September 26, 2012

Even more poly

My wife and decided that we liked the lighter stain that I worked in with a rag and wiped off quickly.  I applied a third coat of poly last night and it is starting to look like a finish.  I have a feeling that I am going to have to apply 4 or 5 coats total to get the finish that I want.  If everything goes according to plan I will be staining and finishing the hall tree this weekend.  I've never stained or finished anything this big so it is going to be interesting to see how eveything turns out.

I lightly sanded it with 220 and then put on the 3rd coat at 9:30 pm last night.

This was at 8:30 am this morning.  I only put the 3rd coat on the piece on the bottom.

September 25, 2012

New stain and poly testing

As I mentioned in my previous post I bought some new stain so I tried it out last night.  I bought a couple of little cans of polyurethane when I did my first ever stain and poly job on my son's step stool.  I have a little can of Minwax Oil-Modified poly that I used on the step stool and a Varathane water based poly.  Since I am using a water based stain I figured that I would try the water based poly too.

The seat and shelves really warped when I cut down the 1x10 to size so now the dividers don't fit correctly.  They are sitting on the crown in the middle and don't touch at the front or back so I decided to glue and tack in some supports on the sides.  I am using the dividers since they are sanded down to 120 grit like everything else.  I am going to sand one more of them to 220 grit to test more staining.  When I stained the step stool it was only sanded to 120 and I was really happy with the way it turned out.

I put supports in for the shelves just to play it safe.  I apllied glue and then just tacked them in with 1.25" brads in my nail gun.

I flooded the sample with stain and let it sit for 10 minutes.

The piece on the left is the one I flooded with a brush and let sit for 10 minutes.  The one on the right I apllied the stain with a rag and just worked it in for a few seconds and then wiped right off again.  It is a little liighter and less blotchy.

This is with 1 light coat of the Varathane water based poly.  The directions on the can of stain said that I could apply poly after 1 hour.  I waited 1.25 hours and put it on at 11:45 PM.

I lightly sanded the pieces down with 220 and then wiped them down with a clean towel and then a tack cloth.

Second coat of poly apllied at 8:20 am.

September 24, 2012

Hall Tree update

I had a car show all day on Saturday and it was like a million degrees on Sunday so there is no real update other than the fact that I bought some stain for the hall tree.  My wife decided that she wants a deep red color.  My son and I had to go to Home Depot so we checked the stain aisle and this was the closest red that I could find.  It is water based and the directions on the back say that it does not require a pre-stain conditioner.  I am going to try staining some scraps tonight and we will see how they turn out.  It was four something for the little tester can and seven something for the bigger one so I went ahead and spent the extra three bucks and got the bigger can.

September 20, 2012

Short update

I stopped by Rockler the other day to pick up another Clampit.  I think putting together the first couple of supports on the hall tree would have been easier if I had 2 of them to clamp at the same time.  They also had the mini Clampits on sale for $4.99 so I picked up a couple of them as well.  If you look in the top righ corner of the picture you can see where I had the pocket screw split the wood.  I glued it back together and clamped it but now my wife wants me to stain it instead of paint it.  The screw is really close to the surface so I may just pull it out now that everything is glued together.  There is still a screw on the bottom half and I don't think it should come loose.

September 18, 2012

Hall Tree assembly part 2

I was able to work on the Hall Tree last night and assembly is almost complete!

I was straightening up before starting assembly and found these right angle clamps that I bought last week at Harbor Freight.  I wish I would have remembered them on the first night of assembly.  They are now hanging on the pegboard in plain sight. 

Here it is with the seat and 2 shelves attached.  It was a really tight fit so I wasn't able to put very much glue on the joints.  Next time I think I will try building it 1 side at a time so I can properly glue everything together.  The seat and shelves warped pretty badly after I cut the 1x10x6 into pieces so I am not sure I am going to be able to install the dividers to make the cubbys.

The back of the cubbies is warped all to hell but it looks fine from the front.  Next time I am going to glue up smaller boards and remember to clamp eveything down before gluing and screwing.

Almost done.  I just need to sand down down the 2 boards I edge glued and install them under the top shelf.  That is where I am going to hang 3 or 4 hooks after some test fits.  I brought the tree into the house for some test fits and my wife decided that she would rather have it stained than painted.  That complicates matters.  I have a car show all day on Saturday so I am hoping to get the back piece sanded down and installed on Sunday.  Then I can give the completed piece a good sanding and hopefully stain and/or paint it during the week and have it ready for install on the following weekend.

