The Woodshop Shed

adventures in woodworking and home maintenance, from my shop in an oversized backyard shed

August 2019
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Finger post road sign

Furnished content.
(from Lumberjocks.com)


Finger post road signI was commissioned to recreate this Finger Post road sign. The only thing the client provided was a photo from 1968, showing the sign from her fathers front yard when he was stationed in England.The post and arms were simple enough, but I had two major concerns; 1, Was which font was used for the lettering, and 2, the spacing of the black and white painted sections.I began researching online and found the font Transport that looked spot on. Then I researched and found some companies in England that still make these style of signs. After emailing the companies, and waiting over two weeks without getting a reply, I decided to just make each section 12 in length.I used an 8' 4×4 as the center structure, then used 4 pieces of 1×4x6 pine and covered the bottom 6' of the post. The pieces lap over 3/4 as they go around the post. This effectively added 1.5 in width to the lower section. I did this to create the stepped shoulder.I created a template so that I could use my router to create a mortise through the upper section in order to pass the long finger through the entire post. I had to route from both sides to cut all the way through the board. I squared up the hole with a chisel.I used the same template and turned the piece 90 degrees to cut a notch for the single finger arm. I used two 5 long lag bolts to secure through the solid arm, into the end of the single arm, essentially locking them all together.I applied 4 coats of primer and another 4 coats of semigloss exterior paint (all white). Then applied 4 coats of the black paint.The only thing I would have done differently was to start with a 10' 4×4 and 8' 1×4's, because once it was put into the ground, at least 1.5' were lost to the foundation. You can see the height difference of the post between the two photos, one of me standing next to it (I am 6'), and the one of the recipient standing next to it once it was installed.The project was a gift for his 74th birthday and his daughter, the one who commissioned it, said he became very emotional when they walked him out to show him his surprise.



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Scroll saw puzzle for grandson

Furnished content.
(from Lumberjocks.com)


Scroll saw puzzle for grandsonI have made about 6 scroll saw puzzles for the grandkids….....they love to play with them.On this one, I thought I would try something different. I wanted to include my grandson's name on this puzzle.My process was:1. Cut pine blank2. Paint blank white on both sidesNote: Use oven at 120F to speed up paint drying process3. Apply blue masking tape to top of blank4. Glue full scale pattern of puzzle from Sketchup onto blue tape using white Elmer's glue5. Scroll saw the puzzle6. remove paper pattern and blue tape7. Using carbon paper, and a Sketchup print-out of the letters, trace them through the carbon paper8. Paint letters 1st time, bake in oven for 10 minutes9. Give 2nd coat of paint to letters and bake10. Apply blue masking tape as guide for top and bottom horizontal 1/4” wide bars11. Paint 2 coats of paint for the 2 bars12. Remove blue masking tape13. Paint back greyIf I do another one like this, I would change my background color from white to maybe grey or dark yellow…...I just don't care for the white.I would also paint the 2 horizontal stripes before I scroll sawed the puzzle. I did them last, and had some paint bleed under the blue masking tape at the saw joints.But, I bet my grandson and his sister will still love playing with it !If you are interested in all the details of this project…..........see my web site.thanks



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The Stair case build.

Furnished content.
(from Lumberjocks.com)


The Stair case build.I,ll try to keep this long story short, The long story can be seen here on a running forumThe short story, My Mate Simon is building an A-Frame house in Japan, he had a very difficult space to fit a stair in. Roof height was the biggest problem both on the A frame side and the height of the initial rise.
I started to do some homework on it and ran the forum, with lots of research and help from people here and in particular Tony_S , this is what we ended up with.This was done over a week of days off. Lumber was difficult to get in Hokkaido Japan and we ran out of time to order good stuff, ended up with low grade pine of 38mm thick. I laminated the stringers to get double thickness.Treads where checked into the stringer using a template and flush trim plunge router bit, then fixed with 9mm 5 inch coach bolts.Anyways , the stair super structure finished nice and strong , The wood will just need some dressing up before oil or hopefully paint.Some pics of the construction.Special mention to My Lovie Cheryl who worked along side me continually for 4 and 1/2 days with out one whinge.Thanks for reading.
Regards
Anth



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