzWDgOI_EtDtWO71sim6i9lW-Sf5CBR0m8Kx3x45tjP_SuWh1xFRey4jlqg0Un-RD9vIN7qIRUrB3RxwYINY42FUhLd0L-6Xd6k-ksWoaUENj4i0727pWX6dTWi2BFZW8XlIzAXCb-L1Gq-yse8V3bUq_bP2FGId9SJ7S72lj0hT8MfD9t1k7gI-N/s320/20230107_122126.jpg" width="240" /></a></div><p></p><p>It turns out that, the farther away from the focal point you get, the wider the cut, and nearby cuts also get closer together. I had to tone my settings WAY down. I set it to cut at 100% power with a speed of 0.5mm/s, and this time I'd be also adding the cross cuts in the material I wanted to remove. I queued up my second pen blank, and let her rip. I <b><i>only</i></b> cut once.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5EI5SOmeLE7SJg4CSUlAHwV5DHEYBbF8Nx1d6mITmD_8Q4yDWQbXiSG3iwmvi8Z8w_Dkue_JR2ko0zbdIEeIoiat4L1ySe_tKbnY70DagNiYVOxAk2pD9oihMt2BNBmjfUTwQ30g6fiGiYd_cbOtI-sPb_z4jxLsOpLqictyMpavs0TYpiaTikjWT/s4032/20230107_105942.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5EI5SOmeLE7SJg4CSUlAHwV5DHEYBbF8Nx1d6mITmD_8Q4yDWQbXiSG3iwmvi8Z8w_Dkue_JR2ko0zbdIEeIoiat4L1ySe_tKbnY70DagNiYVOxAk2pD9oihMt2BNBmjfUTwQ30g6fiGiYd_cbOtI-sPb_z4jxLsOpLqictyMpavs0TYpiaTikjWT/s320/20230107_105942.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEici9VSni91dTpJMjopHTxqYQmBIll_xWwj4SdipuizeLZtGCFYPzMzktt_G8wN70tPrP2nwQ65KFqLNsC6HdP4g1AgQ1EykN0S_jQal2L6dLyniDE91Vy5F9hTEmbowg28a0bneUjHYqDl1pQqi81XXhaxqX_mXEfALCxcFRAEKwGqlT3i2b06WaSL/s4032/20230107_122132.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEici9VSni91dTpJMjopHTxqYQmBIll_xWwj4SdipuizeLZtGCFYPzMzktt_G8wN70tPrP2nwQ65KFqLNsC6HdP4g1AgQ1EykN0S_jQal2L6dLyniDE91Vy5F9hTEmbowg28a0bneUjHYqDl1pQqi81XXhaxqX_mXEfALCxcFRAEKwGqlT3i2b06WaSL/s320/20230107_122132.jpg" width="240" /></a></div><p></p><p>This looks much more promising as a result. I grabbed some tweezers and started breaking the pieces out.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJcLFMrfX0LlMdgjWSdLcXfAJT9AtsDPpvdXUFfKLGc2dMIuooc4jHXwj4P-wNYbXl8UAXabtUyMjhvEzI9xib7Ey4SWgbQhwxAQ8F9BubOxXo9n2D1J9NPAft7-8RdiV_mDjQdIlRkKzsUtWzD5KJL9bAx71cCa1uEJ9a6J2tojBaptjXogk9zI0q/s4032/20230107_123646.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJcLFMrfX0LlMdgjWSdLcXfAJT9AtsDPpvdXUFfKLGc2dMIuooc4jHXwj4P-wNYbXl8UAXabtUyMjhvEzI9xib7Ey4SWgbQhwxAQ8F9BubOxXo9n2D1J9NPAft7-8RdiV_mDjQdIlRkKzsUtWzD5KJL9bAx71cCa1uEJ9a6J2tojBaptjXogk9zI0q/s320/20230107_123646.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKMzMj5MKUsJlLHIj8sAdk-rDXuiEIYXFnlP_vesYDpxmp3V2jJxWFvedQPRZdDq-YXJvAu3nbM6vSqiUxoOVcllHYcjCnG_EtgXIm6CtJL4m8eo6uA7Cfyj2tqlzn_6pj6NdX8MpfaEBLm4YnaJbhZS6FJL7LPKlNKyZ0dSxAZ80-cmceUoe1RRGR/s4032/20230107_123648.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKMzMj5MKUsJlLHIj8sAdk-rDXuiEIYXFnlP_vesYDpxmp3V2jJxWFvedQPRZdDq-YXJvAu3nbM6vSqiUxoOVcllHYcjCnG_EtgXIm6CtJL4m8eo6uA7Cfyj2tqlzn_6pj6NdX8MpfaEBLm4YnaJbhZS6FJL7LPKlNKyZ0dSxAZ80-cmceUoe1RRGR/s320/20230107_123648.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjd-_m40SqBJWDbU2uRLkwym9R4sxXeUSeqQ9vfW8yT5O7QEL-ib7qxyhk3pxkEPG8I3KgZq3BMU9ot7VMr6YekR4bMtAWrhuX-ai3Nu8ofo8LhJP9syDTOsvxXLMpltKNV2kkRmi00-HGD4znQMoQ9_apQ6G0reXNsZPHn41Mh8a7gQXsiKOeeu4jC/s4032/20230107_124010.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjd-_m40SqBJWDbU2uRLkwym9R4sxXeUSeqQ9vfW8yT5O7QEL-ib7qxyhk3pxkEPG8I3KgZq3BMU9ot7VMr6YekR4bMtAWrhuX-ai3Nu8ofo8LhJP9syDTOsvxXLMpltKNV2kkRmi00-HGD4znQMoQ9_apQ6G0reXNsZPHn41Mh8a7gQXsiKOeeu4jC/s320/20230107_124010.jpg" width="240" /></a></div><p></p><p>I used a Dremel to remove some gloss and melting (the epoxy had a hardened finish I think will interfere when I add new epoxy into the cavity.</p><p></p><p>It was at this time I realized I could take my "failure" blank, and break everything away from the failed cavity - essentially xor'ing the blank. Instead of red with a silver "U", this would become silver with a red "U". I could live with that. So, I cleaned that one up, too.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmpX5iMyJFB2iqqkNxI2zrCUkhWH3wl359yh73cUpS2VF2__vydeYIjh3jktMaz-nk7V6CqIYRZMN96UNg90szx8gDP4Do2roWJOkt2fUN0fZzfiYMi4BcFBP9sUaABvJzCQ5J47IPc21BtTHmu2PjTDECsArj7hBjQjxs50AEcrwp3wq5ZoW4YmMx/s4032/20230107_124350.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmpX5iMyJFB2iqqkNxI2zrCUkhWH3wl359yh73cUpS2VF2__vydeYIjh3jktMaz-nk7V6CqIYRZMN96UNg90szx8gDP4Do2roWJOkt2fUN0fZzfiYMi4BcFBP9sUaABvJzCQ5J47IPc21BtTHmu2PjTDECsArj7hBjQjxs50AEcrwp3wq5ZoW4YmMx/s320/20230107_124350.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioklTua8kSyEHgC_JKJj6ssRF18vTETzCuYiymWzGAWvSepBetMa73ipl_dGJHcCXpk5Sirg474hQIxhbL92a9df-VNN_AE-85DnTAvuF09dj1cM9RFK7-XVbIU1SwUhLOAR2552c6ve0rQD5MK155jyZXgwj_k8lol_cZ0F92CYfLL_NUHfdPoVsg/s4032/20230107_124900.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioklTua8kSyEHgC_JKJj6ssRF18vTETzCuYiymWzGAWvSepBetMa73ipl_dGJHcCXpk5Sirg474hQIxhbL92a9df-VNN_AE-85DnTAvuF09dj1cM9RFK7-XVbIU1SwUhLOAR2552c6ve0rQD5MK155jyZXgwj_k8lol_cZ0F92CYfLL_NUHfdPoVsg/s320/20230107_124900.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXKOGXtV49kxUEo-EMOohz53551Tk5qTihidtkLFTUnDfGQeiAoIjUcYc4K5M7OxA1YINrfc-KFTM8SvCkRRv__dKTFszA6kvIQsWdQvYhWmg_CCo-6874cf-QHdIbrQ1wng341WLG7rY0Y-p3qeTtOxIBLq-J99PPd1kzbQGHNRmcvIb6ZmPupuh9/s4032/20230107_130833.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXKOGXtV49kxUEo-EMOohz53551Tk5qTihidtkLFTUnDfGQeiAoIjUcYc4K5M7OxA1YINrfc-KFTM8SvCkRRv__dKTFszA6kvIQsWdQvYhWmg_CCo-6874cf-QHdIbrQ1wng341WLG7rY0Y-p3qeTtOxIBLq-J99PPd1kzbQGHNRmcvIb6ZmPupuh9/s320/20230107_130833.jpg" width="240" /></a></div><p></p><p>I think I have two viable blanks in front of me - I just need to obtain some epoxy resin (the long-curing stuff that has the potential to get into every single nook and cranny of this cut-up blank). I won't be turning these - I'll turn [sorry for the pun] them over to my buddy who can just give me feed back and tell me if they fly apart when turning, or just come up with a terrible finish. But, it's an option!<br /></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-83439620180786345612022-12-31T10:43:00.008-08:002023-02-25T11:33:54.544-08:00Square Woodworkers Clamps - and Band Saw Tuneup<p>Stupid projects! The <a href="/2022/12/puffed-out-chest-part-a.html" target="_blank">tool chest project</a> has now hit a phase where I need to make 33 little tiny drawers, and my OCD is screaming at me about how to clamp them. If you may recall (maybe you've never seen that tool chest part A post), I had some of those 90-degree clamps, and they were fantastic.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGY1Q_gcvGUKvYL-CA2biH-EFTHYlV2f5t3UdbTOAFy7GnRVrKZUmfPLQSwqymsL3Qn9b6EjhljGSk9NITxizHxz3b7kiUX850Z42zacktqXbWCUugZPyKXpbj2cArSnkYwZNHZmwDzsiT8hFanZddPcmqs8ItwbyjLaE_XdkfP4NBNp7c-UHIMU8h/s4032/20221105_174817.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGY1Q_gcvGUKvYL-CA2biH-EFTHYlV2f5t3UdbTOAFy7GnRVrKZUmfPLQSwqymsL3Qn9b6EjhljGSk9NITxizHxz3b7kiUX850Z42zacktqXbWCUugZPyKXpbj2cArSnkYwZNHZmwDzsiT8hFanZddPcmqs8ItwbyjLaE_XdkfP4NBNp7c-UHIMU8h/s320/20221105_174817.jpg" width="240" /></a></div><p></p><p>They came in a package like this :</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaulv1VsnqYiTvRhPzhjfjkvs2Xd7o5yD7Q58_dYe0Yt0eEzeLAIg6fxMbgU9wktJvCe3I6TKDE-PLZA2CV_6J_zgpBsvtKRoQW7L68CAfX7av7BXFxA8Uqde0Of5B92q1_fLJAOdcg-b_-LS6SxhwXfG89zc8S-1Ou7eThZjKAUWvL60tQT1aPOj8/s4032/20221231_112814.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaulv1VsnqYiTvRhPzhjfjkvs2Xd7o5yD7Q58_dYe0Yt0eEzeLAIg6fxMbgU9wktJvCe3I6TKDE-PLZA2CV_6J_zgpBsvtKRoQW7L68CAfX7av7BXFxA8Uqde0Of5B92q1_fLJAOdcg-b_-LS6SxhwXfG89zc8S-1Ou7eThZjKAUWvL60tQT1aPOj8/s320/20221231_112814.jpg" width="320" /></a></div><p></p><p>However, they were just <i>a little bit too</i> large (even the smaller 4.7" ones are too large). Try as I did, I could not find them in the 3" (or even 4") sizes - without regard to color (I'd love green ones, but alas, I'd take any). This one forced me to start thinking about making my own. I ordered a flat bar of 3"x3/4"x12", and mapped them out - I could get six of them out of this one piece, but it would take some fancy cutting. So, that forced me to the band saw.</p><p>Now, my band saw cuts horribly angled (it's about a 15 degree angle), so I had to do this on the vertical side where I could control it. That forced me to make a new table for the band saw :</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixClsZfFva3iSRdILe5QDl0r9C0PtuoEX5tVlJ5TIT6o205tXs7W2nzvlLeJ3WDyGDJ2g3_v68moJnLz7relcFhX3FsrByiK6xr5po2DO6BP9DumIEfTYDKbIke9TtR27vdl6Aiu3BDszj3tU7qITAEdpyYbi7TYOgxdAmzBGyjyVtEaWpvmfIsW5A/s4032/20221230_165119.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixClsZfFva3iSRdILe5QDl0r9C0PtuoEX5tVlJ5TIT6o205tXs7W2nzvlLeJ3WDyGDJ2g3_v68moJnLz7relcFhX3FsrByiK6xr5po2DO6BP9DumIEfTYDKbIke9TtR27vdl6Aiu3BDszj3tU7qITAEdpyYbi7TYOgxdAmzBGyjyVtEaWpvmfIsW5A/s320/20221230_165119.jpg" width="240" /></a></div><p>Transfer screws for the win, to make sure all the holes lined up. Okay, on to cutting....<br /></p><p>About 3/8" into the bar, my absolute laziness kicked in. There was no way I was going to cut for hours on end for each one of these. I had to make my band saw cut straight so I could let it do the work for me, and I could walk away.</p><p></p><p>It was at this time I realized the bearings have this hex plate behind them. I'd always thought that the bolt on the front was how you adjusted those, and boy was I wrong. I used the table to cut out a cheap, fast "wrench" for these (had to be less than 1/8" thick), and finally got those bearings adjusted. What do you know... it cuts straight!<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8vlvKk71ouGZhry9WCqX-xPYcffjl_D4VcRVn0Dc9vpzUCeAB4fRQ4Qu7ekZaoR8G1s_cIGZZ9TltDpx_qFvkG06p22vWK5hN8VL3TT5IreXNwC3Iq9JbLxfV44wu2ZzgO6jUQHuA_v0ZJ5SgN3CDRT439uz8GpY3TBSv7CdLE5I0hC4JvtkGRc9Q/s4032/20221231_112225.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8vlvKk71ouGZhry9WCqX-xPYcffjl_D4VcRVn0Dc9vpzUCeAB4fRQ4Qu7ekZaoR8G1s_cIGZZ9TltDpx_qFvkG06p22vWK5hN8VL3TT5IreXNwC3Iq9JbLxfV44wu2ZzgO6jUQHuA_v0ZJ5SgN3CDRT439uz8GpY3TBSv7CdLE5I0hC4JvtkGRc9Q/s320/20221231_112225.jpg" width="320" /></a></div><p></p><p>Now I can start a cut and walk away! It's about an hour for each cut, so that hour spent tuning the band saw is well-justified. I got through two and a quarter cuts (I have 8 of them), and the bandsaw blade snapped.</p><p>I ordered a 12 TPI blade on Amazon, because it said it would work for tubing (I think I want an 18-24 TPI blade, really for thin walled tubing after looking at how far apart the teeth are), and slapped it on there. That thing made the cut in 5 minutes flat. I absolutely can't walk away with the speed that thing chews through aluminum. Anyway, I finished those cuts, went to the </p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis533nMxTDX1G4t-rgkj4VmSFSue7iaJ0gffFbDwh9BByNPL5fv-WbbO_Z_64GqxGeykXEiRnRPG6lH6sxbojNdLLFVydbt-O4ixvKRiAufekFueBGJei2YDKdLDByiTsyUUo_t6zNs3RPJPfOjeNYrhvVKH5NqEwkCfMer2tmxv-5GGePNgujsdOY/s4032/20230105_171554.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis533nMxTDX1G4t-rgkj4VmSFSue7iaJ0gffFbDwh9BByNPL5fv-WbbO_Z_64GqxGeykXEiRnRPG6lH6sxbojNdLLFVydbt-O4ixvKRiAufekFueBGJei2YDKdLDByiTsyUUo_t6zNs3RPJPfOjeNYrhvVKH5NqEwkCfMer2tmxv-5GGePNgujsdOY/s320/20230105_171554.jpg" width="320" /></a></div><br />I headed out to the scroll saw, ans snapped two blades before I'd even gotten 1/8" through those horizontal cuts. I switched to the milling machine - when you get tired of trying to conserve aluminum scrap size for later use (I was planning on using the middle blocks, cut in half, to make some of the other ends of these clamping tools), you just give up.<p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVLqAdhf2EiAu9J4ZvE-wvUcPq8vyF96w546tKNBfTHXK_C8xBVcitFShYw6W4D2wK3T58LLpx1-O6XTfgA-GiWshLTTxUwD25CE1RKtvoRxNIubZa9HX8a3Kbav6sJfowUiK387X97gUKN9PDCHf3-eZARKpotsjpMHWB1u8rh7PO36SG9PBBuOi7/s4032/20230112_101928.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVLqAdhf2EiAu9J4ZvE-wvUcPq8vyF96w546tKNBfTHXK_C8xBVcitFShYw6W4D2wK3T58LLpx1-O6XTfgA-GiWshLTTxUwD25CE1RKtvoRxNIubZa9HX8a3Kbav6sJfowUiK387X97gUKN9PDCHf3-eZARKpotsjpMHWB1u8rh7PO36SG9PBBuOi7/s320/20230112_101928.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi073Ufm88EI3P8XBLB40mOzd4FKNePlcuAnk7MhLdlf2XGSVIztvnDfTFShzndKQSlYubhPOJ7bkuCJRCeDDXwe8HjSevgSJAImg7Tzm35cy3TilO4NBDsX1I-u0jkQvdsz_dKmQyQ1uhEbSO82s8R7weyQd7xqSVrXJOdSnWBlLMG0EQRBHIQViv/s4032/20230112_105131.