September 17, 2012

Hall Tree assembly part 1

I started assembly on the Hall Tree last night.  I ran into some unexpected problems so I didn't get as much done as I had hoped to.

I started with the rear backsplash for the shelf at the top.  This one went pretty well.  I used my
Rockler Clampit and it did a good job.

This is the bottom with the apron in the front.  Since the pocket holes are on the inside I put the Clampit on the outside.  In hindsight I should have put the clamps all the way to the inside of the Clampit.  I had put them further out to allow me to get the drill to the pocket hole but I think putting the clamps all the way inside would have worked better.  The wood ended up drifting and one of the screws split the edge of the front corner.

I forced some glue into the split and clamped it and you can barely tell now.  I just need to do some sanding and after I paint it you will never know.

I got the top shelf mounted, glued and screwed in and I was very happy with the result.

Only the top shelf, backsplash, and bottom front apron are actually attached.  I dry fit the rest to see how it looks.  I hope to get the rest of it assembled tonight.

Hall Tree update

Pocket holes, pocket holes, pocket holes.....  I drilled like 40 pocket holes for the hall tree today.  This is the first project that has required this many and boy do they get boring.  Then I spent an hour sanding. All people in the videos that I watch always comment on how most of my woodworking time will be spent sanding and I am starting to understand it now.  If everything goes according to plan then assembly will start on Sunday.  I sanded the heck out of the 3 boards that I glued poorly.  I got rid of the ridge but now it's kinda wavy and almost bowed looking.  If it was going somewhere that it would be seen I would go buy some more wood and redo it.  But seeing as how I am on an artificial time limit I am going to leave it as is.

September 13, 2012

Do not glue while tired

I learned a new lesson.  Do not glue wood while tired.  I figured that I would get a step up on the hall tree build and glue some boards together tonight.  I wasn't thinking and didn't clamp the wood down to the bench before I drilled in the pocket holes and the wood drifted.  I hate it when that happens.  The good news is that the boards I glued together go behind the cubbys and nobody will ever really see them.  I'm hoping that I can just sand the hell out of them and even them up.  Once again, this is the main reason I am using cheap wood.  So I can make mistakes like this.

September 12, 2012

DIY Garage Cabinet

This is a pretty good idea.  I never would of thought of making a box and then cutting it in half.

September 10, 2012

Another new project, a Hall Tree!

My 2 year old son has learned the joys of opening the front door as wide as he can when he gets home.  In the course of this learning experience he has demolished the cheap coat rack that I bought at Wal Mart about 10 years ago.  It has been on a steady decline for the last year and he finally just finished it off. 

As a consequence of this my wife challenged me to make a coat rack in 2 weeks to replace it.  She invisioned a board with some dowels sticking out of it screwed to the wall.  Where is the challenge in that?  I did some looking around at some other projects on and decided to make a Hall Tree.  It is going to be 5' high by 2' wide and 9" deep.  It will have a shelf on top with a 2"back and a 5" stretcher underneath for hooks to attach to.  The seat will be about 13" high with 2 shelves divided into 5 cubbys for shoe storage.  I also plan on putting hooks on the sides.  1 at the top of each side and 1 down lower for backpack storage.

I went to Home Depot and bought 3 - 1x10x6 and 3 - 1x6x10 common boards.  I think they are knotty pine.  I also bought a $5 bottle of wood glue and a $.61 dowel for my son and the total came out to $44.40.  Initially I was thinking that I would make it out of all 1x6's but with the 2 week deadline I opted for the more expensive 1x10's. 

The 1x10's were 9.25" wide which messed me up a little because I was expecting them to be 9.5".  I ripped them to 9" wide and 5' long.  I ripped the 1x6's down to 5" and then used the miter saw to cut them down to 22.5" wide.  I also cut one of the 1x10's into 3 - 9x22.5 boards for the seat and cubbys. 

I opted to just cut an angle for the sides to slope up.  My jigsaw is not working very well right now and I am not that good with it when it is working correctly so the 2 equal really crappy cuts.

I will be attaching everything using pocket holes, glue, and my nail gun.

 The seat and cubbys will also have some extra supports glued and tacked underneath just to play it safe.

Cubby dividers same length as supports and 5" tall.  These will be glued and tacked into place.

The next step is assembly.