Tag Archives: plywood

This Week in the Woodshop: Footboard, Pt. 2

Last week, I showed everyone the biggest project sitting on my workbench.  This week I completed the footboard just in time for Valentine’s Day.  I celebrated its completion by buying my wife a dozen roses, and taking her on not one, but two, dates in one weekend.

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Completed footboard. Click on the picture to see the Sketch Up file and examine the construction.

But I’m back in the doghouse, I mean, woodshop now.

I hope you enjoyed the pictures.  I designed the footboard with dovetailed (and splinted) carcass, rear panels from birch ply floating in dados, solid wood support beams on the ends.

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Finishing this guy was an adventure in and of itself.  I discovered a rule about shellac: never use shellac when it’s raining.  The humidity causes a white-ish blushing.  I had to wipe off the shellac with a rag soaked in alcohol to solve the issue…which caused most of the unevenness you can see in the photos.  It’s not terribly noticeable in real life, but the flash brings out the worst.

Make it safe & keep the rubber-side down  this week.

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This Week in the Shop: Plywood Storage & Lights & New Workbench

Since I moved into my new digs in April, my shop has undergone a number of changes.  I blogged about the move-in and of course I went and changed it immediately.

First, a couple bright spots.  Not long after I unloaded everything I realized two very important things about home ownership.  One, you can put holes in whichever wall you want, where ever you want, when you want.  Two, it’s expensive.  But not these lights.  Remember to buy the bulbs and make sure you wire’m up according to  fire code.  I’m a midnight rider now.

My new bench looks a bit beaten in today, but it works great for three months of use.  I made some terrible looking mortise-and-tenon joints at each leg, but 3/4″ pegs have kept it tight and square.  The top is very light – only one sheet of 3/4″ oak ply – so I used 1″ pine strips as reinforcement.  My cheap vise completes the look.  I never really meant to build this bench.  I mean to build a Roubo handtool bench before next summer.  I mean to build my wife a  Craftsmen-style bench.  I mean to do a lot of things.  Which means I’ll have this bench for the next ten years…

Last, but most importantly, new storage for lumber.  I don’t make a lot of things (at least compared to retired guys and professionals) and what I do make tends to be salvaged lumber.  I needed a small place to store lumber for two or three months worth of projects at a time.  Something mobile, something easily organized, something limited.  I’ve always admired the one at work, so I built my own.  You can find plans for a similar cart here.

Make it safe & keep the rubber side down this weekend.

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This Week in the Classroom: Boomerangs and Chalkboard Slates

Two projects really took off this summer – chalkboard slates and boomerangs.  The boomerangs, of course, took off a little bit more.

Back in the fall I built a bike barn.  It’s more of a third-world shanty, but it housed the bikes and kept them sort of organized.  Either way, I picked up a large number of cedar shingles as a roofing material.  Time got away from me – I never roofed the barn.  Instead, I used the shingles to create these cool little chalkboard slates.  I used an exterior paint as primer, then covered them in green chalkboard paint.  A couple of decorative touches later…

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My second big project has been an exploration of flight using boomerangs.  The summer program is themed around continents.  I got stuck with Australia.  Hence, boomerangs.  Here’s a flight test of our third or fourth iteration of salvaged plywood boomerangs.  Pick up the pattern here.

Make it safe & keep the rubber side down this weekend.

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This Week in the Classroom: Art Car

For the past three spring semesters (way back to my work at Citizen Schools) I have led a team of students in the design and construction of an Art Car.  An Art Car, if you don’t know, is an embellished vehicle of some sort.  Last year, I ran a sharkcar, the year before, a gatortruck.  This year, I received permission to use the school bus.  We run our car in The Houston Art Car Parade every second Saturday in May.

Of course, whatever I did had to be removable.  Nothing like a challenge.

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Over two months my students designed, cut out, painted and decorated about sixty monarch butterflies to festoon on the car.  We attached the butterflies using two methods – rare-earth magnets or an unholy sandwich of masking tape-liquid nails-masking tape.  Done right, both methods can withstand highway driving speeds.  Done right, they both can be removed easily.

I did it right.

I found many advantages to the design choices.  I found making the plywood butterflies a manageable one man task.  I probably spent 10-15 man-hours cutting the butterflies out.  During standardized testing in April, I utilized left over time to park the kids in front of a butterfly to paint.  Minimum of time, breadth of involvement.