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi073Ufm88EI3P8XBLB40mOzd4FKNePlcuAnk7MhLdlf2XGSVIztvnDfTFShzndKQSlYubhPOJ7bkuCJRCeDDXwe8HjSevgSJAImg7Tzm35cy3TilO4NBDsX1I-u0jkQvdsz_dKmQyQ1uhEbSO82s8R7weyQd7xqSVrXJOdSnWBlLMG0EQRBHIQViv/s320/20230112_105131.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwI6DnZcF-lOmIPMQZTPviuXkoEYh4AEsZ0WemTMWieLUJ4Jc6iUpKx_XvgO29iBDkFSfSY1DNYXC1tTTFh_zx7TIr_8tvD21CEcS3_TZCjKskNjl6Jx1q7YCQPrmRkoNP3eeu1ul8Ui9pGGsg52K93pe7Eg8U_EtIP_LwTKoMGF6n6tHDO5PYH4VR/s4032/20230112_105206.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwI6DnZcF-lOmIPMQZTPviuXkoEYh4AEsZ0WemTMWieLUJ4Jc6iUpKx_XvgO29iBDkFSfSY1DNYXC1tTTFh_zx7TIr_8tvD21CEcS3_TZCjKskNjl6Jx1q7YCQPrmRkoNP3eeu1ul8Ui9pGGsg52K93pe7Eg8U_EtIP_LwTKoMGF6n6tHDO5PYH4VR/s320/20230112_105206.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwka6LElRLHPJvWRJjrf_SOUGgrEAuPFPERlykugE2etNCn4o2-XSLTa-0maf9diAb_mFOOUCUFm3L_dkoev-vEvBpMruU_hH1BcaysW_gaTt1qeFC8IKiC-ozRVjYuN56TVRSmATEVe4Z3mR2bdgYK7pl_1MAAX7QVqhpqILklIEDETYIq6llLvbZ/s4032/20230112_105302.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwka6LElRLHPJvWRJjrf_SOUGgrEAuPFPERlykugE2etNCn4o2-XSLTa-0maf9diAb_mFOOUCUFm3L_dkoev-vEvBpMruU_hH1BcaysW_gaTt1qeFC8IKiC-ozRVjYuN56TVRSmATEVe4Z3mR2bdgYK7pl_1MAAX7QVqhpqILklIEDETYIq6llLvbZ/s320/20230112_105302.jpg" width="240" /></a></div><p></p><p>With one end cut to separate the squares, I went back to the bandsaw for the final cut to separate the squares from the middle chunks.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-nPRAqqfKuQWoKvHZNg331bmPR_blwzmFkHyCzUb7hL1PSxz1nB1M3ntIvUiIhGUq0GoVmqVmOiw8Awc3n17XXI3QO8-F0QL3g6hrvOkrBqWMsDTyT92BW1uCKwCvXj84jsN4IeFAqaCKQezeQlMWNVkUPtuy6d8W-dM3yKHEindXRNStdEdeUQ4x/s4032/20230112_120509.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-nPRAqqfKuQWoKvHZNg331bmPR_blwzmFkHyCzUb7hL1PSxz1nB1M3ntIvUiIhGUq0GoVmqVmOiw8Awc3n17XXI3QO8-F0QL3g6hrvOkrBqWMsDTyT92BW1uCKwCvXj84jsN4IeFAqaCKQezeQlMWNVkUPtuy6d8W-dM3yKHEindXRNStdEdeUQ4x/s320/20230112_120509.jpg" width="240" /></a></div><p></p><p>I now have six rough squares. I took one of my parallel bars for clamping, and simply used it as a straight edge. I used a known, good square that was clamped to it and trammed it in, then locked it down. The next steps were fairly easy. It was simply a matter of putting a parallel in between that straight edge, and snuggling the good, straight side of the squares to that, then locking it down and milling the perpendicular side.<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjZS0zng8YnNuB1QfsdkBs8qsDXmNjt1ilbdrwAUiU2nZAKZmJiXKW29OMUo_KcULr9-BDByT_ddQ7VdTYSX_hR6m9jeHl-Y5eNUdbJuQcVjpRQW_0GqtQRKIvpVUA5TmUuPXk1ngNgKql5atm0mZcZrwnFZ2e12yKZ1uVV-Y60R2Q0C88E88NZxMT/s4032/20230112_133030.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjZS0zng8YnNuB1QfsdkBs8qsDXmNjt1ilbdrwAUiU2nZAKZmJiXKW29OMUo_KcULr9-BDByT_ddQ7VdTYSX_hR6m9jeHl-Y5eNUdbJuQcVjpRQW_0GqtQRKIvpVUA5TmUuPXk1ngNgKql5atm0mZcZrwnFZ2e12yKZ1uVV-Y60R2Q0C88E88NZxMT/s320/20230112_133030.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhdJQzkDvSuZ4xdlNnEfm5kLhoSoL_W8EuyEZz9wmOgXF8JfDBz17zTosGG2HFvbjaZbmkny5Zw6cl07yQ4RLY_E-MkZO01CcksC86iA_uBchrRluFKbbA1pmiVbibdHQ8LefWxFDvi0i1SYrualv6YUTKujKFatye8CshMPk5gdC9k13vyX0QoaR_/s4032/20230112_141138.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhdJQzkDvSuZ4xdlNnEfm5kLhoSoL_W8EuyEZz9wmOgXF8JfDBz17zTosGG2HFvbjaZbmkny5Zw6cl07yQ4RLY_E-MkZO01CcksC86iA_uBchrRluFKbbA1pmiVbibdHQ8LefWxFDvi0i1SYrualv6YUTKujKFatye8CshMPk5gdC9k13vyX0QoaR_/s320/20230112_141138.jpg" width="320" /></a></div><p></p><p>There we go. Six perfectly good squares, even if they aren't yet usable. So, each one now goes into the tool makers vise, and gets milled parallel (and to the same depth - I used a depth stop to make sure each arm was exactly the same width).</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6WB7T_hNH-stYoi3Mcl1nDyEgDMRStRxroi8asooAnKFkQbve2YgjOhQEDFKHRE7E_b3BYFQbhm5_aahkCrQTu7EytcitOPoEIXMUuW7GXnzjLsDi1u2FEyBo7MTjFJ75ux452Rm9CXilkXOYQToTc4saA8ktnVrAfiEpONycm6X8FGuKE1C6Ktn3/s4032/20230113_111123.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6WB7T_hNH-stYoi3Mcl1nDyEgDMRStRxroi8asooAnKFkQbve2YgjOhQEDFKHRE7E_b3BYFQbhm5_aahkCrQTu7EytcitOPoEIXMUuW7GXnzjLsDi1u2FEyBo7MTjFJ75ux452Rm9CXilkXOYQToTc4saA8ktnVrAfiEpONycm6X8FGuKE1C6Ktn3/s320/20230113_111123.jpg" width="320" /></a></div><p></p><p>Now I have six squares that are parallel, perpendicular, deburred, and almost usable. I marked them out for drilling at 1" between holes, with a 1/2" starting point.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2n8p-ljx-6c-M37Q1bNUsvmBfH_rjOpG3kDKuWQT6SVGl06-YTpzCl_YUin3QckmbHsdtOVYgH46jQNiYwOTN31Y0BpC0IhxiA4zh70Vr8IuPcjZGVQN1k13-j9u8UUiX1qqw5k2r0kRZcdCSguOeXfZxUlicYX0QTStpjfpMty6s3c-so7gGl3_w/s4032/20230113_160814.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2n8p-ljx-6c-M37Q1bNUsvmBfH_rjOpG3kDKuWQT6SVGl06-YTpzCl_YUin3QckmbHsdtOVYgH46jQNiYwOTN31Y0BpC0IhxiA4zh70Vr8IuPcjZGVQN1k13-j9u8UUiX1qqw5k2r0kRZcdCSguOeXfZxUlicYX0QTStpjfpMty6s3c-so7gGl3_w/s320/20230113_160814.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2rGqHmTPMLUb4Wh3LEvgtH4ePbJuvaeXuIGJk2VC_Fm3jpIQP6bxNz9SHgs2viWWfPw7G7K0y_3PaYI1VhnjqlnW5aNj2DZ2P_15eWwA7RjFt8jTe9SlKrdF4VYlj6wl9rVaKyndwm-g_DVSIptJXQtlQPJNO1aMKcqSv3vad3hmePRoUg8QRxFpx/s4032/20230113_162144.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2rGqHmTPMLUb4Wh3LEvgtH4ePbJuvaeXuIGJk2VC_Fm3jpIQP6bxNz9SHgs2viWWfPw7G7K0y_3PaYI1VhnjqlnW5aNj2DZ2P_15eWwA7RjFt8jTe9SlKrdF4VYlj6wl9rVaKyndwm-g_DVSIptJXQtlQPJNO1aMKcqSv3vad3hmePRoUg8QRxFpx/s320/20230113_162144.jpg" width="320" /></a></div><p>After drilling with a letter P (the holes on the original set are 0.316", and I wanted nearly interchangeable clamps, and worried about eventual anodizing decreasing the hole size, so I went with a letter-P-sized bit) and a quick deburr (I couldn't find my countersink bit), I have perfectly usable squares that are the right size for drawers. Incidentally, I found some smaller blocks on Amazon - I don't know if they are square, but I had to buy them. These new ones are tiny, while my custom-made ones are a medium size.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigPntRnBNJS2l-HNNVJTLrv0Pv7mC8OXzSBj8-xNHDZ7F-q-sIKDA8Uf9My-u1Gkwc7m3GlDvHUAWyMn0-4y_TeLNmL1XSwcbdFyQwjPv7LMHH5zeG23qAvQ5PW5r0tM7vaDpypwf74qMS1EMXYTijF2dTEjHfskI0ei5iYiqdNCJh5ri287GclLhm/s4032/20230113_165347.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigPntRnBNJS2l-HNNVJTLrv0Pv7mC8OXzSBj8-xNHDZ7F-q-sIKDA8Uf9My-u1Gkwc7m3GlDvHUAWyMn0-4y_TeLNmL1XSwcbdFyQwjPv7LMHH5zeG23qAvQ5PW5r0tM7vaDpypwf74qMS1EMXYTijF2dTEjHfskI0ei5iYiqdNCJh5ri287GclLhm/s320/20230113_165347.jpg" width="240" /></a></div><p></p><p>Granted, mine still have mill marks on the inside. Since I'm using the outside, I'm leaving that. When (or "if") I ever decide to anodize these things, I'll actually set them all up together and sand with a fine grit to polish them up first, and that should remove mill marks.</p><p>I needed the clamping blocks next. I ordered a 3/4"x1" aluminum bar, and sliced it into little blocks. I squared them up on the tiny mill, and drilled a single hole in each one, with a debur process. Yes, I did set them up as a castle wall once, just because I had a lot of little aluminum bricks.<br /></p><p> <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGEroZn2eshVExzR-Nhx2PfKYaKtyIDZYrslksoWthJNs0YNdabdQ4yvxC0EZ3-ZyebCBG2xEvpvzpM7aQSs2eij1DX4ZKBIOi25xsrXzydyaz_--5_D83zLPEDOdoMb6_ZXxnHEOmODicil9wHRqkhDHZsMGcF3yGcLOQv30m5iKJKnaS5dh2XhLR/s4032/20230114_131733.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGEroZn2eshVExzR-Nhx2PfKYaKtyIDZYrslksoWthJNs0YNdabdQ4yvxC0EZ3-ZyebCBG2xEvpvzpM7aQSs2eij1DX4ZKBIOi25xsrXzydyaz_--5_D83zLPEDOdoMb6_ZXxnHEOmODicil9wHRqkhDHZsMGcF3yGcLOQv30m5iKJKnaS5dh2XhLR/s320/20230114_131733.jpg" width="320" /></a></div><p></p><p>Anyway, with those done, next was to slice a 1/4" stainless steel rod into 5" lengths, round over each end, and then thread one size for 3". These will be the bars. I knew I had to bend these, too, so while I was at the lathe doing the threading, I also cut two work setup jigs that could insert into some pipes I had laying around.</p><p>These work setup jigs are basically a closed-end tube with a set depth specifically to make it easier to get consistent results. Each was drilled one 3 1/2" deep and one 1/4" deep with a letter "F" (just a hair over 1/4" diameter for a slip fit), and turned down on the outside to fit inside the pipe. These were done out of aluminum in order to preserve thread.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhP_NrKoduMAFoWfKfxN8_HqY-YN2vUXbeQKV_zPJ5g_Xrn8KgEWgOG5QeFhzAxD-klJnn9dhuD7erwinRqRuOo6d2YPef8ruw1LD5tbR77jy3dFFH8Oqqss8l7svixVdxbGx7BoIVHbXEHFgNQdk7yF17Q4ZXkLlfZ782lJiDKENxCxOwfCdQnH6vM/s4032/20230220_142022.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhP_NrKoduMAFoWfKfxN8_HqY-YN2vUXbeQKV_zPJ5g_Xrn8KgEWgOG5QeFhzAxD-klJnn9dhuD7erwinRqRuOo6d2YPef8ruw1LD5tbR77jy3dFFH8Oqqss8l7svixVdxbGx7BoIVHbXEHFgNQdk7yF17Q4ZXkLlfZ782lJiDKENxCxOwfCdQnH6vM/s320/20230220_142022.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQjRBZ4hgU1Q4mRjIXwh2VAaCmGj-ZmVnOVmzK3bGRPyw21v8Dp5T2ifNBbXW6CG2zVoRYbj_GZv6Toh_IQDam8clU7JkO0GMM_M6JVbRfb59NBXqb5yLRUw0P95BqUEPcKULHQV9dLSQCHVVZojiRgj8P80SQyohMGcbOWoDubVMCDQx2MDfmiI8z/s4032/20230220_142041.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQjRBZ4hgU1Q4mRjIXwh2VAaCmGj-ZmVnOVmzK3bGRPyw21v8Dp5T2ifNBbXW6CG2zVoRYbj_GZv6Toh_IQDam8clU7JkO0GMM_M6JVbRfb59NBXqb5yLRUw0P95BqUEPcKULHQV9dLSQCHVVZojiRgj8P80SQyohMGcbOWoDubVMCDQx2MDfmiI8z/s320/20230220_142041.jpg" width="240" /></a></div><p></p><p>I took the pipes outside on a cold Saturday morning, and heated up the section of each threaded rod until it was nice and hot, and bent them up to square. Honestly, I should have threaded the whole things on the lathe - those dies messed up on some of the threads.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEheh_SJkD58Nlie9llRTo1SRxD5DRwvqrTOuXrB-XUG6FYhWqHH5Q7yop4df5H-ECKiXa715H7MBmTxM0K29zdnHBUxJxv7tm-Lzu96Iq8zycZvLez_RIQyBIF92Tv3sBWQZ6WW1sp353yavCqDI8Y7xKGRY9s02i2N9DY5Ye54ZJ0WC3wFvG7QjEf2/s4032/20230225_121702.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEheh_SJkD58Nlie9llRTo1SRxD5DRwvqrTOuXrB-XUG6FYhWqHH5Q7yop4df5H-ECKiXa715H7MBmTxM0K29zdnHBUxJxv7tm-Lzu96Iq8zycZvLez_RIQyBIF92Tv3sBWQZ6WW1sp353yavCqDI8Y7xKGRY9s02i2N9DY5Ye54ZJ0WC3wFvG7QjEf2/s320/20230225_121702.jpg" width="320" /></a></div><p></p><p>They are now functional so I can get back to my tool chest build!</p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-6344054727834741822022-12-16T15:00:00.005-08:002023-01-05T15:43:06.342-08:00Turning The Butt End of a Handle<p>We have a Christmas present, with the presentation a week early. So, please don't tell the anonymous person who this is for that it's done. They know it's being made. Anyway.... since I'm letting the cat out of the bag early, here we go.</p><p>I was asked if I could create an <a href="https://www.woodcraft.com/products/stainless-steel-hawk-point-ice-cream-scoop-kit" target="_blank">ice cream scoop</a> for a family member as a gift. I was given a wide berth on this one. Since this unnamed individual is a hunter/fisher, I chose a <a href="https://www.woodcraft.com/products/spectraply-turning-blank-buckskin-2-x-2-x-10" target="_blank">SpectraPly</a> blank. It's essentially a dyed and laminated block of plywood. The full kit stuff is all available through Woodcraft (they even have other things like <a href="https://www.woodcraft.com/products/2-1-2-miniature-pizza-cutter-turning-kit-chrome" target="_blank">pizza cutters</a>). I turned the blank round, cut the surface (this is called facing in the metal lathe world) for whatever was on the front of it, drilled it for an insert (I had to get my own insert for the ice cream scoop, since I do not like threading wood), and glued it all up like any normal turning assignment. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihwDL0xPbBUZfVQkiQYGcNPcvDdSoBTVAsgSYFdaiT1lAVR_2jO_QJQT8LqtV64EXBQXzqthTAOZsFvkjQ3a4uEzHdh5jBUya9lervidTQsIkVpmuG0H0VLrkNITNyEToPQkHseTO-eGA6aRZHTcbKooYkX_4akRxA574SW4V_CZ2U9K402LIN-XXp/s4032/20221210_161455.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihwDL0xPbBUZfVQkiQYGcNPcvDdSoBTVAsgSYFdaiT1lAVR_2jO_QJQT8LqtV64EXBQXzqthTAOZsFvkjQ3a4uEzHdh5jBUya9lervidTQsIkVpmuG0H0VLrkNITNyEToPQkHseTO-eGA6aRZHTcbKooYkX_4akRxA574SW4V_CZ2U9K402LIN-XXp/s320/20221210_161455.