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Lills Quilt Rack Part V The Needed Shelf

Once I had routed all six legs even with the templates I turned to the shelf.

The leg blanks for the left side.

The shelf was made from the same tiger maple stock as the front legs. I milled four (4) pieces S4S and laid then out in different arrangements until I was happy with the pattern made by the grain. I then glued them up as a typical panel glue up.

After glue up the next step was to cut the shelf to size. I made it 24" x 24". As long as youre close the exact size doesnt matter. The cross bars will be relative dimensioned off of the shelf later. The exact size is not critical.

Its a very straightforward panel glue up.

The cuts were made with a track saw and my lovely 26" Woodpeckers try square. I tried to take equal amounts off each side in order to keep the panel seems symmetrical. After cutting to size I set the cutoffs aside, as they will come in handy later.

A big square is big handy.

With the shelf finished, I set it aside on stickers to allow air movement around it. This proved more important that I would have thought as accidentally leaving it directly on my table saw one night resulted in cupping. Luckily once I re-stickered it the sides reached equilibrium again and it flattened out.

Now that my legs and shelf were ready, it was time to begin laying out the joints.

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Lills Quilt Rack Part V The Needed Shelf

Dougs Bench Part V Assembly

The seat and wide leg are cut to size and dovetailed. The square legs and arm are milled and cut to fit. The seat is reinforced and the epoxy has been sanded flush. It’s assembly time.

All the parts, ready to go.

The assembly of Doug’s Shoe Bench is a two (2) step process. First I assembled the seat, wide leg and diagonal stretcher. Because of the direction of these joints, this first glue up was broken down into two (2) sub glue ups.

I began with the one joint which assembled horizontally, between the wide leg and the diagonal stretcher. I coated the mortises and domino with glue and pushed this joint together by hand.

With the seat upside down on the bench, I then glued the mortises on the diagonal stretcher and seat, the domino and the dovetails. All of these joints assembly vertically, so I took the assembled wide leg/stretcher and lowered into on the seat – into the mortise and dovetails. A few rubber mallet blows later and the joints were together.

The wide leg and diagonal stretcher are assembled.

Then I quickly flipped the seat / wide leg assembly over to sit it right way up on the bench. I used a simple L-shaped plywood frame the same height as the wide leg under the far end of the bench to support it at this stage in the glue up.

I used Woodpecker Clamping Squaresto keep the wide leg and the seat perpendicular when I clamped them together. Clamping them with Doug’s Shoe Bench upright on my workbench allowed me to turn my attention to the square legs and arm at the other end while leaving the wide leg in clamps.

Gluing up the wide leg and arm assembly was the trickiest part of glue up because the legs attach to the seat horizontally and the arm attaches to the legs diagonally with reinforced miter joints. I began by gluing up the mortises in the arm and then seating the dominos in them. Then I glued up the seat tenons and leg mortises. I set the legs in place and put a loose clamp on them to prevent them from falling over. Then I glued the domino mortise in the legs and the miter joints overall.

All clamped up.

Because of the miter, the legs needed to be pulled away from the seat in order to start the domino into the mortises. Though I was expecting the clamping of the leg to arm miters and leg to seat mortis and tenons to be hard, it proved to be very easy. Simply running a clamp between the top of the legs parallel with the arm produced enough pressure to drive the arm down as the dominos slid into their mortises.

Once the legs and arm were pulled into place, I added more clamps across the seat and miter joints.

Then, as I usually do I left it to dry overnight. Once it comes out of the clamps, with a small amount of sanding touch up Doug’s Shoe Bench will be ready for finish.

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Dougs Bench Part V Assembly

Nicks Berger Board Part V

The final step before finish was the graphic. Since my cousin Nick (who the Berger Board was for) is a graphic designer, he has his own personal logo. I had another graphic designer friend of mine add Nick’s Fiancée’s initials and the wedding date to the logo. Then I used the ink jet photo transfer technique I learned about from Steve Ramsey at Woodworking for Mere Mortals. I was extra careful to apply the graphic square to the veneer and it turned out excellent.

For finish, I used a shop mixed wiping varnish, 50% Minwax polyurethane, 50% mineral spirits. Because I was rushed on time, I experiment with Japan dryer, adding it to the 2^nd and 3^rdcoats. I can’t say I noticed it speed things up, but I managed not to ruin anything with it.

Laying out the logo.

The first four (4) coats came out nicely. The last coat was the one with grit added to it for better traction to the top of the board. While the polyurethane of this coat came out as well as the others, the grit didn’t. Even though I mixed it according to the instructions, I found that it didn’t apply evenly. Some spots had tons of grit, while others had almost none.

Ready for finish.

Post finish.

After the finish dried I gave the non-grip covered surfaces of the board a final wipe down with a synthetic steel wool and attached the hardware. Never having assembled skateboard trucks, bearings and wheels, I found it a straightforward and simple task.

The board is finish!

Then I wrapped up the skateboard in towel and packed it in my truck.

Have Berber Board, Will Travel.

At Nick and Alana’s wedding the skateboard was the talk of the gifts and just about everyone who knew me came up and complimented me on it. I’m especially glad that Nick and Alana both liked it. It’s been added to the skateboard display in their apartment.

Dylan signs the guest book next to the Berger Board.

The finished board in all its glory.

Thankfully, it was appreciated.

Building the Berger Board was a lot of fun and I learn techniques I had never tried before. Even though I don’t skate I think I’ll be building more skateboards and I know I’ll be incorporating these techniques in my future work.

Dont forget about the +Modern Woodworkers Association Podcast. We talk woodworking with Guests from around the world of woodworking every other week. Subscribe to the RSS feed or iTunes today.

Nicks Berger Board Part V