Dinnerware Hutch

[cflansbaum]

My first "official" commission for my business Studio C Woodworks, is a Dinnerware Hutch.  I'm photo documenting it in more detail here on Picasa.  However I thought I'd put more specific tasks that I use Festools for here.

I'm anticipating that it will take me until the end of next month to finish.  I'm be updating the pics on Picasa as well as here sporadically during this time.

Here's a Sketchup rendering of the Hutch.  I'm building it primarily of Walnut and Honduran Mahogany.
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Of course the first task is to gather the troops!
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Here's me laying out a cut on the rough stock for which I'll use the TS55.
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Here's a setup for using the TS55 & guide rail to rip a 10" wide board.
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Worked great!!!
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It will be about a week before I get back to this project so I'll do another update after that.

Carl

 

[cflansbaum]

I didn't get as much done over the past week as I hoped as the Jet 22-44 3HP Pro Drum Sander I ordered for sanding my veneers hasn't arrived yet.  I did cut the MDF substrates for the veneered panels however.  For the lower solid panel veneered doors, I glued on some hardwood (H. Mahogany) banding.  Festools were used as followed.

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I used the TS 55 and guide rail to flush trim the initial top & bottom banding to the substrate. 

I then used the MFK 700 to flush trim the hardwood banding to the substrate. and glued on the side hardwood banding pieces.

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I then used the MFK 700 to flush trim this banding. 

A few things I learned with using the MFK 700.

• The micro adjustability with this little router is fantastic and easy to use - as long as you remember which direction to turn the adjustment knob  ;D
• You must use the 0 degree horizonal base to do what I'm doing above
• The only bit that I've found that works here is the Festool Two Flute Trim Bit for MFK 700 which really only allows about a 1/2" cutting length

Probably not much more going on with this project for another week or so 

Carl

 

[cflansbaum]

Sorry for the delay in updating...

I've got almost all of the veneer work done.  I used the MFK 700 with a flush trim bit to joint the veneer edges before I edge glued them.  My wife had the camera this day, so unfortunately I didn't get any pics.

After veneering the door cores, here are pics of the lower doors.
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I then used the TS55 and my MFT to cut the veneered panels to final dimension.
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With all the legs and aprons cut to final dimension, I routed dados for the panels and then used to Domino for loose tenon joinery.
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I'm now working on the joinery for the front and back aprons.
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Carl

 

[woodshopdemos]

Carl,
  A great project and a super tutorial. What glue did you use for veneering in the vacuum bag?

 

[Jimhart]

Carl,

The tops of your MFT's look shiny. Did you put a coat of lacquer or shellac on them to keep glue from sticking?

Jim

 

[cflansbaum]

John - thanks , I'm using UltraCAT from Veneersupplies.com.

Jim - I put on two coats of wax.  I probably wouldn't do this again, as it makes the tops slick and I always use wax paper under my glue ups anyway.

Carl

 

[cflansbaum]

I spent the other day cutting the 2 sheets of walnut ply I have for this project to rough dimension.  At over $100 a sheet, I wanted to wait to this point of the project  to cut these.

Even though my wife has graciously allowed me half of our house for my shop, I'm still tight on space when it comes to cutting sheet goods (of course, who isn't).  I've always wanted to be able to use my 2 MFTs, but this has always required me to remove the fence - which I hate to have to re-square again.

I have a stack of old 1x boards that I use to lift sheet goods off of the table when I'm making cuts, and I realized if I stacked these high enough I could clear the fence.  At this height, there's just enough room for a 3/4" sheet to fit below the guide rail. 

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After cuts to final dimension, the first panel is in place.

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Carl

 

[Les]

Half the house for your shop?  Surely you jest :

Nice project and great pic's. ;D

 

[cflansbaum]

A lot of work with the walnut ply this past week.  Cut all of the panels for the back as well as most of the shelving to final dimension.  Spent alot of time routing the back and shelf supports and doing the domino joinery to tie them into the legs.  Here's a few pics of the lower and upper units coming together.

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I also used the TS55 and MFT to cut the taper on the legs.

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Starting to see the light at the end of the tunnel -- hoping to be done in about 3 weeks.

and Les, yep almost half the house!  We have a split level -- the garage was already my shop, and I just recently converted the rest of the downstairs to assembly area / wood storage / office space!

Carl

 

[Frank Pellow]

Carl, it's now almost four weeks since you reported on this project.  I am really enjoying your reports and am looking forward to the next insallment.

 

[cflansbaum]

busted...  I'm still working on it!  It has really been a much more complicated project than I anticipated; so much so that I've kind of let taking pictures through the process lag.  I'll try and get some up in the next few days.  It is going to be a really nice piece, the client is really happy.

Don't know how I could have done it without my Festools!

Carl

 

[Matthew Schenker]

Carl,
We're all waiting to see more about this!  So far, it's been a great project to share.
Please post more!
Stay in touch,
Matthew

 

[cflansbaum]

ok, here's a few more festool related pics -- I have also put up more pics on this page at Picasa.

This first one shows me using the MFK700 for trimming the hardwood border for the top of the upper unit.
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This pic shows me using the TS55 and guide rail for cutting the plywood panels for the upper unit shelving.
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This one shows me using the Domino to cut mortises for use in the upper door frame members.
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I used  the OF1400 router for quite a lot of tasks in this project so far:  along with my Leigh superjig to cut dovetails for the drawers,  to cut profiles on the upper and lower unit tops, as well as cutting the inlay dado's in the legs. Unfortunately no pics... :-(

I promise to take some pics today of the progress so far...

Carl

 

[cflansbaum]

ok, a few more I quickly took this am before starting my day...

Upper door frame.
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Upper shelving (note hardwood edging and domino joinery.
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Top of upper unit placed on upper shelving.  Hardwood trim flushed with MFK 700 and profile routed with OF1400 routers
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Top of lower unit - walnut stained with GF Walnut Get Stain, and whole piece has first coat of GF Clear Seal-A-Cell.
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Lower unit doors (drilled for all hardware with a Festool C12) and drawers (dovetails with a OF1400 and Leigh superjig).  Finish on inside of drawers is shellac and wax.  Pic shows first coat of oil on doors and drawer fronts.
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more below...

 

[cflansbaum]

lower unit, upper front and back aprons with coat of GF gel stain.  Note domino mortises. These are for the drawer supports shown in the second pic.

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Carl

 

[cflansbaum]

ok, a few pics from today...

here's the dado channels cut in the legs with the OF1400 and then with the inlays.
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glue up of the back section, and then most of the rest of the lower section.
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Carl

 

[Les]

Looking forward to the finished product. Hard to recognize you without your hat.

 

[Frank Pellow]

Thanks for all the recent updates.  I am looking forward to seeing more.

 

[cflansbaum]

just a little update...

because of the design of the upper unit, I've decided to prefinish all the parts.  So with such a big project and so many parts, I've had to do this in 2 phases.  Good news is I'm almost done!  I'll be assembling the upper unit early this upcoming week and it should all be complete mid week.  I promise more pics then.

In the meantime, here's one of the lower unit pretty much complete.

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Carl

 

[cflansbaum]

Well at long last, the dinnerware hutch is complete!  With the exception of installing one last piece of glass for one of the upper doors (which I mistakenly broke when installing), it's ready for delivery.  The client stopped over this afternoon and is ecstatic!

One of the more complicated and involved glue-ups I've ever done for the upper unit (which I had to do upside down).

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So here's some completed unit pics.

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Carl