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8OwQlb1fkJuZqqMswAFL4kVm3j-hd1J3GeB-P6wvU_ecoDlSXvdMjlbTQRvG7bGYOYIqGp2AYj6k03PV-Y_fNmSLhxVQeGkXc9j5obxq0LHJAYpfsYxHr4nqD8IGaviQMT2kO0mD68vH20SfpGq-6eSmoFVwUAgVAByb7cD1NwOmCJDDqxs1Z-8tE/s4032/20221210_161503.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8OwQlb1fkJuZqqMswAFL4kVm3j-hd1J3GeB-P6wvU_ecoDlSXvdMjlbTQRvG7bGYOYIqGp2AYj6k03PV-Y_fNmSLhxVQeGkXc9j5obxq0LHJAYpfsYxHr4nqD8IGaviQMT2kO0mD68vH20SfpGq-6eSmoFVwUAgVAByb7cD1NwOmCJDDqxs1Z-8tE/s320/20221210_161503.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuGuWhC8iXdopPQArXCrSmzYH2RGYUi6t-MVTI7hKSK_eLivCA9cINr11R4bJP6HsXsOXS1YTLSMfh5owPg96a-rbkL9xrXQZzGaDro7s9j2teXNni1pbwLNw-1INF0z28paMJ7zzqUbz5C0S1vWllMRhgfk2RDNFDKXvCmoYhztNP_UlaMo4bd0lF/s4032/20221210_161509.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuGuWhC8iXdopPQArXCrSmzYH2RGYUi6t-MVTI7hKSK_eLivCA9cINr11R4bJP6HsXsOXS1YTLSMfh5owPg96a-rbkL9xrXQZzGaDro7s9j2teXNni1pbwLNw-1INF0z28paMJ7zzqUbz5C0S1vWllMRhgfk2RDNFDKXvCmoYhztNP_UlaMo4bd0lF/s320/20221210_161509.jpg" width="320" /></a></div><p>So, if you check those pictures, you'll see that the butt ends of these two handles are still square. I do want them turned better, and this is the challenge presented to me. The handles are all about 1 1/4" inner diameter, which is a little larger than the handles. PVC pipe is under pressure, and will compress more when those stresses are released, so I opted to use it for the solution. I cut along the lines about 2" (for a spacer for the chuck jaws), and then cut each off. If you cut the band off and then cut lengthwise on the PVC, be prepared for the pipe to grab the saw and do weird things with it (like a table saw throwing it at high velocity right at your face, arms, or chest).</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiS0jjz7u73IOrFU_Fdkx1J1Lu0a0lfWhSJx-DnYNFeeJuAxLki8L2FHmuqDOfhtK8hlDeOwDJL82uQPBL7EhQ_fjYPB8wOljYkZTem9q41rJLC_HiCqAfTHyK_VFbqr5j8m908DLGbRd6QrBOk45lpytFTXXFLT9qnK109eR9ogwXcjPZ8V2ixsiro/s4032/20221210_161533.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiS0jjz7u73IOrFU_Fdkx1J1Lu0a0lfWhSJx-DnYNFeeJuAxLki8L2FHmuqDOfhtK8hlDeOwDJL82uQPBL7EhQ_fjYPB8wOljYkZTem9q41rJLC_HiCqAfTHyK_VFbqr5j8m908DLGbRd6QrBOk45lpytFTXXFLT9qnK109eR9ogwXcjPZ8V2ixsiro/s320/20221210_161533.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmh5b_cHF-ST6oqx8rDh-sJJpBR5WEghvdcNxFckMU-I5sd1xwzjwXuAw6Pb5lWstpJxU8-rsIpHmQrhbwRDCS9ojfEQALsP6r4nrRH3MdFzVE-q6iWKozn3Xeoyi8PesgX2VvUrN6yzyoCl4DFL5QVRg1TNGCGJV4--1HPsh34iSO0kMR6Gti3WaG/s4032/20221210_161537.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmh5b_cHF-ST6oqx8rDh-sJJpBR5WEghvdcNxFckMU-I5sd1xwzjwXuAw6Pb5lWstpJxU8-rsIpHmQrhbwRDCS9ojfEQALsP6r4nrRH3MdFzVE-q6iWKozn3Xeoyi8PesgX2VvUrN6yzyoCl4DFL5QVRg1TNGCGJV4--1HPsh34iSO0kMR6Gti3WaG/s320/20221210_161537.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitOHdsTEM0y9XEgupwJTTPc7QcxjPyIRNOeBlCJgwfQbI7j1DymCPM3Aa7TpsNTCygKPziBxuU-YxEf_Ca5vyg-a-yoCZZoCCO3vVO4TiCZYGSSJtUm3Ic8V0uLgtxvMJJxE2am2CRYYXr1x6i5RayNOvY3o8V-o70vVw3teYe5aSHgvuz4uOnat3I/s4032/20221210_161555.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitOHdsTEM0y9XEgupwJTTPc7QcxjPyIRNOeBlCJgwfQbI7j1DymCPM3Aa7TpsNTCygKPziBxuU-YxEf_Ca5vyg-a-yoCZZoCCO3vVO4TiCZYGSSJtUm3Ic8V0uLgtxvMJJxE2am2CRYYXr1x6i5RayNOvY3o8V-o70vVw3teYe5aSHgvuz4uOnat3I/s320/20221210_161555.jpg" width="320" /></a></div><p>This allowed me to put it in the only chuck I had with a large enough inside diameter for this handle, where I could turn the remainder down and put the grip grooves in.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSU9WnwjKdT-Ju4CLqye1vamjgQNIzv98jDTy-couTMyTj1EvCz5-mLjruhGPyyQfSKqulGFdvhy7c1TAsKv-ow0cLNe0YUFTy8RPuaAi3OnQg1Y2runQv1tPacxl8WyJSvuT_AgG4gKCHnv63ykvBKSUb4zJdrAjpmrHrHpgP8gEc2gdW5iAJE6wQ/s4032/20221215_173816.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSU9WnwjKdT-Ju4CLqye1vamjgQNIzv98jDTy-couTMyTj1EvCz5-mLjruhGPyyQfSKqulGFdvhy7c1TAsKv-ow0cLNe0YUFTy8RPuaAi3OnQg1Y2runQv1tPacxl8WyJSvuT_AgG4gKCHnv63ykvBKSUb4zJdrAjpmrHrHpgP8gEc2gdW5iAJE6wQ/s320/20221215_173816.jpg" width="320" /></a></div><p></p><p>A quick coat in lacquer and glued together, and it looks sharp!</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9BTr1kEQg9pq3icfnrjCh9JgQkhf0nz25IIxfWSa6lHW9L1-OSB0tQXzrF6XnPLz-7D4U5IgZlOUogJPVv---TV6PR-NySVYiPu5O_aGSemerZxdL1-4QRW6aqTG4Do2X6wrw4a-MGljgQ7df2KZ8eGcFIPnEaPZH58CQXjAwMy2QLHx39nbXPqsX/s4032/20221216_154031.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9BTr1kEQg9pq3icfnrjCh9JgQkhf0nz25IIxfWSa6lHW9L1-OSB0tQXzrF6XnPLz-7D4U5IgZlOUogJPVv---TV6PR-NySVYiPu5O_aGSemerZxdL1-4QRW6aqTG4Do2X6wrw4a-MGljgQ7df2KZ8eGcFIPnEaPZH58CQXjAwMy2QLHx39nbXPqsX/s320/20221216_154031.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4ildpPxrA2LGjdMYLQvZvZbeW-l3_0BMNKlL-9Fh6nIVYLA62k7Ao2mIj9bkwnqo8Twkd9f7S0FO_wsCW09Dn4QUEhTo8uDU1MWIpHIiuhAy6jKG9jmvpUgUouFaSQ2NPq_0D9Djr2EN5Vg96vHmqFAr_l43opSEBJse4PPUOlUmnL5bsU2fUUNPV/s4032/20221216_154040.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4ildpPxrA2LGjdMYLQvZvZbeW-l3_0BMNKlL-9Fh6nIVYLA62k7Ao2mIj9bkwnqo8Twkd9f7S0FO_wsCW09Dn4QUEhTo8uDU1MWIpHIiuhAy6jKG9jmvpUgUouFaSQ2NPq_0D9Djr2EN5Vg96vHmqFAr_l43opSEBJse4PPUOlUmnL5bsU2fUUNPV/s320/20221216_154040.jpg" width="240" /></a></div><br /> I hope they like them!<br /><p></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-18284095726942509792022-12-08T20:29:00.004-08:002022-12-08T20:29:44.163-08:00Puffed Out Chest - Part A<p>The <a href="http://www.silverhawk.net/2022/01/i-should-table-that-project.html" target="_blank">table project from over the late-summer/fall/early-winter</a> had a few left-over beams. I decided to try my hand at making a few <a href="https://www.garagejournal.com/forum/threads/gerstner-42.326394/" target="_blank">Gerstner #42</a> tool chests from some of the boards, in an attempt to flex my woodworking muscles. This is going to be similar to the table top exercise only in a few parts. There are eleven panels for this, and I'd suggest a quarter of an inch bigger in every dimension to ensure that when you are done, you have good sizes that can be trimmed back down :</p><ul style="text-align: left;"><li>Back panel (20" wide x 16" high)</li><li>2x side panels (16" high x 9.5" deep)</li><li>Top and bottom panels (20" wide x 9.5" deep)</li><li>One front, top panel (20" wide x 5" high) for the top</li><li>One front, movable panel (not glued into the box) (20" wide, 11" high)</li><li>One internal bottom for the bottom inside the lid area (19.5" wide x 9" deep)<br /></li><li>One horizontal, internal drawer separator (19.5" wide x something deep I can't remember)</li><li>Two vertical drawer separators (can't remember any of these dimensions)<br /></li></ul><p>The process is :</p><ol style="text-align: left;"><li>Slice the beams into boards (showed how to do that on the table project linked above, and I'm too lazy to show it again)f<br /></li><li>Plane the boards down (just over 1/2" for later sanding to final dimensions) (again, too lazy)<br /></li><li>Rip the boards to length to give clean edges (lazy... sensing a trend here)<br /></li><li>Slice the boards to length for each panel (TL/DR [too long, didn't read])</li><li>Cut dowel or biscuit joints/holes into the boards</li><li>Glue them up</li><li>Apply epoxy resin to fill the nail holes (and other imperfections)</li><li>Trim the boards to both squareness and size</li><li>Cut box joints (a new tool should show up here to cut these)<br /></li><li>Use a router guide (another new tool) to cut the slots for the draw runners)</li><li>Drill holes and cut mortises for panel locks, hinges, handles and actual key-locks</li><li>Test fit everything together <br /></li><li>Final sand all of the panels to prepare for the final glue up</li><li>Glue everything together</li><li>Stain (if that is going to happen)</li><li>Coat with a varnish or other protective layer <br /></li><li>Install the hardware</li><li>Make a lot of drawers<br /></li></ol><p>Oh, yeah... I'm making three of them (for a few people). (WHY do I always bite off more than I can chew?)<br /></p><p>So, with that let's get moving. I have a feeling (with how long the table top exercise went) that this could be a long project.</p><p>I sliced the beams down to length, planed them to thickness, and then ripped them lengthwise to get my basic building blocks.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrd5cZp8Bf790pOziJcwM-aPJujDrNO0jH1ZtGB1eYxsRwtc_6d41CJFERhMSCk_GSh_FT1n_KIPfLLn0GKpbYUMeahspKbSZCbAkRrhAZMcPzgntjgLB6bWtVDlZ7P6tT9gP9CaZGFtMi76P3Cey9QMKtGobdEZjMIg675iXqwdP0ZlZ5nyPHD-RU/s4032/20220302_144924.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrd5cZp8Bf790pOziJcwM-aPJujDrNO0jH1ZtGB1eYxsRwtc_6d41CJFERhMSCk_GSh_FT1n_KIPfLLn0GKpbYUMeahspKbSZCbAkRrhAZMcPzgntjgLB6bWtVDlZ7P6tT9gP9CaZGFtMi76P3Cey9QMKtGobdEZjMIg675iXqwdP0ZlZ5nyPHD-RU/s320/20220302_144924.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9IQeM5YmuXxDrqxFwXxU3pyuYZCfdsdvbfDkU_8BWWJz43jcbVVyq4WOb-nrayPpf04yLz2VFEgaymYDkfnEcSdsIGzD1FB3wgR_L9lS_sbWFPl3uyClwd-nFNyZaw5c5L69LTBVfvlRw4sjV2lTvOz5Rod69oW_zvgDNBeYjUlynVNVokRbiKt0S/s4032/20220302_144932.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9IQeM5YmuXxDrqxFwXxU3pyuYZCfdsdvbfDkU_8BWWJz43jcbVVyq4WOb-nrayPpf04yLz2VFEgaymYDkfnEcSdsIGzD1FB3wgR_L9lS_sbWFPl3uyClwd-nFNyZaw5c5L69LTBVfvlRw4sjV2lTvOz5Rod69oW_zvgDNBeYjUlynVNVokRbiKt0S/s320/20220302_144932.jpg" width="240" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4-q51denGAip3vkJ910mCYEuf3fk78lrDlFSmOdcs3wbiCQCxwytgPNpFq4zED9yGFFq3hetsGG_FSmqLkkewIWAMBQIi1F4abbVVZfuKPH4fL_4y93rBEWbux3lgPV-9x6uSX1VVdEoTewup8fYQ7-UC9w3XKFPwCeO0OQZEeDZuOfyLZzvaE5aZ/s4032/20220114_180049.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4-q51denGAip3vkJ910mCYEuf3fk78lrDlFSmOdcs3wbiCQCxwytgPNpFq4zED9yGFFq3hetsGG_FSmqLkkewIWAMBQIi1F4abbVVZfuKPH4fL_4y93rBEWbux3lgPV-9x6uSX1VVdEoTewup8fYQ7-UC9w3XKFPwCeO0OQZEeDZuOfyLZzvaE5aZ/s320/20220114_180049.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUfi2nP6B_Ro3ZLBswq66kac8sPnMBHWCPBhEKaNyuGSZPJUpHq689AKMO4LcBONzjVEGCIzjiqpu_H78osX8lhZlWjsllbpOmaFuSQhkZT8JymUWVyRJfGujUlT75tDX2_CVQfzEyxJudf1-pC5WDNCmFor9ESslA9P80XntmsTgydMEykQO5Rzrc/s4032/20220114_182255.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUfi2nP6B_Ro3ZLBswq66kac8sPnMBHWCPBhEKaNyuGSZPJUpHq689AKMO4LcBONzjVEGCIzjiqpu_H78osX8lhZlWjsllbpOmaFuSQhkZT8JymUWVyRJfGujUlT75tDX2_CVQfzEyxJudf1-pC5WDNCmFor9ESslA9P80XntmsTgydMEykQO5Rzrc/s320/20220114_182255.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcpQXzJdxlJXkjnianDLkPZusoBgRtmLH34ChX3KYpnS6GVI15RwDUZA0DWAIfX2_F5YkKB8deHQAI4Ed1PYkGwSVTnWXCqBylTZHTPEOycOHD6L7He4DJZkcACHFSHvj6yfwDSXoymteLvTbFbQ92_STSHa_49jpNkqVg6gU0F8v42oIhxQWrdG6r/s4032/20220114_182302.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcpQXzJdxlJXkjnianDLkPZusoBgRtmLH34ChX3KYpnS6GVI15RwDUZA0DWAIfX2_F5YkKB8deHQAI4Ed1PYkGwSVTnWXCqBylTZHTPEOycOHD6L7He4DJZkcACHFSHvj6yfwDSXoymteLvTbFbQ92_STSHa_49jpNkqVg6gU0F8v42oIhxQWrdG6r/s320/20220114_182302.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyGyaDQ0lYPm7FaUwb0n-8ZdKIr9K_DeZ0Ne2d65dJkS10Mz8tVMya0DKleFuV2f9j5RgkAdCL7idOfS8uo65sggbaduKstDCCkmpoVzO5grm0eWspik_sVceqea8L0JJJGyIYfCLxevm9V64GOcPfd-GWlKXKV5m7h26yO_MbS_QpgGSkjMYbOHwZ/s4032/20220114_182304.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyGyaDQ0lYPm7FaUwb0n-8ZdKIr9K_DeZ0Ne2d65dJkS10Mz8tVMya0DKleFuV2f9j5RgkAdCL7idOfS8uo65sggbaduKstDCCkmpoVzO5grm0eWspik_sVceqea8L0JJJGyIYfCLxevm9V64GOcPfd-GWlKXKV5m7h26yO_MbS_QpgGSkjMYbOHwZ/s320/20220114_182304.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8kmAsn9quQCzsB8f7R8qwnNU-atbaanI0J3DiosTxwOzfIlEP70LJf_mPNnbOrwkmBdLeUKDN1pgMfsRhhJV5vGy7gIbqcQmYTP0mouzf8M52UqadfldSH9yjFN6wcS6yz8HgPMpEx9B1d3yFM_COXcMU8bEqNB7EdzWzSP6TD-YPvMHu_8PdOMxI/s4032/20220114_182912.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8kmAsn9quQCzsB8f7R8qwnNU-atbaanI0J3DiosTxwOzfIlEP70LJf_mPNnbOrwkmBdLeUKDN1pgMfsRhhJV5vGy7gIbqcQmYTP0mouzf8M52UqadfldSH9yjFN6wcS6yz8HgPMpEx9B1d3yFM_COXcMU8bEqNB7EdzWzSP6TD-YPvMHu_8PdOMxI/s320/20220114_182912.jpg" width="320" /></a></div><p>Next, I sliced them all to length for the panels I needed. Here are two tool boxes organized in "panels" that aren't glued up.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDbJndEO4GLn594ZV5Nyq3660wY5yzmprXxL0Ismn9sgs1Crb3Xl4pGNb3JbI48o72VRlWJ91rPkrGfvmM4UyJjpXVUjE4_2c0WFK0CHP0JUxChTX4lzQLalWj4Mjf-L31f-hjec30EGn2NKlg6DYCp1f4WMbhW_QtkecEDKBpfPcgHyWkblvdnPEa/s4032/20220305_081736.