 |
In
looking for another SuperStation project, my friend, Sal, said that a bar was on his
wife's to do list, so I said "let's make one."
It didn't take me long to see that Rockler Hardware had plans for a very nice
looking bar. Normally, I would draw plans from scratch, but this time I thought it would
be interesting to see how it would be to work from a set of finished plans. After all,
they only cost $20.00 or so — I should be able to make that up in time saved from
having a complete set of plans, not to mention errors I might make from doing my own.
|
When I received the plans,
I looked them over very carefully. Clearly they were professionally done, and the various
charts and diagrams should make the building of the 2' X 6' bar much easier.
But one thing I missed right off the bat was any detailing of total panels
and board feet of solid stock needed. And, to me, that is a real short coming. There are
90 pieces to cut. Each piece is exactly described...but you (or I) have to put each piece
on a cut list and add it all up to order the right material. That was disappointing, but I
got over it.
|
 |
 |
I started doing this
wood breakout by doing what I usually do, sitting down and marking on a piece of yellow
paper each and every part. For 90 pieces it took two hours and a lot of adding of numbers
— an area where errors can creep in. [23 1/8 by 6 1/4 plus 17 1/2 by 8, etc...]
|
So I turned to my computer
and the art program I use, Corel Draw. I started by laying out a page that was 48" by
96", the size of hardwood ply, of course. Then I took one part at a time and used the
Plan's dimensions to create a block and then moved the block onto the page. I didn't have
to add the pieces up as long as I didn't overlap the blocks.
I found that I would need 3 sheets of 3/4 ply...I had 3 pages of little
blocks.
I carefully specified in each block, the part number, description, and
dimensions.
|
 |
 |
Printed out, these
pages gave me a cutting plan for the panels. The draw program took about an hour to
complete with a lot of that time spent double checking the numbers.
So here I am at the first panel and ready to start cutting.
|
I said that this was a
project for the SuperStation — and it is. But very often, I find it is easier to make
the first panel cuts with the panels resting on horses and using my trusty circular
saw. I don't usually have an assistant to help me heft the whole panels onto the table
saw, and I am limited in the maximum size my sliding table can handle — not a whole
4' X 8' panel.
Here, I am setting the depth of cut to just exceed the thickness of the
3/4" panel. You will note that I have the ply laying on top a 1" board of foam
insulation material. This is a great way to keep the board raised above the horses. I cut
slightly into the foam material but not the horses. The foam panels are used over and over
and when they are really shot, they are discarded.
|
 |
 |
I clamp a straight edge onto my
board where I want to make my first rip. I set it at the width I want plus 1 1/8",
the distance from the edge of the saw to the blade.
There are some good straight edges that can handle the 96" length but I
bought an 8' level that could serve double duty. I would stay away from the 8' straight
edges that are two lengths clamped together in the middle. The one I had was never really
straight...kind of defeated the idea of a straight edge. This works very well.
|
I try to keep my left hand
on the straight edge as I proceed with the cut. If, for any reason, the straight edge
doesn't lay flat to the panel, the saw can move under the straight edge and make a mess of
the cut. This can happen where the panel isn't supported well and sags.
By the way, I find this 6" saw perfect for these panel cuts. It is
easier to handle than my 7 1/4" unit. With a 40T carbide blade on it, it makes a
great cut.
|
 |
 |
As I make each rip, I
add a piece of blue masking tape and mark the part number from the Rockler Plan list and
the dimensions. I will make the final cuts at the SuperStation.
Let me discuss the issue of cutting twice. My portable saw makes a very good
finished cut, but it isn't as good as the table saw. I usually cut these parts leaving
about 1/4" so that I can make the final trim later. In addition, I add more waste to
be cut off if the panel's edges are less than perfect.
|
At the SuperStation, I make
the cross cuts.
|
 |
 |
And then make the final rip
using the Incra TS III fence. While this may seem like an extra step at times, I feel that
I can get the most precise dimensions of each and every part when I do it this way —
unless, of course, I simply make an error in writing the dimension. I check and double
check to reduce that possibility. After all, good hardwood stock is expensive.
Since there are so many parts (90), I cut one panel at a time. At this point,
I have 11 parts dimensioned. 79 to go. So on to the rest of the plywood cuts.
|