I found some cons too.  Minimum of time doesn’t stack well against the competition.  Our school was up front, #112, behind the low-riders & previous winners and followed immediately by the political statement crowd.  I felt the bus was slightly naked, especially for a “glue stuff on” art car.  I had a dearth of participation from my students – only one showed up!  I blame this on my design choice:  by making the system so rigid, I de-vested ownership from the kids, instead of investing it.  I’m going to be making a few changes next year to boost participation.

I’ve discovered the need for a partner for this project.  At three years, I’m at a breaking point.  I can’t build and host the event.  I know which one I want to do…we’ll see which piece I’ll get to do next year. (Update-since-Draft:  a co-worker and long-time attendee has agreed to “host” the school’s meet-up.  I made the impressions I had to.)

One last reflection – this is a semi-permanent design.  I will add more kinetics props, a hood ornament and roof-thing over the years.  This was just a beginning…

Keep it safe & keep the rubber side down out there.

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This Week in the Shop: Tangled Up (Dining Set) in Blue

In the past few weeks, I’ve had the chance to photograph my completed big fall project from 2011.  I put together the table base over a few weeks in August and built the top over a couple weeks in September.  I don’t remember much, other than my wife traveled overseas during that time.  I remember my stomach tightening when she said “well, the country is in a state of emergency, so I might need a bodyguard” and the guys  at the lumberyard telling me “a great story” about said country which involved his friend being smuggled out of a military dictatorship.

I built the top in a fury and spent the rest of the day re-learning or learning prayers for safety in a number of religions.  Then I listened to a lot of soft rock power love ballads.  Just to cover all bases.

My wife came home safe to a new table.

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Of course, if you build a table, you have to have chairs.  I’ve always wanted to build an “exact” copy of a project from Make: Magazine.  I built four in November, and they looked like this.  I added a support brace across the back and front, which mitigated the thinness of the plywood.  As is, the chairs have some flexing but have held up quite nicely for six months.

If you build a puzzle chair, make sure your sides stay parallel to the ground or lean towards each other slightly.  One of mine tilts the wrong way and my “total-testing apparatus” (my three-year old) has flipped that chair a few times.  I figured out which one caused the trouble and made it “Daddy’s Chair”.

 

Make it safe & keep the rubber side down this weekend.

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Art Car 2012 is coming…

…soon.  For those you in the Houston area, join us at the Art Car Parade on May 12th.  More info at www.orangeshow.org.

Giant bugs in Texas. We do it bigger here...

Make it safe & keep the rubber side down this weekend.

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This Week in the Shop: Fixing the Couch

My wife bought a beautiful used Craftsman couch for the new house.  Unfortunetely, the previous owner had two young boys.  Boys, as any parent knows, have an instinctual hatred of nice things.  My parents used to run around my house yelling “this is why we can’t have nice things” at random intervals throughout my childhood life.  Often, I would not actually be engaging in destructive behavior, but they thought judicious over-use of the saying would compel me into good behavior.

I am now the father of two young boys.  I believe they didn’t yell that enough at me!  I got off easy!

Anyways, the couch came with a busted back support.  Here’s a slideshow showing the repair I made.

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STEM Project: The CO2 Rocket Car

This is my favorite project from this month’s STEM Fair.  A student of mine decided to build CO2 Rocket cars.  I loved building one of these in middle school.  I distinctly remember my simple teardrop design coming in last and remarking – well, that’s unfair.  I didn’t know I could do THAT! – when I saw the winners thin, stretchy, leggy thing.  I looked like a duck next to a greyhound.

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Last time, my teacher bought a kit.  This time, I chose a simple design for this piece – a pine wedge cut from a 2×4, 1/4 inch dowels as axles and wheels cut from plywood using a hole saw.  A 3/4 inch Forster bit cut away the hole for a CO2 cartridge (bought at the late night supply run superstore) Walmart – shooting goods section!.  My student assembled it and I rigged a firing mechanism and guide rails.

I know my next CAD/Aerospace mash – up.  Gliders, racing boats, rocket cars…any other type of fluid dynamics we need to cover?

Make it safe & keep the rubber side down this weekend.

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Student-Built Seesaw (He see-d, he saw-ed, he fell down)

Yesterday, we completed a physics demonstration: The adjustable see-saw.  This seesaw has holes drilled into the balancing beam, allowing students/users to experiment with the capabilities of numerous levers.  You just shift its position along the beam and viola!  Instantly, a foolish grin hits your face as you try to balance anew.

More pictures after the jump…

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New Year, New Classes

Spring 2012 is here!  I have just a (few) new classes.  A quick rundown after the jump:

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