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDbJndEO4GLn594ZV5Nyq3660wY5yzmprXxL0Ismn9sgs1Crb3Xl4pGNb3JbI48o72VRlWJ91rPkrGfvmM4UyJjpXVUjE4_2c0WFK0CHP0JUxChTX4lzQLalWj4Mjf-L31f-hjec30EGn2NKlg6DYCp1f4WMbhW_QtkecEDKBpfPcgHyWkblvdnPEa/s320/20220305_081736.jpg" width="320" /></a></div><p>Okay. The next phase was something new. I had a biscuit joiner, but my weird little brain said this was a good chance to try my doweling jig. I took the panels, and I'd drill a hole in the side using the jig to get perpendicular. Then, I'd use the little nub that the jig came with to transfer the drill hole to the next board, and then (using another scrap board in between the hammer and the board I'm marking) I'd give a slight tap to transfer the point to the other board. Then I could use the same jig to drill new holes in the mating board. So, here we go. First, drilling the board :</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhU3hSR6tgkgt8MLymOCDE0P6C22k-lVaZkGVyhEBnvsaz9zqzIEgA0I_aLMACJrIdu3_K8LKSxsIk0VHQwqJmPib1EYz7M32FYOZJYTBwo3Q_Dt70xUc0kGUEqdQ7YI8HyelKaWn6jX0ykbsS50cN1U-3w1u7ktiCnCCaodbaTywHiQ-TLvZE_aZlm/s4032/20220305_132433.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhU3hSR6tgkgt8MLymOCDE0P6C22k-lVaZkGVyhEBnvsaz9zqzIEgA0I_aLMACJrIdu3_K8LKSxsIk0VHQwqJmPib1EYz7M32FYOZJYTBwo3Q_Dt70xUc0kGUEqdQ7YI8HyelKaWn6jX0ykbsS50cN1U-3w1u7ktiCnCCaodbaTywHiQ-TLvZE_aZlm/s320/20220305_132433.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhb0Qm580DobeP15dgA30hpqOq5aF836P984d2rYBiYlif8C7TaRwZk3-dbPBy1h8Roa6vXWsE6kz87nt9qoJ3wv7FH-zkIOYVAA6LGf1A9IdIFAcxwiJa3VUiOxybkvccjUFzAvj0Q4ycdD2_221rzwjHM6wTEDuaXUNIokO4n9TcmCxTFvhjurqKL/s4032/20220305_133003.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhb0Qm580DobeP15dgA30hpqOq5aF836P984d2rYBiYlif8C7TaRwZk3-dbPBy1h8Roa6vXWsE6kz87nt9qoJ3wv7FH-zkIOYVAA6LGf1A9IdIFAcxwiJa3VUiOxybkvccjUFzAvj0Q4ycdD2_221rzwjHM6wTEDuaXUNIokO4n9TcmCxTFvhjurqKL/s320/20220305_133003.jpg" width="240" /></a></div><p></p><p>Then, marking the next board :</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis-UzeouIZhjJ7oYdaFaX25S__mRg-XaCl5xB9368fAoDqudDdcr6ltpFK-nwl7wqyQp8BuSOZH4pS_PVK8Sn3XAZ-jzZ6MxiPHikMGx0e1akAoiHo790-8PfI1Gcnw0OxrB_hk4qe-lDYL_DdJoLWSCK6SqC-JXprhx1FTmOeLUCfJbDkOh8NThJx/s4032/20220305_134246.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis-UzeouIZhjJ7oYdaFaX25S__mRg-XaCl5xB9368fAoDqudDdcr6ltpFK-nwl7wqyQp8BuSOZH4pS_PVK8Sn3XAZ-jzZ6MxiPHikMGx0e1akAoiHo790-8PfI1Gcnw0OxrB_hk4qe-lDYL_DdJoLWSCK6SqC-JXprhx1FTmOeLUCfJbDkOh8NThJx/s320/20220305_134246.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOpbDmtuT7Xu3nmZteRZVQZsuM6TazM4YOyRE1mHagHofP2c8RFGzHjgiQiEQP9pQtFn65Rx2ETo9dd_WmUbpZF2RDHBQhnCEJUAVS1spR9Xac--8X9NGT0rXY4y9HPpGZZjv-5jPvVtYKnBv8KQhorr_ut826myH9PxkZ1KP0zwvwEsRSSj8y590I/s4032/20220305_134249.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOpbDmtuT7Xu3nmZteRZVQZsuM6TazM4YOyRE1mHagHofP2c8RFGzHjgiQiEQP9pQtFn65Rx2ETo9dd_WmUbpZF2RDHBQhnCEJUAVS1spR9Xac--8X9NGT0rXY4y9HPpGZZjv-5jPvVtYKnBv8KQhorr_ut826myH9PxkZ1KP0zwvwEsRSSj8y590I/s320/20220305_134249.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3NPF5bIVeEXIdnJh-IXUgQ-ztBrgOpCzEek6FXXKb_iMWXN802HJt4mFYpvvt-EaAH8tooGlVB_I5y7e8emJeoai6QDec0RqSKI3Bn_qKQwq_qK1wjQ3pjovAHiy-Yd15crnN_CClLGb5FLqOH3P9fPdu8OYmW5psNWfaro0t0u8tAkhl63IN8Y4i/s4032/20220305_134339.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3NPF5bIVeEXIdnJh-IXUgQ-ztBrgOpCzEek6FXXKb_iMWXN802HJt4mFYpvvt-EaAH8tooGlVB_I5y7e8emJeoai6QDec0RqSKI3Bn_qKQwq_qK1wjQ3pjovAHiy-Yd15crnN_CClLGb5FLqOH3P9fPdu8OYmW5psNWfaro0t0u8tAkhl63IN8Y4i/s320/20220305_134339.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhi361Pt_pebt13Foq7B9OT-tIBAoY43RlgthDAsErA7HeHyMsbBadHPpTUQUTxow7y818tv6TxcglwD-Li0JdZweFZMX37J5JPQDKII7mvB7yyfl5aI3aLUN4nytS7HEFkVNAXBQQc9JS5tIibyty-Bof1kaidq7F9_5Qsu0___T6VtU_lRdR25_ml/s4032/20220305_134352.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhi361Pt_pebt13Foq7B9OT-tIBAoY43RlgthDAsErA7HeHyMsbBadHPpTUQUTxow7y818tv6TxcglwD-Li0JdZweFZMX37J5JPQDKII7mvB7yyfl5aI3aLUN4nytS7HEFkVNAXBQQc9JS5tIibyty-Bof1kaidq7F9_5Qsu0___T6VtU_lRdR25_ml/s320/20220305_134352.jpg" width="240" /></a></div><p></p><p>At this point, I can glue the panels up. Lots of clamps would have made this MUCH faster, but I could only do one at a time.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcGuH_-VR7jiKzDmEBpDv8l7YpkKaLU2S8dClR4Ew6que6UYKM6u-w9mq6f22piEYSsrX45veFoN5AxdCS1QtkyH-KxrGRps3mqV9FJviakoUbtaAJFQpbUy13wXYONsup9Aspj3xaaxCV8ZNBGTzdlJzAsm8PLEwOEJD3czqROU7XzJDGu4Xmauoa/s4032/20220305_094037.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcGuH_-VR7jiKzDmEBpDv8l7YpkKaLU2S8dClR4Ew6que6UYKM6u-w9mq6f22piEYSsrX45veFoN5AxdCS1QtkyH-KxrGRps3mqV9FJviakoUbtaAJFQpbUy13wXYONsup9Aspj3xaaxCV8ZNBGTzdlJzAsm8PLEwOEJD3czqROU7XzJDGu4Xmauoa/s320/20220305_094037.jpg" width="320" /></a></div><p></p><p>I never did the holes in the same places. I had this fear that I'd mix up boards and get grains all wrong, so I intentionally placed the holes at different points along the boards. I put two dowels in the side panels, and three along the lengths of the front, folding panel and the top, bottoms, and the back. That should give some strength instead of a simple butt joint, and make this chest fairly stout and solid. I am doing 1/4" dowels for these, as I'm working in 1/2" wood.</p><p>It was at this time I wore my hands out (drilling and transferring holes and drilling the other side for 156 dowel, but who's counting?), and tried biscuit joining them - but that had horrific results. Those panels became the internal panels, because they could be cut a little shorter.</p><p>With the panels glued up, and with me organizing as much color grain continuity as I could, I had one tool chest with slightly darker walnut (transition from sap wood to heart wood) and two tool chests with the lighter wood (these are walnut, but not black walnut). With the slightly-darker walnut, I'm opting for brass hardware (which means a gold epoxy), and the other two will be chrome or nickel hardware (which means a silver epoxy). I went with "queens gold metallic mica" by Littarby to be exact, and I went with the brightest silver I could find (just "silver"). </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitADN_FD-YM-afj7hRew6VVq4BTLnWnVDwoypAMSs7o3JtZpzCNQYq8GaLR2mImyul2ir2mcka25LXuh4Tc9lfwJtGioTDdBBNrWhdH2tpz0FVXaVRW_E3lwy-Z-JngKEKqR7vc1gNAY8xgytPA4db42G75LgtW_FyqYnJGmcT71BRGofa_ZTFT8rf/s4032/20220430_160149.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitADN_FD-YM-afj7hRew6VVq4BTLnWnVDwoypAMSs7o3JtZpzCNQYq8GaLR2mImyul2ir2mcka25LXuh4Tc9lfwJtGioTDdBBNrWhdH2tpz0FVXaVRW_E3lwy-Z-JngKEKqR7vc1gNAY8xgytPA4db42G75LgtW_FyqYnJGmcT71BRGofa_ZTFT8rf/s320/20220430_160149.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiV1rRxJLx8_yNv-dwAmQyns6ZadcWPwd4dgSihVqlzOvOfLw6TjVkuKp4I64sV0IiBf1S4ies8Tc2CANqPeIvx3ATd8riInwExImjziWpvIWUyCXhVSd9_l_0UJ26GKw3dZZfc53aCVZRGCRXsf7RrbOCadsoMg7dwSJndqRZkoLSf4KBksnkLhN2M/s4032/20220430_160208.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiV1rRxJLx8_yNv-dwAmQyns6ZadcWPwd4dgSihVqlzOvOfLw6TjVkuKp4I64sV0IiBf1S4ies8Tc2CANqPeIvx3ATd8riInwExImjziWpvIWUyCXhVSd9_l_0UJ26GKw3dZZfc53aCVZRGCRXsf7RrbOCadsoMg7dwSJndqRZkoLSf4KBksnkLhN2M/s320/20220430_160208.jpg" width="240" /></a></div><p>The filling process also took as long as the glue up - I didn't have enough work surfaces, and I could only do one surface of each panel at a time (there are 6 for each panel - both faces and four edges - but I always left one edge along the grain exposed for a base surface to use when trimming to size later).</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsm9unjPv_p81aZcuI5w0IJOEKRjjWixNDF1uU3eP5I-v1vZO9puqI6kLkGsbVYqlNDsdVtnuTO5RzBFqGABjsIYxZumy2X4YaTS8qfkONo4dhdkkbkUUQCZ27FUeJI-CY0cr2hjPWdjtqIyhfNOltZOulao5rmn2zXRK6XzuQRGlul_0q1bAUt-OE/s3264/20220407_103846.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsm9unjPv_p81aZcuI5w0IJOEKRjjWixNDF1uU3eP5I-v1vZO9puqI6kLkGsbVYqlNDsdVtnuTO5RzBFqGABjsIYxZumy2X4YaTS8qfkONo4dhdkkbkUUQCZ27FUeJI-CY0cr2hjPWdjtqIyhfNOltZOulao5rmn2zXRK6XzuQRGlul_0q1bAUt-OE/s320/20220407_103846.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-2lVfjuPnLUowSTFqs2Q3RqLDpytN_D5pX21dK1R-ffl0WgOkymj4cteUSU_-hyiceKdFSIxr_MHFkuIuOh-s6dstl9gonTP9c20uBRJy3jjeC76mCNKmlMEnKYesHfImDIj06RObqv2b55tBQ8VOhGZRbMCdtCJxgKdI6GdSOjhwbmMPkW_cujdc/s3264/20220407_103853.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-2lVfjuPnLUowSTFqs2Q3RqLDpytN_D5pX21dK1R-ffl0WgOkymj4cteUSU_-hyiceKdFSIxr_MHFkuIuOh-s6dstl9gonTP9c20uBRJy3jjeC76mCNKmlMEnKYesHfImDIj06RObqv2b55tBQ8VOhGZRbMCdtCJxgKdI6GdSOjhwbmMPkW_cujdc/s320/20220407_103853.jpg" width="320" /></a></div><p>This, alone, was about a month in labor, continually mixing up epoxy, vacuuming the bubbles out, and pouring it over every single void (or crack where the edge wasn't lined up perfectly when ripping to length), and repeating for the same surface until the cracks and voids were full. I'm not using a fast cure on epoxy, primarily because I want to give it time to slowly get into the cracks - essentially, I want every void in these boards filled with epoxy.</p><p>On edges where a crack transitioned to, those also mandated a surface for pouring (and there were a few). All cracks on the edges were filled, and most of the end-grain was also filled as much as I could get. I did this by taping the ends, standing the boards up, and pouring into the tape "moulds".<br /></p><p>Once the epoxies had cured, I could finally get to the sanding. This was a bit annoying - because I already sanded previously (after gluing) so that I could find the voids. But, I have to do it again. I'll do the finish sanding after the routing for the drawer guides/runners.<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTL2Ew61uMEMSJeZt8mNq16z576FdhvcxN0EM5HIX0HYMg3j6LxqwMt-l2xRkAdjoAdnm79eZqoV2XIFHto7ymiz5FIFBiPWg9g1UuyYNC5Rup2O52B72ETS1QwmB_llmJRlQGY4UngBPFlSz5wqckn3aAmzrDSZsGyviFglyrdm4S_ZyQQnj3t8nM/s4032/20220524_172525.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTL2Ew61uMEMSJeZt8mNq16z576FdhvcxN0EM5HIX0HYMg3j6LxqwMt-l2xRkAdjoAdnm79eZqoV2XIFHto7ymiz5FIFBiPWg9g1UuyYNC5Rup2O52B72ETS1QwmB_llmJRlQGY4UngBPFlSz5wqckn3aAmzrDSZsGyviFglyrdm4S_ZyQQnj3t8nM/s320/20220524_172525.jpg" width="320" /></a></div><p></p><p>Unfortunately, there was a snafu in which one of the boards was epoxied to the clamping boards, and releasing it snapped and cracked one of the side panels (not along the glue line, either - that joint seems to be holding well enough). You can see the crack in the above photo. This was epoxied together to get a good fix. At one point, I also broke one of the sides - this was glued together (with a biscuit to give the joint as much strength as I could).</p><p> There was so much sanding to be done that I ultimately used a grinder to knock large swaths of epoxy down to "close enough" before engaging the sander.<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9Ire3ob8ZURlXsS7HZqoM8PS8EkWDu3VKvYjtLe89X8pQzX3AhbXHpTfn9BrxeJABjtseiVinmqqTtVGZkI4L-fbzNWgR9oxHGw9gW3FejmwSeSAjg_KB9nFE_Zl2NV0q133itxSmdZFYB77PtNMRy1-NeuF0OpPlimhgxqtquI6osmn8psFUWDJJ/s4032/20220604_145516.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9Ire3ob8ZURlXsS7HZqoM8PS8EkWDu3VKvYjtLe89X8pQzX3AhbXHpTfn9BrxeJABjtseiVinmqqTtVGZkI4L-fbzNWgR9oxHGw9gW3FejmwSeSAjg_KB9nFE_Zl2NV0q133itxSmdZFYB77PtNMRy1-NeuF0OpPlimhgxqtquI6osmn8psFUWDJJ/s320/20220604_145516.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkT2cGE8BcQWIx372hepLTaW-D02c9QiWl9ZB-ZDefkVB3b1ReBp7k5VctrtERXgZKh61hOJ22e3IInl8L_Wub9KjuoINVcZz5o9ambftW8mSrjfwc-p6vd6kbzXX9qKIAaNcPYn43HIgZI9_hoUhukM2nlVh7j0avjc36nCJe6QiRfiDn547MXI6J/s4032/20220604_145523.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkT2cGE8BcQWIx372hepLTaW-D02c9QiWl9ZB-ZDefkVB3b1ReBp7k5VctrtERXgZKh61hOJ22e3IInl8L_Wub9KjuoINVcZz5o9ambftW8mSrjfwc-p6vd6kbzXX9qKIAaNcPYn43HIgZI9_hoUhukM2nlVh7j0avjc36nCJe6QiRfiDn547MXI6J/s320/20220604_145523.jpg" width="320" /></a></div><p></p><p>You can see in the pictures above that I have three piles of boards on my workbench. Each pile is a matched set of panels.</p><p> It was a lot of sanding the epoxy used to fill cracks down, but the day that happened was a BIG day!</p><p>Once the sides were sanded, the boards could be cut to final dimensions on the table saw. Each board had a single, good edge at this point. I'd first cut the parallel lengths for each board with that length, then I would move on to another dimension and cut all boards for that one (on all panels). As each cut was made, a mark was put on it to know which ones were done. The marks were in pencil so that they could be sanded off once the box was glued together.