36" Window Box
Edward Keogh
WINDOW BOX'S: ALL FINISHED
WINDOW BOX'S: ALL FINISHED
36" Window Box
Edward Keogh
WINDOW FLOWER BOX : PHASE 6
WINDOW FLOWER BOX : PHASE 6
36" Window Box
Edward Keogh
WINDOW FLOWER BOX : PHASE 5
WINDOW FLOWER BOX : PHASE 5
36" Window Box
Edward Keogh
WINDOW FLOWER BOX : PHASE 4
WINDOW FLOWER BOX : PHASE 4
36" Window Box, Outside Projects
Edward Keogh
WINDOW FLOWER BOX : PHASE 3
WINDOW FLOWER BOX : PHASE 3

Day 1

Craft Beer Flight : Part 1

So today I started making the craft beer flights and boy was it a messy start, mainly because I needed to do pretty big glue-ups. They were not widest glue-ups but they sure were plenty long, anyway more about that later.

Today’s Events Included:

  • Ripping all the wood on the table-saw

  • My Designs

  • Glue-up Prep

  • Glue-Up


Ripping the wood

So I needed to take all the wood and cut them to the dimensions that I made on my plan, I ultimately wanted a 4-1/2” wide flight and using 3 species of wood which were Sapele, Maple and Walnut. So I needed to take these boards and cut them into smaller strips.

so I installed a rip blade in my table-saw and also placed a feather-board in place so as that the wood piece would move while I was ripping it.

Here is the table-saw set up I made with the feather-board in place

Here is the table-saw set up I made with the feather-board in place

Here is the 3 species of wood that I will be ripping.

Here is the 3 species of wood that I will be ripping.

Here are all the pieces ripped and came out great as there was no burn marks on the wood as I used a rip blade.

Here are all the pieces ripped and came out great as there was no burn marks on the wood as I used a rip blade.

Here is another close up of the boards that were just ripped.

Here is another close up of the boards that were just ripped.

My Designs

So here is the design I came up with I really like the contrasting woods and should come out great, I was lucky enough to make another design by some of the leftover off cuts that I had.

So here is the design I came up with I really like the contrasting woods and should come out great, I was lucky enough to make another design by some of the leftover off cuts that I had.

Since I had more maple and sapele left over I could make this design as well its really nice as well. So what started out as making 6 flights I will be able to make 8-9.

Since I had more maple and sapele left over I could make this design as well its really nice as well. So what started out as making 6 flights I will be able to make 8-9.

Glue-Prep

The glue-up was going to be a little complicated because I wanted to glue up three 5 foot sections all at one time. I wanted a system where I would clamp all three together with dividers between each of the glue-ups and that way I would not need a ton of clamps, but that turned out to be not the most efficient way and I didn’t get one of the glue-ups done. I was using Titebond II and the open time was not long enough to fit in 3 glue-ups so I just did 2.

I really dislike the method I used and really need to rethink my process, I use 3 pieces of plumbing white pipe on top of wooden risers as you can see in the picture below, and the dividers that I used to separate each glue-up were different heights so I couldn’t use clamping cauls, I will know more tomorrow after the glue has set but I think I am going to have a fair bit of surface sanding because I don’t have a planer.

I also had to make a trip to the local big box store to purchase more clamps as the clamps I had were too short so I got the Bessey Pipe Clamps and a couple of 24” black pipe pieces. After I finished for the day I started researching better clamping set-ups If my shop was a little bigger I would just make a clamping table but since that is not possible I found another method which is portable and can be broken down and stored away when not in use. I think I am going to make this tomorrow and probably make a few different rail sizes depending on what size clamps I will be using at any specific time.

As you can see its a front and back rail with stretchers on either side, he notched out half circles to accommodate the pipe clamps, The stretchers are help together using a half-lap joint and when not in use can be just pulled up and the jig can be…

As you can see its a front and back rail with stretchers on either side, he notched out half circles to accommodate the pipe clamps, The stretchers are help together using a half-lap joint and when not in use can be just pulled up and the jig can be stored away.I think I will make mine the same but I will add different sized stretcher depending the size of clamps I will be using, they usually range from 12” - 36”. Click here for the website I found this on.

Here are the white PVC pipe that I have nesting in some scraps, but didn’t work great because the scraps kept falling over.

Here are the white PVC pipe that I have nesting in some scraps, but didn’t work great because the scraps kept falling over.

The idea of the white pipe was that it gave the work-piece a flat surface to sit on, and it also afforded me to add height to the glue up so as that I could place clamps on the bottom and top surfaces of the work-piece.

The idea of the white pipe was that it gave the work-piece a flat surface to sit on, and it also afforded me to add height to the glue up so as that I could place clamps on the bottom and top surfaces of the work-piece.

Here is the final pieces with all the glue applied, I will not be doing this again. But we live and learn.

Here is the final pieces with all the glue applied, I will not be doing this again. But we live and learn.

I really do like the patterns on the flight and think they will be really nice when finished.

That’s all I got done today and thanks for reading.


NEXT

  • Build the pipe clamp glue-up jig… I might need to get some plywood but I am not sure if I have enough scrap to get this done.

  • If I have enough time I need to do some surface sanding on the 2 glue-ups I got done today and I would like to get the other glue-up completed hopefully using the new jig.