Dan Dubeau
Ultra Member
Finally had enough painfree time on Sunday to get back in the shop to finish what I started a few weeks ago. Still not done, but decided to post anyway to shame me into finishing it and not drag it out any longer.....
I didn't take a lot of pictures, because I didn't really plan on making a science project out of it. Just wanted it "done", but here are a few from along the way.
Here is the initial concept I had to make the whole thing out of plywood.
Here is what it kind of morphed into because I didn't want to do it that way...
And I've called a few more audibles on the design as I went.....
First cut. Seems I need to make a saw stand next....
This is how I usually do my mitered corners. Cut square to length with with horizontal, and then miter with a portaband. It goes pretty quick (I hate adjusting the fence on the bandsaw for miters) and with the 0.1-0.25" angle I normally use it leaves a nice corner gap to weld, and finishes with a nice rounded ouside corner. With this 3/8" wall it didn't quite fill as nice, but keeping the end use in mind, I didn't fret too much about it. Noted for next project I build with this angle (I have a bunch). The mitered weld is beveled and welded from the inside.
The cutoff angles make nice feet too with a little flap wheel cleanup. I also save them for instant gussets whenever you need one too.
Had to take a break last weekend because somebody wanted to build a shelf for her room. She did it all from laying out the curvy edge, to cutting it out with a jigsaw, and sanding it. I just routed the edges with a roundover.
Anyway, that was the past 3 weekends of chipping away with an hour or 2 here and there when my back felt like it.....From here down was a bit on Saturday, and the rest Sunday when my back finally felt somewhat back to normal again......
Shimmed up level on my crooked floor....
That's where I am as of last night. Was planning on plywood shelves/sheeting, but am undecided again (might buy some sheet steel to finish instead of plywood). You can see the plywood I have leaned up in the pictures. Remnants of a long lost custom cabinet build from over 15 years ago (we moved, and it would no longer fit the space so I didn't finish it), that I've been slowly cannibalizing over the years. I think I have enough to finally get rid of the big pieces on this one. But a few of the rabbets and dados will show through. Not that big of a deal for me and it's purpose....
The main goal of this design was to be mobile, but also a place where I can store my pallet jack when not in use. It's also been a design exercise in trying to use up scrap, and some small offcuts and other crap material (see the curved upper cross brace?
). It's ultimate resting place will be in the corner next to the garage door where my stacked red box is (and one of the 3 piles of material is learning....). I've lost track of how many times I've had to move those leaning piles of material over the past couple years as I've shuffled stuff around. No more.....
I don't have any cool projects to share lately, as this one has been a roadblock for a while, but I'm starting to make some ground. Hopefully will get to finish it 100% this weekend, and take some finished pics that will fill in the blanks, as it's kinda hard to visualize the intent without the sheeting on it.
I didn't take a lot of pictures, because I didn't really plan on making a science project out of it. Just wanted it "done", but here are a few from along the way.
Here is the initial concept I had to make the whole thing out of plywood.
Here is what it kind of morphed into because I didn't want to do it that way...
And I've called a few more audibles on the design as I went.....
First cut. Seems I need to make a saw stand next....
This is how I usually do my mitered corners. Cut square to length with with horizontal, and then miter with a portaband. It goes pretty quick (I hate adjusting the fence on the bandsaw for miters) and with the 0.1-0.25" angle I normally use it leaves a nice corner gap to weld, and finishes with a nice rounded ouside corner. With this 3/8" wall it didn't quite fill as nice, but keeping the end use in mind, I didn't fret too much about it. Noted for next project I build with this angle (I have a bunch). The mitered weld is beveled and welded from the inside.
The cutoff angles make nice feet too with a little flap wheel cleanup. I also save them for instant gussets whenever you need one too.
Had to take a break last weekend because somebody wanted to build a shelf for her room. She did it all from laying out the curvy edge, to cutting it out with a jigsaw, and sanding it. I just routed the edges with a roundover.
Anyway, that was the past 3 weekends of chipping away with an hour or 2 here and there when my back felt like it.....From here down was a bit on Saturday, and the rest Sunday when my back finally felt somewhat back to normal again......
Shimmed up level on my crooked floor....
That's where I am as of last night. Was planning on plywood shelves/sheeting, but am undecided again (might buy some sheet steel to finish instead of plywood). You can see the plywood I have leaned up in the pictures. Remnants of a long lost custom cabinet build from over 15 years ago (we moved, and it would no longer fit the space so I didn't finish it), that I've been slowly cannibalizing over the years. I think I have enough to finally get rid of the big pieces on this one. But a few of the rabbets and dados will show through. Not that big of a deal for me and it's purpose....
The main goal of this design was to be mobile, but also a place where I can store my pallet jack when not in use. It's also been a design exercise in trying to use up scrap, and some small offcuts and other crap material (see the curved upper cross brace?
). It's ultimate resting place will be in the corner next to the garage door where my stacked red box is (and one of the 3 piles of material is learning....). I've lost track of how many times I've had to move those leaning piles of material over the past couple years as I've shuffled stuff around. No more.....I don't have any cool projects to share lately, as this one has been a roadblock for a while, but I'm starting to make some ground. Hopefully will get to finish it 100% this weekend, and take some finished pics that will fill in the blanks, as it's kinda hard to visualize the intent without the sheeting on it.
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I would like to make some racks above my garage door for longer 10-12 sticks still, but not a huge priority at the moment. Maybe next year....