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEC29bp0pWqz4xc2-x89Wq_oaMy1m9SdUU8dqA7x931JXxB8KoVUUu_eST1QzAzE_Gt8wjYy6VKrSQtfnjSGztvUyYDzyKxe2XRw2tmOD65I_OWyMXCa0VaHza0LhgWbTFU8xn72viN-gVYy4qbVN9aogdQgY5-eQCTBwXwRt-PcWkn2ab2fWQ_m9O/s4032/20220611_134629.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEC29bp0pWqz4xc2-x89Wq_oaMy1m9SdUU8dqA7x931JXxB8KoVUUu_eST1QzAzE_Gt8wjYy6VKrSQtfnjSGztvUyYDzyKxe2XRw2tmOD65I_OWyMXCa0VaHza0LhgWbTFU8xn72viN-gVYy4qbVN9aogdQgY5-eQCTBwXwRt-PcWkn2ab2fWQ_m9O/s320/20220611_134629.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjw5YlsoWNQtfS8QiVAcXts3J8vVpA1azP5qEJm-0oVaBMuf_DHh8zLoyKqW9aOalIpEtcPu4VI8q6hn1YpGooZD_JKkXzCl_qzauMqfbyTfOmvc31zgTEFc_KuLgadLAFU-UdmSkOECcUoDxsXxD9muZqbBXvtmfX50BeZmv85RzuYqNUrt0MSBP_p/s4032/20220611_143807.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjw5YlsoWNQtfS8QiVAcXts3J8vVpA1azP5qEJm-0oVaBMuf_DHh8zLoyKqW9aOalIpEtcPu4VI8q6hn1YpGooZD_JKkXzCl_qzauMqfbyTfOmvc31zgTEFc_KuLgadLAFU-UdmSkOECcUoDxsXxD9muZqbBXvtmfX50BeZmv85RzuYqNUrt0MSBP_p/s320/20220611_143807.jpg" width="320" /></a></div><p>If you look closely at the last picture above, you can see I put marks for widths of each panel on my panel sled. It's a technique called "story boarding" - you write down exactly what will happen, and then you make it happen. I would set one width, mark it, put the stop block clamped down, and then make ALL of the cuts that were the same dimension. In other words, every single width was cut. Then every single depth was cut. Then every single height was cut.</p><p>The result was a set of panels that were perfect in every way except for... the depth.</p><p><i>[sigh.]</i></p><p>The depth, because of the narrowness of the dimension (supposed to be 9.375" or 9 3/8"), I chose to use the fence instead of my marked story board sled. Unfortunately, I measured to the same side of the 9" mark, which actually turned out to be 8 3/8". That meant each of these boxes is going to end up 1" shallower than what they were patterned after. Oh, well. <br /></p><p>With the panels all cut to size and prepped, I could then cut the box joints. I had picked up a Rockler jig for cutting box joints on a router table, and before fully engaging, I had to finish the jig. It requires one pass with the cutter you want.</p><p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOuj9wuHY7wuOAP2HYaqJQEtFQNr3Nc7544GulOJwXrg0pMpglbOjPnckhkFrWeggv5qv88wj6AZamw8EQeUGV-P44rHgmd5IGLr5Kx5RWDiLsGvF1xKC-6CWYufja63k-2lQqJRG38NMuf_IIbn0D49G6MdSun3sMSQsUEBXZOTBJM8XTyUml5j1n/s4032/20220614_202255.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOuj9wuHY7wuOAP2HYaqJQEtFQNr3Nc7544GulOJwXrg0pMpglbOjPnckhkFrWeggv5qv88wj6AZamw8EQeUGV-P44rHgmd5IGLr5Kx5RWDiLsGvF1xKC-6CWYufja63k-2lQqJRG38NMuf_IIbn0D49G6MdSun3sMSQsUEBXZOTBJM8XTyUml5j1n/s320/20220614_202255.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0PPwFn257KXCqRlL1AEprZm8JCtkCY5w9lmo5jT_93XJYJR94xMBf6jeQGFH9-2375qvSAErleSWXv8FMxr1qMDEcqGfABhBaSY3FR8jW7Ken_1qKuR7ST91xbHgRT8WqNEldy2iNWHjty1BufjggWsiKawVf9pByFdvP0R6YuR2y_6nQpC9k8f7a/s4032/20220614_202253.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0PPwFn257KXCqRlL1AEprZm8JCtkCY5w9lmo5jT_93XJYJR94xMBf6jeQGFH9-2375qvSAErleSWXv8FMxr1qMDEcqGfABhBaSY3FR8jW7Ken_1qKuR7ST91xbHgRT8WqNEldy2iNWHjty1BufjggWsiKawVf9pByFdvP0R6YuR2y_6nQpC9k8f7a/s320/20220614_202253.jpg" width="240" /></a></div><br />At this point, I needed to do some careful planning. I didn't want to mess these up. So, I had to use some left-over MDF (it was 1/4" thick, but I'm testing for 1/2" thick - gonna have to glue some boards up) to cut some test cases just to see. I have a couple of oiler cans that I've been collecting, so I decided to use this MDF as a shelf when done. I've intentionally cut the depth a little too deep, so that I have a slight forked lip all the way around the shelf to keep the oil cans on the shelf when we have another earthquake roll through.<p></p><p>The part that I was most worried about was the corners where three panels met together - and this little test candidate was perfect for the test. First, glue two "boards" together to get the 1/4" to 1/2" thick (matching the tool box panels).<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-NDz9UQeoj0CSuko2Vijd1AwPhRl5ncx8oxQFf_lD1PhBiNlgBv7drOCRS0tBkjE5IN-d2YHLd5ElVy21wG7sBFusxfvwDytgP5wdEOUdKfSqEJZ8h4x_xwvrgWJr_RXqyQKt_usWxrw8AaaliDowSreeiFq50IPfpm9jyf8W8bScB6YHQiLx3zmf/s3264/20220608_171727.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-NDz9UQeoj0CSuko2Vijd1AwPhRl5ncx8oxQFf_lD1PhBiNlgBv7drOCRS0tBkjE5IN-d2YHLd5ElVy21wG7sBFusxfvwDytgP5wdEOUdKfSqEJZ8h4x_xwvrgWJr_RXqyQKt_usWxrw8AaaliDowSreeiFq50IPfpm9jyf8W8bScB6YHQiLx3zmf/s320/20220608_171727.jpg" width="320" /></a></div><p></p><p>Each of those boards were fed through the table saw to get them square and to size. I had three boards the exact same dimensions. One would become the "back" (toward the bottom, used to attach the shelf) for attachment to the french cleat, one would be split into sides, and the last would be the actual shelf.<br /></p><p>It's time to cut the box joints. It took a while to get the jig set up, because it kept changing on me, and wouldn't line up. (Widths kept growing.) It resulted in a lot of scrap tests completely failing.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFyg7tQpGqq05vZKF8S5XPUlAMEev1rW2vr-j3kzZOfiMaGNwERS2Pf1qrF5AhwyLmM9jswwqH2ZqxAW_i1sU0164oh-9YaB7FBAKZszxQFXrLarsSIckLGcbEDB6NyFu3OjkdHMgPgnU0P0R55D7YJxCYz9h2VaJTPKhJi2xJtT0AExQ7zm7zq5yj/s4032/20220614_132633.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFyg7tQpGqq05vZKF8S5XPUlAMEev1rW2vr-j3kzZOfiMaGNwERS2Pf1qrF5AhwyLmM9jswwqH2ZqxAW_i1sU0164oh-9YaB7FBAKZszxQFXrLarsSIckLGcbEDB6NyFu3OjkdHMgPgnU0P0R55D7YJxCYz9h2VaJTPKhJi2xJtT0AExQ7zm7zq5yj/s320/20220614_132633.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2YQYd-CzIMgUUdgq-RjB0ZN2dJu1Sk3dZ_xFTpXi0qG2ZWM3SlpkqMr6VTUip_Bx9hX8am3rGZEjtjZvyCE1SOS_ouLsW7RpfLAgQJ7IKwhlyjfWaQNeCR6Xqwx_lTTI7hHo_cIjcVirS3PxtvRp21DMWI48uj5IwR-V1_GK82GKUG3PGegngISBM/s4032/20220614_132636.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2YQYd-CzIMgUUdgq-RjB0ZN2dJu1Sk3dZ_xFTpXi0qG2ZWM3SlpkqMr6VTUip_Bx9hX8am3rGZEjtjZvyCE1SOS_ouLsW7RpfLAgQJ7IKwhlyjfWaQNeCR6Xqwx_lTTI7hHo_cIjcVirS3PxtvRp21DMWI48uj5IwR-V1_GK82GKUG3PGegngISBM/s320/20220614_132636.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu47h3-Aho3XcoKa59PM6KRjqlsRcgL1WeNhygSdphP0rWe250hece4mS5jp7IQU7jMw3RTaE_q98TGMWE1UfWVmU1mrTW1i9azMXNT6ran7QGZGFw8ZtskHnz5Q9adIo08tkBq2oQxhkabBJag402QmVPProcJIrTjpgRhr9hjEeAwjCZQSSyRFV3/s4032/20220614_162954.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu47h3-Aho3XcoKa59PM6KRjqlsRcgL1WeNhygSdphP0rWe250hece4mS5jp7IQU7jMw3RTaE_q98TGMWE1UfWVmU1mrTW1i9azMXNT6ran7QGZGFw8ZtskHnz5Q9adIo08tkBq2oQxhkabBJag402QmVPProcJIrTjpgRhr9hjEeAwjCZQSSyRFV3/s320/20220614_162954.jpg" width="320" /></a></div><p></p><p>So, I punted. I found the device kept sliding, and the dimensions would change with each cut, too. I grabbed some brass shim stock, and slapped it into the grooves that the jig attached to.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyXGwkNnGKp14T0NPL6aOAl8oShwnUc88yeeJscTT0Qj0sfDK9bSe4E3c1srUYhHecfNb0BVVeLDEmF3JI9pZAiXM1pDhzeXjmjdlq8Hir94UpKOgls7ySYx9SdNbyN63ZyJ8MNUy4NY4d-EVTyLt0UF-kwm3mqlzuxOj7dVqTVQJScEWjvjNmoNyX/s4032/20220614_165547.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyXGwkNnGKp14T0NPL6aOAl8oShwnUc88yeeJscTT0Qj0sfDK9bSe4E3c1srUYhHecfNb0BVVeLDEmF3JI9pZAiXM1pDhzeXjmjdlq8Hir94UpKOgls7ySYx9SdNbyN63ZyJ8MNUy4NY4d-EVTyLt0UF-kwm3mqlzuxOj7dVqTVQJScEWjvjNmoNyX/s320/20220614_165547.jpg" width="240" /></a></div><p>The shims allowed the jig to stay in place long enough to cut a longer edge on both sides. It was still tight, <i>but it worked</i>.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9C0oT4NAbCdzeZeBCd5tEztQ70wAVh6ymlQCCCuHWJtlGhFuexXkIHQ1Lw1cyTGbyuFcsmrXG9cg0ob1BL1gfHRPjyiijB7JzI3DbODp8VvsZiMmHTbs95w_8jFJ01XMT0RZeaslzEcoF9Mxnae9Z2y_WDyudmRUOnUjXLwzfkXsKawrFBmJf001f/s4032/20220614_162959.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9C0oT4NAbCdzeZeBCd5tEztQ70wAVh6ymlQCCCuHWJtlGhFuexXkIHQ1Lw1cyTGbyuFcsmrXG9cg0ob1BL1gfHRPjyiijB7JzI3DbODp8VvsZiMmHTbs95w_8jFJ01XMT0RZeaslzEcoF9Mxnae9Z2y_WDyudmRUOnUjXLwzfkXsKawrFBmJf001f/s320/20220614_162959.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0MfjCQksG0UUOB2444xeHL1GXDO35gwEY8DnFe_UfCEm_F5TbW2_swl7eE_S-4lEUapb9TQHvJunYGE-LNSxJQfbBvxUdIg4rg0VgEUXoB_MNd-3aN71BsvSsVJ3r1Wdg3VNMeNMNZ7Z8wqM0P6qwq9WqIWCPpQVJ8FmhZEwThU2nWTK_e6XgfL_2/s4032/20220614_165540.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0MfjCQksG0UUOB2444xeHL1GXDO35gwEY8DnFe_UfCEm_F5TbW2_swl7eE_S-4lEUapb9TQHvJunYGE-LNSxJQfbBvxUdIg4rg0VgEUXoB_MNd-3aN71BsvSsVJ3r1Wdg3VNMeNMNZ7Z8wqM0P6qwq9WqIWCPpQVJ8FmhZEwThU2nWTK_e6XgfL_2/s320/20220614_165540.jpg" width="240" /></a></div><p>Next up, I have to get back to my test case - the oiler shelf out of MDF. I ran 4 edges of 24" long edges through the jig. I also grabbed the side edges (both sides), and then glued it together.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoyMZU_V0DPQ9fxbJnprzdC-bwn070rc8McsOBpfEH85W3B4ylLpvEMYaTfL207PcYpSqINZL_ibwTGjrfqM8Ikf_0nQpP9bGNlf940TggpnAV-dRHQ9S-6umYuiDb0gqcTGuwZASjMRmN1UmPQjTonDm-ECbIPX4a-XFwkY8vWkNkyc1msgUMtGvg/s4032/20220614_174021.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoyMZU_V0DPQ9fxbJnprzdC-bwn070rc8McsOBpfEH85W3B4ylLpvEMYaTfL207PcYpSqINZL_ibwTGjrfqM8Ikf_0nQpP9bGNlf940TggpnAV-dRHQ9S-6umYuiDb0gqcTGuwZASjMRmN1UmPQjTonDm-ECbIPX4a-XFwkY8vWkNkyc1msgUMtGvg/s320/20220614_174021.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh3MdmiO0tg89nEhmLmNqJe2_mpZvJULtinZGIgPp7WT5qF1gCGRxH7GyJNZDQgIhMwsy-DoGg-FpdGrsmneOjo9iI7Vpt-FTnaOYXlp3-uQhFygoE9s95queS056vypYE0BSZppuMdX1mbFsND3n8IswGRdQagkaLERw3UJ_A7N6xC1bIRBF0dXfW/s4032/20220614_180942.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh3MdmiO0tg89nEhmLmNqJe2_mpZvJULtinZGIgPp7WT5qF1gCGRxH7GyJNZDQgIhMwsy-DoGg-FpdGrsmneOjo9iI7Vpt-FTnaOYXlp3-uQhFygoE9s95queS056vypYE0BSZppuMdX1mbFsND3n8IswGRdQagkaLERw3UJ_A7N6xC1bIRBF0dXfW/s320/20220614_180942.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjFsHLMhZGAi3l5fznEamEkrCY3cxyOkVrjYKuN4WMOWBGu2jZFwl6vJMZGYwCy8vzeiciRk9frttj5wRXzFJmGwDHRISvrhihOlHYIyxFAYjPV3d96UEiMnWEBEndlpKdquGh_VjsHsxFa5B7scV9UhmcIOcb-JXYv79c7CjHQDEmTzwGzfhZWaLV/s4032/20220614_182759.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjFsHLMhZGAi3l5fznEamEkrCY3cxyOkVrjYKuN4WMOWBGu2jZFwl6vJMZGYwCy8vzeiciRk9frttj5wRXzFJmGwDHRISvrhihOlHYIyxFAYjPV3d96UEiMnWEBEndlpKdquGh_VjsHsxFa5B7scV9UhmcIOcb-JXYv79c7CjHQDEmTzwGzfhZWaLV/s320/20220614_182759.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5ZICnl56mJGC1jJ2IctqkHS6IE61b4fU48pLatMEu8l1xrYcOXzqwnhdbZRLAm_n-ZfH5GNH8Da5JGGnetW5-WhIqbm_bYYZnulDvVd1EyGfhZXGfHkUgh0pd_4HydKa-ri4w-D0wseHIaUGz6A34fZcr0Ga53P1tWA7ll3TQNdImztn0aMINxQs2/s4032/20220614_183159.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5ZICnl56mJGC1jJ2IctqkHS6IE61b4fU48pLatMEu8l1xrYcOXzqwnhdbZRLAm_n-ZfH5GNH8Da5JGGnetW5-WhIqbm_bYYZnulDvVd1EyGfhZXGfHkUgh0pd_4HydKa-ri4w-D0wseHIaUGz6A34fZcr0Ga53P1tWA7ll3TQNdImztn0aMINxQs2/s320/20220614_183159.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiblGsLnIk3S4Kal4J2aU9x9d3jPChoblV3Q0QjEi3IeJ0N4czQCzgZ_Zd-aOMbfKf4jMbOMsiu3qbZlng-jf-eqil8psIX44MBYbqzbGiRXcGae_sLMYpS3UxbtdFDNv0WJQf4Pfk7BvEbGbKPSv0DjmhQC-JVfJcOiuIRAldqQz2wp5vItiTGEZr-/s4032/20220614_183715.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiblGsLnIk3S4Kal4J2aU9x9d3jPChoblV3Q0QjEi3IeJ0N4czQCzgZ_Zd-aOMbfKf4jMbOMsiu3qbZlng-jf-eqil8psIX44MBYbqzbGiRXcGae_sLMYpS3UxbtdFDNv0WJQf4Pfk7BvEbGbKPSv0DjmhQC-JVfJcOiuIRAldqQz2wp5vItiTGEZr-/s320/20220614_183715.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikLd0cWQpvFcyuCXs7GXUeZIdwSBm3GZ_65QXCm4OAU-09tXom2yp7unVHhJAoaqsmt91r0ynW9wbOWo028AUsrYgVMDs8ZkN-umCLjn7k99wXlbeNpJyiveGQJJA4wo0HVVaoKKsAlKnFTOji-Bbf3jrFl65p7LQq2p21-xOzpzqQ7NTqN47yvFdk/s4032/20220614_183718.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikLd0cWQpvFcyuCXs7GXUeZIdwSBm3GZ_65QXCm4OAU-09tXom2yp7unVHhJAoaqsmt91r0ynW9wbOWo028AUsrYgVMDs8ZkN-umCLjn7k99wXlbeNpJyiveGQJJA4wo0HVVaoKKsAlKnFTOji-Bbf3jrFl65p7LQq2p21-xOzpzqQ7NTqN47yvFdk/s320/20220614_183718.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6yMJA7s--sYZ9hETk1S_P6RZS7ORnac71Fiy8152NzP-OKRC-tJzXLZIAmFdY1imgy04kV6WQmoCPlGV04d7Z7ZU5NnBFORHrrWaGJ6CtxyZt2SZOz1aHJwXQgoRp_kVEd5DlPKTt80G68pfMbuvyt78CnDppxTiBQyXQ0u97NZoAVj0SSVXtMcSk/s4032/20220614_183727.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6yMJA7s--sYZ9hETk1S_P6RZS7ORnac71Fiy8152NzP-OKRC-tJzXLZIAmFdY1imgy04kV6WQmoCPlGV04d7Z7ZU5NnBFORHrrWaGJ6CtxyZt2SZOz1aHJwXQgoRp_kVEd5DlPKTt80G68pfMbuvyt78CnDppxTiBQyXQ0u97NZoAVj0SSVXtMcSk/s320/20220614_183727.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMNRpvDTPAJDdimP7k2Ez__P3mz891WRuscJS3S_63iiz8KxW28SFtyPiw2qjmpyXdYRdLjxDdAKfg8MTu-dHyBtqtLI_fGpHoqFIRVe2cZFfBWq5SoLcmdyYB7eHESo_B1KVYz7QbeR2rkhxHTN0YoyY8aKBOH3KbstdB39Tq0smdTDuWQpqLF1yA/s4032/20220614_184632.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMNRpvDTPAJDdimP7k2Ez__P3mz891WRuscJS3S_63iiz8KxW28SFtyPiw2qjmpyXdYRdLjxDdAKfg8MTu-dHyBtqtLI_fGpHoqFIRVe2cZFfBWq5SoLcmdyYB7eHESo_B1KVYz7QbeR2rkhxHTN0YoyY8aKBOH3KbstdB39Tq0smdTDuWQpqLF1yA/s320/20220614_184632.jpg" width="320" /></a></div> <br />If you look closely, you'll see a gap on one end. I completely put one single board in the wrong way. <i>[sigh]</i>. Assembly will be critical.<p></p><p>The other thing that I learned (which is why I did the test) is that, on a box-cut corner where three sides come to a point, the actual corner is not complete - there is a small chunk of wood that is not in place. It's a side effect of box cutting, really, if you think about it - three sides, binary on/off. Anyway, I can fill the corners with epoxy before rounding everything off, so I think I'm going to be fine.<br /></p><p>Now I can engage the REAL box cuts, knowing that I have to reset the jig after every long edge. Lots of box joint cutting, each mating surface at it's own time (e.g. cut one edge of a board, then cut the same edge on the adjoining board). In this way, the joints should be going to be perfectly aligned. I went through each set of boards and marked every single edge.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0W4VFFUF_dzNC3d1-EdYa4hqcO3nOc7XYj2jt5-r8SpXEXQwYMaSo25AxN9ZpgP_EEyXzetrcHLbQmeLULCrPGMqGxolnxHQuCsdq0WtVr4ZK3qGAUAs6KgY-H708dOKwkeSiLo7uIF7FfAr-hp8O1JBzJFYzI1Xm3Hcny1VlSF7OWu6TH_F9L5bR/s4032/20220616_095310.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0W4VFFUF_dzNC3d1-EdYa4hqcO3nOc7XYj2jt5-r8SpXEXQwYMaSo25AxN9ZpgP_EEyXzetrcHLbQmeLULCrPGMqGxolnxHQuCsdq0WtVr4ZK3qGAUAs6KgY-H708dOKwkeSiLo7uIF7FfAr-hp8O1JBzJFYzI1Xm3Hcny1VlSF7OWu6TH_F9L5bR/s320/20220616_095310.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqC9mIvSYaJ-Pu1GbdqKGrci23ErhOcIGfM27e3I3msZTnhaN8nGIX5R7HHM7D2Os0PInK7rUT1chBJ9XTT01isIwGW4O7rBUHRwmOs1PqTJrhvP4bCvEfMWsfgjrREpmzhkJ4oe2W847bfbXMgFkjqz0frsD0ByxIvP-k7irJtYU9fBTzaNXsf3vF/s4032/20220616_110315.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqC9mIvSYaJ-Pu1GbdqKGrci23ErhOcIGfM27e3I3msZTnhaN8nGIX5R7HHM7D2Os0PInK7rUT1chBJ9XTT01isIwGW4O7rBUHRwmOs1PqTJrhvP4bCvEfMWsfgjrREpmzhkJ4oe2W847bfbXMgFkjqz0frsD0ByxIvP-k7irJtYU9fBTzaNXsf3vF/s320/20220616_110315.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibvyRQEQBYClUIjVePvvB3jrOrkcGG75VpteFo5vYm9JI6AYNUr6cmrbRFQKBKnd1vm3XlBL1x8k0CCS0pL8Dwtrz9alEDZVnP_eAA_YZEWaug8obbPJ7lx-_0wwTquVouwgERsQl7bI7_P0EexoLgE1BgNJxvoY3TnDu5A7tS_CgWxZbuNJV4gttH/s4032/20220616_120403.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibvyRQEQBYClUIjVePvvB3jrOrkcGG75VpteFo5vYm9JI6AYNUr6cmrbRFQKBKnd1vm3XlBL1x8k0CCS0pL8Dwtrz9alEDZVnP_eAA_YZEWaug8obbPJ7lx-_0wwTquVouwgERsQl7bI7_P0EexoLgE1BgNJxvoY3TnDu5A7tS_CgWxZbuNJV4gttH/s320/20220616_120403.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiT9n126Io9DlwMShNJ7DILw5jmDrsMVSaC3gEsIA77yWZjLNIKk1oicM5xBB0exKRv3BQ-y11yMH1Kc9uzcpVFs-GvUoGKcx-tcGhT2mn3LJEFDk9e1pJVHt5LFZAhYPmUBIanUZtjkSR-o3CClBJJV3_SnmWLa74TMDY4kkAXZD9L01xD2JFMne6/s4032/20220616_125353.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiT9n126Io9DlwMShNJ7DILw5jmDrsMVSaC3gEsIA77yWZjLNIKk1oicM5xBB0exKRv3BQ-y11yMH1Kc9uzcpVFs-GvUoGKcx-tcGhT2mn3LJEFDk9e1pJVHt5LFZAhYPmUBIanUZtjkSR-o3CClBJJV3_SnmWLa74TMDY4kkAXZD9L01xD2JFMne6/s320/20220616_125353.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjf3y7uVzReRIYxORtHJBr4nGsAOq8XYp3IjCMdi-CPOzq3_1YIlaaiDnDlQsDEuRL9BaokkRBrYJ-07Fh9Afevas2GQmyJN_qoAceWCmmeYumcDNlKZHFMrR6r9jEdjuzEMrgV1p8wcXPPcFruqeErkqNU2fIWPH7Wwe4kJBkB0dAvnb9L4XuXo0F2/s4032/20220616_144854.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjf3y7uVzReRIYxORtHJBr4nGsAOq8XYp3IjCMdi-CPOzq3_1YIlaaiDnDlQsDEuRL9BaokkRBrYJ-07Fh9Afevas2GQmyJN_qoAceWCmmeYumcDNlKZHFMrR6r9jEdjuzEMrgV1p8wcXPPcFruqeErkqNU2fIWPH7Wwe4kJBkB0dAvnb9L4XuXo0F2/s320/20220616_144854.jpg" width="320" /></a></div><p>I now have three piles of boards, one for each chest. Now, on to the inner routing that needs to happen. I have to cut grooves for two horizontal (bottom of the lid, and the separator for the drawers). This will need to be the thickness of the boards. Before I could do anything, I ran a test. I anchored the aluminum angle that I'd be using as a guide, and ran the router. I could measure the distance from the angle to determine how far I needed to get the cut where it should go. I needed 2 3/32" with a 1/2" router bit.<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUVQxBR3gzlRre6XgHE5u_I2FY9he_BcK3cIsKwYcTC_VLV92b8ifM8dlWLX8rnFq_2_Ax1zFDzmbgPtq-K1nZIzyUNlVhpQ3igRbHRCUQ1CNzJAOgBg1F4m6CSB_L3qdsuULZwyl0B30Qq6RLhZw9tNbWgB4Isd914XW2zFVemjAgoDDQg2NvWU3f/s4032/20220616_212259.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUVQxBR3gzlRre6XgHE5u_I2FY9he_BcK3cIsKwYcTC_VLV92b8ifM8dlWLX8rnFq_2_Ax1zFDzmbgPtq-K1nZIzyUNlVhpQ3igRbHRCUQ1CNzJAOgBg1F4m6CSB_L3qdsuULZwyl0B30Qq6RLhZw9tNbWgB4Isd914XW2zFVemjAgoDDQg2NvWU3f/s320/20220616_212259.jpg" width="240" /></a></div> <p></p><p>Okay, now I can cut the shelf support grooves.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEim76Lz2yUXhkBw6W_M7R2spRR5MkQebXZqd-XL0pwGttRqQ9AgCB5JePfKtwLPtpfdbhJyuCSBQb9bpVJtUnBbNq5453E2EmF4_-Gqd1OGvDNJDXBzgJaEYMMD6evcErllgiPd3CVWxWx7Q-BfUunKe82AzetXOmqzBEyFiFCuhgrh52cwY0WDtk1P/s3264/20220617_103030.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEim76Lz2yUXhkBw6W_M7R2spRR5MkQebXZqd-XL0pwGttRqQ9AgCB5JePfKtwLPtpfdbhJyuCSBQb9bpVJtUnBbNq5453E2EmF4_-Gqd1OGvDNJDXBzgJaEYMMD6evcErllgiPd3CVWxWx7Q-BfUunKe82AzetXOmqzBEyFiFCuhgrh52cwY0WDtk1P/s320/20220617_103030.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgl6czfPbUHy74OoJCTreIPNjLZvhOQB1IQbePZICn1B6InPxG3VQHxmctdxyz20AKL1GjMqIb0sWUgIlsGF3XMdbthoHyl7AvlMbBcpfkLbRG1gUQoXpkjMhKsZF0TrvjZ1Bpnl1mAfKjWk8Bhe9_jvTen15vlVSntBWA8j1I-fZwYHPIrhKUJaV7D/s3264/20220617_092443.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgl6czfPbUHy74OoJCTreIPNjLZvhOQB1IQbePZICn1B6InPxG3VQHxmctdxyz20AKL1GjMqIb0sWUgIlsGF3XMdbthoHyl7AvlMbBcpfkLbRG1gUQoXpkjMhKsZF0TrvjZ1Bpnl1mAfKjWk8Bhe9_jvTen15vlVSntBWA8j1I-fZwYHPIrhKUJaV7D/s320/20220617_092443.jpg" width="320" /></a></div><p>I only hosed up one tool box and got a groove on the other side. Yay! I'll just fill that apprentice mark with some epoxy, and everyone that sees it will be completely the wiser (too easy to know what happened - it's on the outside).</p><p>The next groove I needed to cut was the bottom one for the front panel to slide in. This was a bit difficult as it was 0.397" from the bottom board, and 0.197" in diameter. I don't have anything in that diameter - even a 3/16" router bit comes in at 0.1875". I settled for the 3/32" router bit I picked up explicitly for the drawer runner slots (more on that later), and then did a lot of math until I had the right numbers. Then I could set up a piece of angle and cut the path. It would require three passes with the 3/32" bit (3/32" is slightly less than half of the 0.197").<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFHbV8P6VADkXyfvBDrkV7a3cLQn2p5AIDrWLgnFhtVS7MHrsSgBDDC04yev2W9qeyE-xrDV5Vs5gA8-PxwHEf0_tmtQUjQrT1weBpdjf9za_wON05LXgDTFopE73_UVA4ItSMU_W_fJQBkHOphrjpy-7NmJKtPIwZryXCBOnFUe71gszRvUQVECHS/s4032/20220617_124511.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFHbV8P6VADkXyfvBDrkV7a3cLQn2p5AIDrWLgnFhtVS7MHrsSgBDDC04yev2W9qeyE-xrDV5Vs5gA8-PxwHEf0_tmtQUjQrT1weBpdjf9za_wON05LXgDTFopE73_UVA4ItSMU_W_fJQBkHOphrjpy-7NmJKtPIwZryXCBOnFUe71gszRvUQVECHS/s320/20220617_124511.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtTapaXhocw2uNYeiAmLnpTZQhU2OfbMPGxn_uZDg0rxaOIa3hPvVU5p7m3VpolJLlDFUdWZa32KeZteDrfW2xu-P2lwV7pmHmtnwIzBWoHAOyLiZVwyCnR4w5G8PX3sK61lJ0O0y1vgPiFXZeaSZLrh5XzkTvT964vditPCwDiFdoZ2ueGrM7uN1C/s4032/20220617_124524.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtTapaXhocw2uNYeiAmLnpTZQhU2OfbMPGxn_uZDg0rxaOIa3hPvVU5p7m3VpolJLlDFUdWZa32KeZteDrfW2xu-P2lwV7pmHmtnwIzBWoHAOyLiZVwyCnR4w5G8PX3sK61lJ0O0y1vgPiFXZeaSZLrh5XzkTvT964vditPCwDiFdoZ2ueGrM7uN1C/s320/20220617_124524.jpg" width="320" /></a></div><p></p><p>While there, I routed out the metal frame so I could inset that. Gerstner sells the little front panel pivot point that keeps the wood from splitting out when people abuse it. I'll need to order two more of those (for the other two chests).</p><p>Unfortunately, the box joints didn't quite line up perfectly. I had to manually fit each joint by hand using a rasp, a Japanese pull saw, and sandpaper glued to a 1/8" metal bar that fit between the pins. I gotta tell you, for joinery, those pull saws are amazing. I'd set the edges together that were to be joined, and transfer lines from one to the other board just using a pencil on the edge. The pull saws could make some very thin slices, and things just came together quickly.<br /></p><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh2h4rfcj9kXT2nyJYKNlroV2K8PPjr-It8fAp6mxluZNHiGdRGaoEYDlroweTjSUGNFYXo53wfa5_UwxlnAcBQ8qSTNbRSt9aVYzi6mqnt2O3-ctAi9ml89FhC9_40Ok0Vjwpy46jvHE931wdTEmoMaRj2WdT1N092Jczl966ARnkIaNkgjc4UK_y/s4032/20220709_212129.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh2h4rfcj9kXT2nyJYKNlroV2K8PPjr-It8fAp6mxluZNHiGdRGaoEYDlroweTjSUGNFYXo53wfa5_UwxlnAcBQ8qSTNbRSt9aVYzi6mqnt2O3-ctAi9ml89FhC9_40Ok0Vjwpy46jvHE931wdTEmoMaRj2WdT1N092Jczl966ARnkIaNkgjc4UK_y/s320/20220709_212129.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg50srQKSPkCsh7u3bD7ibikVimAVnQauEJlpaiGILlACGUN1_yW6Zz-fFHX8Vsak-LJIE-5ISP8nVMYTxhVltlOyJ6ijYBZLaECH4vv27r5jondt6XqZeZ1ja7KDN5H4eLWd3bc031TuchfY_BgO48rcahDbz3BwfcHO00kA_xT3KdQsQjArLcj746/s4032/20220709_212255.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg50srQKSPkCsh7u3bD7ibikVimAVnQauEJlpaiGILlACGUN1_yW6Zz-fFHX8Vsak-LJIE-5ISP8nVMYTxhVltlOyJ6ijYBZLaECH4vv27r5jondt6XqZeZ1ja7KDN5H4eLWd3bc031TuchfY_BgO48rcahDbz3BwfcHO00kA_xT3KdQsQjArLcj746/s320/20220709_212255.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCivy5sgC1vD2HmeAp4i6IMtvkiv3gbzfUnKeGwVWp10Z_VLM1kWnJGWlrvq0lrLKKGWYrNaghCXSfb144PmSghfufH8UqACIhrOT31LTeiPnh8kM3eIGvEtg-s9LcF89qhtAS5wvwxqtV4cleNkw-uMMAjFASZR17qWRz87_JiUfQpop32nB20pr6/s4032/20220709_213154.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCivy5sgC1vD2HmeAp4i6IMtvkiv3gbzfUnKeGwVWp10Z_VLM1kWnJGWlrvq0lrLKKGWYrNaghCXSfb144PmSghfufH8UqACIhrOT31LTeiPnh8kM3eIGvEtg-s9LcF89qhtAS5wvwxqtV4cleNkw-uMMAjFASZR17qWRz87_JiUfQpop32nB20pr6/s320/20220709_213154.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEit4dHBBNl7LEQOFV_UJ3AiTcXCdoaftXbskplPA90zNFkxEXY2FMLfTnutJ2f0jOmXnB8-W1CYe5UeCYmKtR1s9G6JWy6Kwf6ibSAADX3BKazI1UiBOmnckQmsTd6m5ZCVcYObMAigPhiyEogm9dPCPxfiKme89Zcg97W3U7gUJgexFUfx4q_hUK4s/s4032/20220709_213311.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEit4dHBBNl7LEQOFV_UJ3AiTcXCdoaftXbskplPA90zNFkxEXY2FMLfTnutJ2f0jOmXnB8-W1CYe5UeCYmKtR1s9G6JWy6Kwf6ibSAADX3BKazI1UiBOmnckQmsTd6m5ZCVcYObMAigPhiyEogm9dPCPxfiKme89Zcg97W3U7gUJgexFUfx4q_hUK4s/s320/20220709_213311.jpg" width="320" /></a></div><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6HEUpx43uXLUNnNVfH4nxFoRWsIuacIDPulhY8bljxqorZ3uRMzZu6QcBTPgWSPHms426Chol0DMD-evKq6JcXFHLh9Ra9OJAieMQE2GBvlZpRsDbkQPbDmYhfiOJyccRDs2BEGMtwU8NhxBRr5dt1AT16eEXVeW2aNshTgadTwFoKsnUmv9sqSrz/s4032/20220624_170403.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6HEUpx43uXLUNnNVfH4nxFoRWsIuacIDPulhY8bljxqorZ3uRMzZu6QcBTPgWSPHms426Chol0DMD-evKq6JcXFHLh9Ra9OJAieMQE2GBvlZpRsDbkQPbDmYhfiOJyccRDs2BEGMtwU8NhxBRr5dt1AT16eEXVeW2aNshTgadTwFoKsnUmv9sqSrz/s320/20220624_170403.jpg" width="320" /></a></div><p></p><p></p><p>Three boxes' worth of hand sawing various tenons for these box joints was excruciatingly time consuming. The rasp, hand sand bar that fit in between the tenons, and the pull saw/coping saw combination did the job, but it takes a while to line everything up. When the day came that these were done, I was ecstatic. I still wasn't remotely complete.<br /></p><p>My next task could only be done assembled without being glued. I needed the actual inside dimensions of those grooves I'd cut. Sure, I can measure where things go, but with the difficulty of things potentially not lining up, I am going to make absolutely sure. So, I put the boxes together and slapped some measuring "bars" in place.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvDO4Bu3GxP-FaBkaqBz0bCBIx17nSBqFU3pGyL_d3fPOS7peJyfZXs-hiDNm-54hfpd5ywPrHcnPOEODNrFlk7Ya1-ilEyu3_HZVORXGy83McEfxyC4N_UaV2XpTGD8lQzFdz131BzcPnx-AQAUnTqbBBb_z8I0frLxo8nMvcD9O43chRlHF28eRc/s3264/20220704_152620.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvDO4Bu3GxP-FaBkaqBz0bCBIx17nSBqFU3pGyL_d3fPOS7peJyfZXs-hiDNm-54hfpd5ywPrHcnPOEODNrFlk7Ya1-ilEyu3_HZVORXGy83McEfxyC4N_UaV2XpTGD8lQzFdz131BzcPnx-AQAUnTqbBBb_z8I0frLxo8nMvcD9O43chRlHF28eRc/s320/20220704_152620.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrlmf9nKDR8_qJgpj6bp4HdUJaWwbTc7wBLIJCAvdYlgkPbT4v3weaxfpBtAF9oJhal-38PucI0-VUo43PyCnrXUwKOoCyJrIBAj4ExSFY2MjOTcpxNOsXoJ1Mg4HXuxBBR23Zf---dlL7EZgPu4U5jSENYphyORkWGiS1oBcsluEH8SqRaUzpCAP3/s3264/20220704_153926.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrlmf9nKDR8_qJgpj6bp4HdUJaWwbTc7wBLIJCAvdYlgkPbT4v3weaxfpBtAF9oJhal-38PucI0-VUo43PyCnrXUwKOoCyJrIBAj4ExSFY2MjOTcpxNOsXoJ1Mg4HXuxBBR23Zf---dlL7EZgPu4U5jSENYphyORkWGiS1oBcsluEH8SqRaUzpCAP3/s320/20220704_153926.jpg" width="320" /></a></div><p>Granted, because I don't trust the tape measure on the inside of a tool box where I need to measure the groove, so I used a 1/4" piece of MDF. Then I could measure the gap using the telescoping snap gauges (yes, a machinists' tool rears it's ugly head). Each box has to be assembled and checked for this dimension so I can cut the drawer supports.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9bkqn8dAgW53PJzS8RizBEA-7vaaXvt5RhMMM9Dx3ajMzrzfoBhizFpnGD-SMDGXdMoUpYsZMy7UK184cp3vW_HyuTn1fhuBS4EmAgMKiVPDpgY13MReYXInQ34snhDtwcENIr3ADTXUQ8YFQGwo-vIa9tnbypD_87AqWbmefVBdMikRse43GBgQl/s4032/20220723_103930.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9bkqn8dAgW53PJzS8RizBEA-7vaaXvt5RhMMM9Dx3ajMzrzfoBhizFpnGD-SMDGXdMoUpYsZMy7UK184cp3vW_HyuTn1fhuBS4EmAgMKiVPDpgY13MReYXInQ34snhDtwcENIr3ADTXUQ8YFQGwo-vIa9tnbypD_87AqWbmefVBdMikRse43GBgQl/s320/20220723_103930.jpg" width="320" /></a></div><p>With these measurements, I could now cut the bottom board for the top area, as well as the drawer supports. First was the top, because it is very simple. It's just a rectangular board. The horizontal drawer frame was easy to, but it needed a rabbet. And, once the rabbet was cut, I could then cut the two vertical drawer supports to match. But, alas! There not enough wood here to finish the supports for the drawers!<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWU5n52FMRKYMfHbTbLq25pgRnC9pL7mZSR4H67iqAgVx4kmxXYXLzmFyh_YdDs4CWlISn2OtPP5r_Z7MV1HMMrJA9pcZygAzsocq781GZGosS9HlB33B2PlCda_E2aO0MTPWhNcl2CMH68v5Aas_jbfW4WS3b9MJZOISaMrqJ1yDg0Zp5kcc2gtxa/s4032/20220723_163901.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWU5n52FMRKYMfHbTbLq25pgRnC9pL7mZSR4H67iqAgVx4kmxXYXLzmFyh_YdDs4CWlISn2OtPP5r_Z7MV1HMMrJA9pcZygAzsocq781GZGosS9HlB33B2PlCda_E2aO0MTPWhNcl2CMH68v5Aas_jbfW4WS3b9MJZOISaMrqJ1yDg0Zp5kcc2gtxa/s320/20220723_163901.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ6GN9S982Zi2XtvYsfNiYZXX6_yUAyuCGsaI8EojtOVUFSoFrggZzNqBP7LRxoO3mh4wm_Ft4vK6R7XeGFcMh2qwyHVMrk0gTrGoT0W7FsrOdS1LTElT1lxaxGvqhN3mUNCiYD9-_DYlrEGJNd857gfW0RD7RobiQ3f42s-nIqq1VDN85bc9M45Yq/s4032/20220723_163908.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ6GN9S982Zi2XtvYsfNiYZXX6_yUAyuCGsaI8EojtOVUFSoFrggZzNqBP7LRxoO3mh4wm_Ft4vK6R7XeGFcMh2qwyHVMrk0gTrGoT0W7FsrOdS1LTElT1lxaxGvqhN3mUNCiYD9-_DYlrEGJNd857gfW0RD7RobiQ3f42s-nIqq1VDN85bc9M45Yq/s320/20220723_163908.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMoG3i3ab6zzmTO1aTakJMr4GD-81SJRFpTcpIvrnjI_9ES1LmpMebAOTsR6Bpn7atMQCpR2kuHhnPku-Q_BcLjX_PCZlHO5ozZw6SX5L6lL-7BqnUfhTAFYCbhxforzdKX6J0OfMtLeEssjrPyWPp0Z4VMBQoWC2JAn4LraLwmUPeh1X-jXZkY9rd/s4032/20220723_164103.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMoG3i3ab6zzmTO1aTakJMr4GD-81SJRFpTcpIvrnjI_9ES1LmpMebAOTsR6Bpn7atMQCpR2kuHhnPku-Q_BcLjX_PCZlHO5ozZw6SX5L6lL-7BqnUfhTAFYCbhxforzdKX6J0OfMtLeEssjrPyWPp0Z4VMBQoWC2JAn4LraLwmUPeh1X-jXZkY9rd/s320/20220723_164103.jpg" width="320" /></a></div><p>The next task was routing the grooves for the drawer runners. This task turned out to be a lot of math. First, I had to determine the distance from the router flat surface to where the router bit actually cut. Then, I had to calculate for each box where to set up the jig (e.g. distance from the top or bottom), and then route each one. I had to use my wood working machinist square because it had 16" of room for me to play with.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGtxWehvwjsPqSUWT036XYbDI16AFpvIPHOA1AMImESBY4KM7cQAmti0dKosaRzoKyDRAPmEV77fJlwz-niUhPqboUY9aEMg6H3eCGYNnQEummwkUVrIhmEDCd6RUhTQhAHXwRwV4_ss4737mRPdYgjKssLRIPGmFKJa1unft_lPJyb1oiISw80iGY/s4032/20220820_163922.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGtxWehvwjsPqSUWT036XYbDI16AFpvIPHOA1AMImESBY4KM7cQAmti0dKosaRzoKyDRAPmEV77fJlwz-niUhPqboUY9aEMg6H3eCGYNnQEummwkUVrIhmEDCd6RUhTQhAHXwRwV4_ss4737mRPdYgjKssLRIPGmFKJa1unft_lPJyb1oiISw80iGY/s320/20220820_163922.jpg" width="320" /></a>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLTdKGgp3Jofp6C9oGUqp1qEbhhR4U_UK36A2nitQzhyrKHu0rwoyLyzeBB4gd2TTSkGnDWSGnslDUo1vKQqEwReYluhYGITzQ_J-1la0XXvy2g-NlW171CgUHIELaAbSvYRUgr5wfshSnX-LJAelVdsHSVb6ELPclzLA6_8p028sXzg8CZ-8VtFKe/s4032/20220820_163954.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLTdKGgp3Jofp6C9oGUqp1qEbhhR4U_UK36A2nitQzhyrKHu0rwoyLyzeBB4gd2TTSkGnDWSGnslDUo1vKQqEwReYluhYGITzQ_J-1la0XXvy2g-NlW171CgUHIELaAbSvYRUgr5wfshSnX-LJAelVdsHSVb6ELPclzLA6_8p028sXzg8CZ-8VtFKe/s320/20220820_163954.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWHeqwuQ6dr8x18lhl7S02fsYdmURkrzepb7MDpRCU5htdhTienTTwKYxtBqHinN26mylM4twkcT4So6fUFgTQ1fG9Xh03XIqYSnVGSXMqq4UIjF36pglona7p3nPtx2jAfFTUP6jz54HmFW4wxlYoxsvoFLf0rlil9IaoyOdaitIB8i8i84T_UzCr/s4032/20220820_164106.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWHeqwuQ6dr8x18lhl7S02fsYdmURkrzepb7MDpRCU5htdhTienTTwKYxtBqHinN26mylM4twkcT4So6fUFgTQ1fG9Xh03XIqYSnVGSXMqq4UIjF36pglona7p3nPtx2jAfFTUP6jz54HmFW4wxlYoxsvoFLf0rlil9IaoyOdaitIB8i8i84T_UzCr/s320/20220820_164106.jpg" width="320" /></a>
</div><p>
</p><p>With them routed, I have three piles of chest carcass. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWj0lCsjJQsk6NHph-5C5riW4qb-KleFNkLdfih7qTAapBYu8UoH9Xvn4CNB0YtsbQvTWZwe03w_Ru53BEmqo31phWfuih4OkihGdwNRCgOMlzzdwAzPJlP4p3vwPeiVZq9RdvuDTf02Pki3SHCioZoEQL58hgT2Vdpup80XyTsWcpv5Pz78gFzv2I/s4032/20220820_164314.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWj0lCsjJQsk6NHph-5C5riW4qb-KleFNkLdfih7qTAapBYu8UoH9Xvn4CNB0YtsbQvTWZwe03w_Ru53BEmqo31phWfuih4OkihGdwNRCgOMlzzdwAzPJlP4p3vwPeiVZq9RdvuDTf02Pki3SHCioZoEQL58hgT2Vdpup80XyTsWcpv5Pz78gFzv2I/s320/20220820_164314.jpg" width="320" /></a></div><p>The next step was to sand all the inside surfaces (because I wasn't going to be able to sand them once glued up). I went to 320 grit, using the old carpenters trick of using a pencil on the surface of each run and sanding until the pencil marks are gone. Once that was sanded, it was time to glue things together.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOgB9C4WNz3gqVCCsEjWQvfyaHreo8inoh-UGcG3FbKKd7_cBZm8NxaGo0nFJoTuv8A8IoBBrNsbFWNTmLFt7IYFz-Xi5I-SVGgAGCjhjfergheJSZtdN4P8Csajn13CV6egZZS92TmpnjRB2oFHOUaAckZZ-U8Wc8Bqw0NKQjogqSaUwPm5heg2UN/s4032/20221105_174817.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOgB9C4WNz3gqVCCsEjWQvfyaHreo8inoh-UGcG3FbKKd7_cBZm8NxaGo0nFJoTuv8A8IoBBrNsbFWNTmLFt7IYFz-Xi5I-SVGgAGCjhjfergheJSZtdN4P8Csajn13CV6egZZS92TmpnjRB2oFHOUaAckZZ-U8Wc8Bqw0NKQjogqSaUwPm5heg2UN/s320/20221105_174817.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9Z6ESbK1JocOdRfwe0U2rOixj_y9HiFABql31d6uJERCvo2GOGcSX_6CvXjZdOR6Rwsqj3ADNvzFSFDdxBCMSRQqMN1QhTcRoKLHA-Jy_vWGSxQZbaMYKPkdipZcAFwdw7NuM882SvSQ7AvhMciHSv2Df97AUGheQBlt5c7e2L81MKUpnX2YMGOWB/s4032/20221109_115355.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9Z6ESbK1JocOdRfwe0U2rOixj_y9HiFABql31d6uJERCvo2GOGcSX_6CvXjZdOR6Rwsqj3ADNvzFSFDdxBCMSRQqMN1QhTcRoKLHA-Jy_vWGSxQZbaMYKPkdipZcAFwdw7NuM882SvSQ7AvhMciHSv2Df97AUGheQBlt5c7e2L81MKUpnX2YMGOWB/s320/20221109_115355.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigEIGy-tMVaw9w-yrF_cnNBb25FXXN6GgI-xcE5BmmIGIQdIiWzaovEbtXvJAAbqGh2wDu4b14me50ty-nhxIfqNTnWhWlTwhHHxpggyan0TYz649JOjXtplCfseeJAVmujFe78KGjMyJJTArelljRn3Od6NoED5VK2SJI7miz7vQ9zAIVkL-16PZU/s4032/20221109_115421.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigEIGy-tMVaw9w-yrF_cnNBb25FXXN6GgI-xcE5BmmIGIQdIiWzaovEbtXvJAAbqGh2wDu4b14me50ty-nhxIfqNTnWhWlTwhHHxpggyan0TYz649JOjXtplCfseeJAVmujFe78KGjMyJJTArelljRn3Od6NoED5VK2SJI7miz7vQ9zAIVkL-16PZU/s320/20221109_115421.jpg" width="320" /></a></div><p>I messed up on one side, and had to use one of those fancy orbital saw thingies. With a 3/8" blade, it cut a 1/2" slot, which matched up perfectly to the 1/2" box joints. Unfortunately, after that, I was using a chisel, and (while intentionally trying to keep my wrist out of the way), slipped. An involuntary reaction jerked my wrist right into the path of a sharp chisel.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXah6wpGsF6kcOrvDVZS4ZmIBy-Wm2eMCVyKKivwVeAKiAJmzEO2MnLqewcmLX5-YuRkojL_zQua7I96DFLgZYlJcHBn4mFFIEU0iiGHvkeoIcfe77kbOeNl9KiHK4K0cJB3WCez1ptgy-BuqXCCM2ePcAgdity2D8gtX_0cd_O4eelSE7HX4y_Uma/s4032/20221113_092243.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXah6wpGsF6kcOrvDVZS4ZmIBy-Wm2eMCVyKKivwVeAKiAJmzEO2MnLqewcmLX5-YuRkojL_zQua7I96DFLgZYlJcHBn4mFFIEU0iiGHvkeoIcfe77kbOeNl9KiHK4K0cJB3WCez1ptgy-BuqXCCM2ePcAgdity2D8gtX_0cd_O4eelSE7HX4y_Uma/s320/20221113_092243.jpg" width="240" /></a></div><p>The doctor was kind enough to tell me how to remove the stitches on my own (which I did - I didn't want to see anyone). So, on to finishing the glue ups of the tool boxes.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgl0e2pyMcPjHZcKy_5T_pibjQMM3dXgGnK1TCZsibva5O_iHQwkFJR-4rnn3GS1WkToCo3DQYNTL0P-r16RLB-LOxwKiJjjRGvOST_PdzM7LQ2bBZp-F6tHXU3Z9B_LeU4lBL8LWAoGFzQHEtuN-9fNO_CECAz6qLhwYsVsyG6k6v9vbhWj9Utikgf/s4032/20221113_100506.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgl0e2pyMcPjHZcKy_5T_pibjQMM3dXgGnK1TCZsibva5O_iHQwkFJR-4rnn3GS1WkToCo3DQYNTL0P-r16RLB-LOxwKiJjjRGvOST_PdzM7LQ2bBZp-F6tHXU3Z9B_LeU4lBL8LWAoGFzQHEtuN-9fNO_CECAz6qLhwYsVsyG6k6v9vbhWj9Utikgf/s320/20221113_100506.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBj-nZcqhouja57Ecz-jjGKfI8RN5JrfpqEknjzAEqMOg-MCWUntD6JlFu0hN-QZDyXrGGcdsDowSsMhNYN7Y_bglO63jwGF2nEegpWJ7AW6-ko6VJ3WlK-yDz8748ajT2mobGu4tWjoTF6kpBRk34gix1ACVCBMUqccKYk3LzLhkh06UuzmYd1oN6/s4032/20221128_203714.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBj-nZcqhouja57Ecz-jjGKfI8RN5JrfpqEknjzAEqMOg-MCWUntD6JlFu0hN-QZDyXrGGcdsDowSsMhNYN7Y_bglO63jwGF2nEegpWJ7AW6-ko6VJ3WlK-yDz8748ajT2mobGu4tWjoTF6kpBRk34gix1ACVCBMUqccKYk3LzLhkh06UuzmYd1oN6/s320/20221128_203714.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYfBAN5vRPrFVxxQxE7GCGLTq5yKrvw1FQXgsbCBHgbvvN9kfvRwFTBu7S2zqteIFM7CNOAoGndRRMAb_XI6b9MHznc4H7ic4veW75v_UjUDYCihzT6BjYebofmUyMCKiumq1mrOSxQV35-xEiF9Otq4zRgF8EWOGM9zDi4b24UK0gU0qO2TVASoGF/s4032/20221128_203719.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYfBAN5vRPrFVxxQxE7GCGLTq5yKrvw1FQXgsbCBHgbvvN9kfvRwFTBu7S2zqteIFM7CNOAoGndRRMAb_XI6b9MHznc4H7ic4veW75v_UjUDYCihzT6BjYebofmUyMCKiumq1mrOSxQV35-xEiF9Otq4zRgF8EWOGM9zDi4b24UK0gU0qO2TVASoGF/s320/20221128_203719.jpg" width="320" /></a></div><p>The next step was to cut the tops off.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtMBDigNQtIRvaV4KgIx68uLcAQq0pWFKZXi9M8zrG_5Hp0AL5TH7KWuw6mHiovSc5kHn5T7hfMAwwfgOBexTo6cGlBD3yi9qWpXM2xokYgDuqdcau8Hrgv97t6PM_iaGz73yAmomsHUvWb6twIhi1GyCSwed-O2RGMJwvStBDx59dGzWs9CztY-wT/s4032/20221208_131913.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtMBDigNQtIRvaV4KgIx68uLcAQq0pWFKZXi9M8zrG_5Hp0AL5TH7KWuw6mHiovSc5kHn5T7hfMAwwfgOBexTo6cGlBD3yi9qWpXM2xokYgDuqdcau8Hrgv97t6PM_iaGz73yAmomsHUvWb6twIhi1GyCSwed-O2RGMJwvStBDx59dGzWs9CztY-wT/s320/20221208_131913.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2iWKxJmtSDPKNkGZ0LWA5nclN4g0or2wQzJjUtmCw1qw34B250EahPxKovEJPhm-cVey5vZj6EhHvRfF565w3efKDZ3CaPe-SIoLqKY_j3jWEUfG1-zv8L8KAj0djpCbO6BuX7d3ekZerQGrZaE8h1fRxPh89y5ACFSSc7jQVqgUDBcfhOeU9Is_x/s4032/20221208_134537.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2iWKxJmtSDPKNkGZ0LWA5nclN4g0or2wQzJjUtmCw1qw34B250EahPxKovEJPhm-cVey5vZj6EhHvRfF565w3efKDZ3CaPe-SIoLqKY_j3jWEUfG1-zv8L8KAj0djpCbO6BuX7d3ekZerQGrZaE8h1fRxPh89y5ACFSSc7jQVqgUDBcfhOeU9Is_x/s320/20221208_134537.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7vu99gEERFmNRwMQ5m-0Lmnz4Utfj6eW61WaV3wtstvVgs_a1cuen13VnwW_urUzmM1jsa3kvtsVCLUma48H80RYGmuyO4venlhXpWLWEBrU9VBK5ICk6IRhFDfrMOi2CM0SIMxNg49Tz8pE6Y5M0T2x0-LKAKsEoFc2jvKSykWtswbNcjMwMJ7yW/s4032/20221208_134941.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7vu99gEERFmNRwMQ5m-0Lmnz4Utfj6eW61WaV3wtstvVgs_a1cuen13VnwW_urUzmM1jsa3kvtsVCLUma48H80RYGmuyO4venlhXpWLWEBrU9VBK5ICk6IRhFDfrMOi2CM0SIMxNg49Tz8pE6Y5M0T2x0-LKAKsEoFc2jvKSykWtswbNcjMwMJ7yW/s320/20221208_134941.jpg" width="320" /></a></div><p>Now, I should be able to fill the box joint imperfections with epoxy to match (one box in gold, two of them in silver). I also used a laser engraver to throw my makers' mark on the front panel (inside) on each one. You can see it in one of the photos above. I'll use a wire brush to clear out charcoal, and then fill it with epoxy resin to match the rest of it. Then I can do the final sanding and the hardware installations. (I did mark the plunger dimensions on each one.)</p><p>However, this post is getting very long, so I think I'm going to split this into two posts. See ya on the next post!</p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0tag:blogger.com,1999:blog-2052463488286316429.post-35671174083323240912022-11-12T12:15:00.000-08:002022-11-12T12:15:06.849-08:00Conical Laser Engraving?<p>My sister bought a laser engraver. I'd always been curious and had the desire to have one, but she pushed me over the edge when she told me they had a coupon for purchase off of Amazon. I ordered the 5 Watt Smernit, and they accidentally sent me the 10 Watt. First, a quick layout of the parts :<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVjiMvFLW5T5C-FZjEanfwqZOsa5kuCFKu8cWhEdx2AjyO6t_JktCOb8Vv4tNiOsnHbBT6e_KQTCfb9zjXWcYfGHP6mfPIB_BI07AJQBkd7CV2Kcn8ACJmLovYHNWDfxhH1-be1PdwvWOLxCTvzp3x_nFgxtjL7_swmKq-KxajBRv8ISY0n1cR14X5/s3264/20221021_074208.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVjiMvFLW5T5C-FZjEanfwqZOsa5kuCFKu8cWhEdx2AjyO6t_JktCOb8Vv4tNiOsnHbBT6e_KQTCfb9zjXWcYfGHP6mfPIB_BI07AJQBkd7CV2Kcn8ACJmLovYHNWDfxhH1-be1PdwvWOLxCTvzp3x_nFgxtjL7_swmKq-KxajBRv8ISY0n1cR14X5/s320/20221021_074208.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivMEMhyv18UhR9FKqThpNkw9CjW5S-CUWKFpbRoSB0ub0Qp9Gw7f2OYsFCNtK2cUTDLRC8uB6LoFV-X0PQ-1XdbMKFajaDyzbTcOqtAPUzYpPxV3ALZ1MKZr9PGWFbwagoPyKeSS_xzE5zeGXye7Fmyf5LQCBENIKF-udBEctGjUA-cOk7mb9K0ucq/s3264/20221021_074118.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivMEMhyv18UhR9FKqThpNkw9CjW5S-CUWKFpbRoSB0ub0Qp9Gw7f2OYsFCNtK2cUTDLRC8uB6LoFV-X0PQ-1XdbMKFajaDyzbTcOqtAPUzYpPxV3ALZ1MKZr9PGWFbwagoPyKeSS_xzE5zeGXye7Fmyf5LQCBENIKF-udBEctGjUA-cOk7mb9K0ucq/s320/20221021_074118.jpg" width="240" /></a></div><p></p><p>I put it together like a welder - corners set up, three points for squareness, 1-2-3 blocks, etc. I wanted this one to be more solid than my 3D printer.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJY4LDrY1gMRBcCX2iYGQr41YC3dJZHs02Z21_MJ9PjdJGE60GU68-wZD6Hy1I9kxL9qGkI4nFycGAEdiBl566VfgvM63rDxdKofHWFDahyGAv1I2AtWVCafvWgAZ8WjE5BxGwHBZ0IifHLSV5IaQdze2ci21--CX3f8AUN80Z1nDGR_F2sH4eBYmb/s3264/20221021_074532.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJY4LDrY1gMRBcCX2iYGQr41YC3dJZHs02Z21_MJ9PjdJGE60GU68-wZD6Hy1I9kxL9qGkI4nFycGAEdiBl566VfgvM63rDxdKofHWFDahyGAv1I2AtWVCafvWgAZ8WjE5BxGwHBZ0IifHLSV5IaQdze2ci21--CX3f8AUN80Z1nDGR_F2sH4eBYmb/s320/20221021_074532.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfjhvUfZLy-110TqDVwVQGRBSjVLb8hkOKg___8Shh2MjPHlnkwt0PfhHnDRXDExksStkXbix0ESSFnqXtMOr05R9aGLTpbUBQJzP4-N18Ij4efVlk3Ar0ElGHCv1Hy5AaA-krq5Zo_JelZ9zuIeoeaB7qiUAA2qH21Ha1h9pqyZVCHINqaAGjdYww/s3264/20221021_075302.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfjhvUfZLy-110TqDVwVQGRBSjVLb8hkOKg___8Shh2MjPHlnkwt0PfhHnDRXDExksStkXbix0ESSFnqXtMOr05R9aGLTpbUBQJzP4-N18Ij4efVlk3Ar0ElGHCv1Hy5AaA-krq5Zo_JelZ9zuIeoeaB7qiUAA2qH21Ha1h9pqyZVCHINqaAGjdYww/s320/20221021_075302.jpg" width="320" /></a></div><p></p><p>Once it was assembled, I had to finish the software side of it. Being a proponent of open source, I needed something that would run on Linux, and was recommended specifically for laser cutters. I ended up choosing LightBurn.<br /></p><p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGlED8kX3dZxFSE6zPyMzewkopfJkY5XQMNd3R9-hlK-r1oAJOyAaS5xsU74yXNi3FuUeVpFe8v5Sp8uhDjQaNiD9z1eFm8Xo01jS0kkxo7-SdE1txD45-1BwLAngkMJ4yT5wtMKWgND-JfFf1iqoTFKAZTwvBRghsTR30093uwEYjrmFISV9AZC6M/s1507/light.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1050" data-original-width="1507" height="223" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGlED8kX3dZxFSE6zPyMzewkopfJkY5XQMNd3R9-hlK-r1oAJOyAaS5xsU74yXNi3FuUeVpFe8v5Sp8uhDjQaNiD9z1eFm8Xo01jS0kkxo7-SdE1txD45-1BwLAngkMJ4yT5wtMKWgND-JfFf1iqoTFKAZTwvBRghsTR30093uwEYjrmFISV9AZC6M/s320/light.png" width="320" /></a></div><p></p><p>Make sure your user is a member of the "dialout" group so LightBurn can talk to your USB, if you are going to hook the computer directly to your cutter. I don't keep the tools and the computers close together (smoke in the house kind of thing), so I opted to just create a "laser cutter" based on GRBL that had 400mmx400mm (15.7"x15.7" is the manufacturer-claimed cutting area) inside of LightBurn. The Smernit has an SD card, so I can export G-code, copy it to the SD card, and walk it out to the "shop" for cutting. My settings :</p>
<table>
<tbody><tr><td align="right"><b>Type :</b></td><td>GBRL</td></tr>
<tr><td align="right"><b>How to Connect it :</b></td><td>Serial/USB</td></tr>
<tr><td align="right"><b>Name :</b></td><td>Smernit 10 Watt (Make your own up)</td></tr>
<tr><td align="right"><b>X Axis Length :</b></td><td>400 (mm)</td></tr>
<tr><td align="right"><b>Y Axis Length :</b></td><td>400 (mm)</td></tr>
<tr><td align="right"><b>Origin :</b></td><td>Front Left (determined by finding where the limit switches are)</td></tr>
<tr><td align="right"><b>Auto "Home" On Start</b></td><td>Yes (really, doesn't matter, I'm not connecting it)</td></tr>
</tbody></table>
<p>I could not get it to find the laser cutter, hence I had to create it manually.<br /></p><p>Anyway, I ran a few tests on the excess panels used in the tool chest
build (as of this writing, it hasn't been published) using my SilverHawk logo (registered trademark, folks) SVG until I had the power and speed right.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgoxcLYjzl5sMStrxHd53Z6gY0n8kNr97gXzIyxNtWVOo7ZVGAFfY2E5WPbcOvtLbRNETwqbdGE7DOhn9GPGnQX9xqqA9pI5E_4puhdcdGprBqwr2VaOBG4DoTXuphMcYkUudfJ46aQqYoQOchx-LUzzg6bDyJ_qzFeO8j3oTtaDL9BlD7kom3vrIAh/s3264/20221112_083938.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgoxcLYjzl5sMStrxHd53Z6gY0n8kNr97gXzIyxNtWVOo7ZVGAFfY2E5WPbcOvtLbRNETwqbdGE7DOhn9GPGnQX9xqqA9pI5E_4puhdcdGprBqwr2VaOBG4DoTXuphMcYkUudfJ46aQqYoQOchx-LUzzg6bDyJ_qzFeO8j3oTtaDL9BlD7kom3vrIAh/s320/20221112_083938.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjegWnNPhW9spaEPSZRfmKMkdVwkNyVIF8kxGvw7yqIhLS5X14sNgVory56OnlceWNy_ry1dH5qzT8neD6vcGM3dVTtA9yV87Qa3DEKwilcjYKpN39PDF4N-b8qg6EqUGJOO7fMfC2eC2_YISGqOPoN3OMuG0b8N3n6w8Wz42ysu5h_lraJaPBHiXsi/s3264/20221112_090827.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjegWnNPhW9spaEPSZRfmKMkdVwkNyVIF8kxGvw7yqIhLS5X14sNgVory56OnlceWNy_ry1dH5qzT8neD6vcGM3dVTtA9yV87Qa3DEKwilcjYKpN39PDF4N-b8qg6EqUGJOO7fMfC2eC2_YISGqOPoN3OMuG0b8N3n6w8Wz42ysu5h_lraJaPBHiXsi/s320/20221112_090827.jpg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHdvD-vPjucS3vtcjcgXSr9JBbUqqHju3lR3iieEuInaR5qjuFsLLpJHngBvdxfAG2AOsNG2VnxpEm9_3MZooW6KRPpAg8mIRiepdPa-gWgIGxzycp3au2zyQcSUWAjIrdRBzYeHTYdIENg6mMpBYnxBzltREsze231M52quXSlfF5aaZXfF9cjyXA/s3264/20221112_090829.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHdvD-vPjucS3vtcjcgXSr9JBbUqqHju3lR3iieEuInaR5qjuFsLLpJHngBvdxfAG2AOsNG2VnxpEm9_3MZooW6KRPpAg8mIRiepdPa-gWgIGxzycp3au2zyQcSUWAjIrdRBzYeHTYdIENg6mMpBYnxBzltREsze231M52quXSlfF5aaZXfF9cjyXA/s320/20221112_090829.jpg" width="240" /></a></div><p></p><p>My next objective was to engrave on a hot cocoa mug (I had ordered the rotary attachment from another device). I grabbed a mug from the dollar store, and later realized that rotating a cone on one of these will eventually cause whatever is sitting on it to slowly work it's way off, completely messing up the engraving.</p><p>So, I built a quick little bearing to keep it aligned while the conical shape could be turned. First, the drawing (on my tablet):</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8dfS_ACfUgIpD0I7hT-847ANMEXRYJrECnw9MK8cu-SxPvlKbWBsRhhXS3dVssr3mpZLi1aN_YRu06Ilf4ZcBytz3AO7OSmVszBpVMCe0kxC2KeHrUug58rTNaUz871uMJ512fosdlgi0Aw3ZxES-urQTAiJz0O3XNNMxOU7ya5Rv8XUR8vBxbSKp/s2000/Screenshot_20221112-131250_HandWrite%20Pro.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2000" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8dfS_ACfUgIpD0I7hT-847ANMEXRYJrECnw9MK8cu-SxPvlKbWBsRhhXS3dVssr3mpZLi1aN_YRu06Ilf4ZcBytz3AO7OSmVszBpVMCe0kxC2KeHrUug58rTNaUz871uMJ512fosdlgi0Aw3ZxES-urQTAiJz0O3XNNMxOU7ya5Rv8XUR8vBxbSKp/s320/Screenshot_20221112-131250_HandWrite%20Pro.jpg" width="192" /></a></div><p></p><p>Then, I used an old machinists trick to make washers the size of my bearing. I drilled three sheets of shim (the thin stock is sandwiched between two boards to allow you to grip, and to prevent rip) to the inner bore of the bearing, then put the shaft into the collet between the same boards. This allowed the outside to be turned to diameter.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgk6imeBgtXBafdgcmuL8fwpgWZ8ytvOrZFZ24reBaHAjG6q1ho0BiDWFTJ1faQRDlpbuNLHCnvefSd2lnrU_OauSrY0yG3zYkE9jhD_SJUCX_3QQOySkGukf2SuCSKyXHpLSENwKyk57PSLM1rUUj2ChLyzsvvSeMtqay6-xNpUEH81MwMsy8MpRIN/s3264/20221112_092632.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgk6imeBgtXBafdgcmuL8fwpgWZ8ytvOrZFZ24reBaHAjG6q1ho0BiDWFTJ1faQRDlpbuNLHCnvefSd2lnrU_OauSrY0yG3zYkE9jhD_SJUCX_3QQOySkGukf2SuCSKyXHpLSENwKyk57PSLM1rUUj2ChLyzsvvSeMtqay6-xNpUEH81MwMsy8MpRIN/s320/20221112_092632.jpg" width="320" /></a></div><p></p><p>Then, using a small piece of aluminum angle, I drilled holes for two slots, and one hole for the bearing shaft. I filed it all smooth, and then assembled it.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVLoDjwG4GGdjrusSfO1q6gu_HxU-YtBpMoA9EFHnVW_YR6I9MG--c_UPDK5U58-HfUDmhIQ1xhidn22J99soUHR_ZghjnbN1lb36Z-13iUBUHF8yaQwRIwdchIeI0haoIE43CVymJmJ67Ic6BhHZP0nzvlXauB9aYjOKDQOAwH6F6vWhpWar61UJs/s3264/20221112_094725.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVLoDjwG4GGdjrusSfO1q6gu_HxU-YtBpMoA9EFHnVW_YR6I9MG--c_UPDK5U58-HfUDmhIQ1xhidn22J99soUHR_ZghjnbN1lb36Z-13iUBUHF8yaQwRIwdchIeI0haoIE43CVymJmJ67Ic6BhHZP0nzvlXauB9aYjOKDQOAwH6F6vWhpWar61UJs/s320/20221112_094725.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5H4k6D25WZxaZYY7QNV_svMTIBa5SMCTd4x9EZ9dRWUnLuW4dH_qg-ccujt4iasH9DqdFB3m6Rs_eh9me0Vzp92vgvgGnN0BMrFpiwJqYi6q6NgI4PLRKkzdLOdJftsRcFE1z6gglQrhK3hcTyXpfJiKbAayYelzPfWaUCMm1pmDmsz5ZrtLWdv8G/s3264/20221112_102111.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5H4k6D25WZxaZYY7QNV_svMTIBa5SMCTd4x9EZ9dRWUnLuW4dH_qg-ccujt4iasH9DqdFB3m6Rs_eh9me0Vzp92vgvgGnN0BMrFpiwJqYi6q6NgI4PLRKkzdLOdJftsRcFE1z6gglQrhK3hcTyXpfJiKbAayYelzPfWaUCMm1pmDmsz5ZrtLWdv8G/s320/20221112_102111.jpg" width="320" /></a></div><p></p><p>This allowed the cocoa mug to rest on the rollers, and to prevent it from slipping off.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0cOKGg3_C-1FxTi4xoOr8yCFL8TIErwRDSbLatpuUYQCRTq4vIPFYzW_5r4GM2wTfYUGe3N3XDO4ZX4uX3qoxNSiO4t18qEK-8BiN92QWwh4w9_6kkWpp_SZrOw2IbEHAd5a8Nhd_dzPm2fAGvwwjCke7EYSkiRK6VVxygVwcz1lGg1u1FyE0UqJM/s3264/20221112_104708.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0cOKGg3_C-1FxTi4xoOr8yCFL8TIErwRDSbLatpuUYQCRTq4vIPFYzW_5r4GM2wTfYUGe3N3XDO4ZX4uX3qoxNSiO4t18qEK-8BiN92QWwh4w9_6kkWpp_SZrOw2IbEHAd5a8Nhd_dzPm2fAGvwwjCke7EYSkiRK6VVxygVwcz1lGg1u1FyE0UqJM/s320/20221112_104708.jpg" width="320" /></a></div>Only then did I realize the rotary attachment used a 4-pin plug, but the laser engraver used a 6-pin one. So, now I wait for materials to build an adapter.<br /><p></p>Joehttp://www.blogger.com/profile/07492032184666524437noreply@blogger.com0