Dark Chocolate and Sponge Cake (8)

Yesterday I found myself deep into my milling machine – well, not so much, but this is the most apart I’ve had it so far:

The motor was quite a lump and way too heavy to lift physically.

Once the motor was off with the aid of a come-along, I could remove the drive pulleys and the drive pulley housing:

Getting the drive pulley off was quite a chore, as the M35mm fine threads were a bit chewed up:

The above picture is after I had cleaned things off with a feather file.

The cause of the damaged threads was found, the obvious clue being the tip of the two set screws which fixed the locknut in position:

It looks like these set screws had been modified by a previous owner of the machine. It makes no sense from an engineering perspective to drive hardened points into fine threads if you have any future plans of disassembly. Many German craftsmen are skilled and fastidious workers, however the person who did the above should reconsider his career path perhaps. Maybe I’m too grumpy!

The reason for all of this malarky was to get at the machine’s brake mechanism, which lay under the drive pulley. It had been making noises for a while now, and as I was in between tasks on the milling machine, it seemed like an opportunity for a ‘quick’ (hah-hah!) look-see. Besides the noises, which were obvious but not too alarming, there had been the odd piece of fibrous brake shoe material eject from under the pulley, so I knew at a minimum that the fiber needed replacement.

When I got the pulley off, I found that one of the cast aluminum shoes had broken in half:

I considered for a bit making a new one with the mill from some ½" 6061T-6 plate I had kicking around, but decided to investigate another angle first, just in case. Parts for old Zimmermann mills are non-existent for the most part, however it just so happens that the model of mill that I own was licensed for manufacture in the Czech Republic-  now called Czechia on the maps – by TOS Kurim, who made a metal milling version called the FNK-25a.

I located the North American distributor for TOS milling machines, in Ontario, and lo and behold they even had the brake shoes in stock, with shoe lining already affixed:

Though the parts were not cheap, it made sense to order them rathe than futz about. It would have been fun to make one, but not the best use of shop time, and i was unsure about dealign with the lining anyhow.

Back to the work on the upper frame. In order to trim off the remaining joint portions on the shaper, I made up a backing piece, a mirror of the molding profile – here, I’m checking the fit to the stock:

Once that was fitting suitably, I could finish off the trimming work. Here’s one of the completed corners, and bear in mind that the view is of the underside of the connection:

Work then turned to trimming trenches for the locking pins, or shachi sen, on the half laps:

Some opportunity was there for trimming on of the sloped ramp ways with a shoulder plane, so I took it:

This joint half is pretty much there:

An assembled corner:

The joinery was completed then through the other corners, with just the sen themselves to be fabricated. I’ll save that for later on.

Next task was to fabricate the battens which span across the panel of the top. I had rough cut the parts several weeks back, and boy oh boy this ‘special’ mahogany just does not move at all! No twist, no bow.

Nevertheless, I jointed, planed, and finish planed the pieces to final dimension, cross cut to dimension, and then formed the tenons, which are slightly off-center of the vertical axis:

These tenons will be formed into half-dovetails, something I should get to shortly.

Thanks for dropping by the Carpentry Way.
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Trueshopping Conveni

Trueshopping Convenient Folding Foldaway Two Seat Keruing Hardwood Wooden Bench Chair | Garden / Patio Furniture Mahogany Effect 1140mm x 630mm x 900mm
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Dark Chocolate and Sponge Cake (7)

Momentous session today, as it was time to run the upper framing members through the shaper. With the Aigner back fence in place, the result was going to be dimensionally accurate after having done test cuts with scrap, but you never know what can happen sometimes with wood being fed past a molding cutter. If things go south, they do so in dramatic fashion with 11 hp behind the cutter.

In we go:

And out it comes:

The result, as with most times when you combine Martin + Aigner, was without defect as far as I could tell:

The frame went together well, just a slight amount (0.004") interference in the fit of tongues and dados at each corner:

Another view:

The frame after the joints have been fully drawn together with clamps:

I was pleased with the outcome at this stage. Corner #1:

Corner #2:

Corner #3:

And corner #4:

At this stage, there were some protruding bits at the lap intersections to take care of:

I clamped the frames and placed a couple of temporary screws at each corner, in the space to be later occupied by a mortise, and this set up allowed me to get started with the shaper, sans back fence, one completing the molding of the end grain portions:

All for this round – thanks for tuning in and comments always welcome.

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Dark Chocolate and Sponge Cake (6)

After quite a spell of toiling, the 4 latticework panels are completed, featuring ‘fully woven’ laps between bars:

Another view:

This pattern is termed, generally, chidori-gōshi, with chidori roughly translating as ‘houndstooth check’. Kōshi/~gōshi, heavier stock than kumiko, the type of lattice normally seen on shōji, etc. could be called ‘bars’ or ‘grillwork’.

The floating tenons, used to attached the latticework assemblies to their surrounding frames, are made next – here, I’m about halfway through making them:

The attachment of the floating tenons is going to be rather time consuming. While I’m working on that for the next while, I’m also moving along the joinery on the upper framework for the cabinet.

To that end, I’ve set up some paring blocks to trim the end grain of the lap joints:

Here’s a view mid-process:

A closer look:

First task is to clean the 90˚ end walls to the line:

Some shots now of the joint pairs after the mitered end walls have been trimmed also; this first pair I’ll call set #1:

And here’s #2:

Lookit all da white flecks…



I’m enjoying working the ‘other’ mahogany.

The first step after a bit more lay out is to rough trim the miter return on the end of the lap:

This pair has already had the mitered clips trimmed to their marks:

Onward and upward-  lots of joinery work still to go on these frames. Thanks for visiting the Carpentry Way.
from Tumblr https://davidpires578.tumblr.com/post/172052514614

My Journey As A Creative Designer – Woodworking and Beyond #1856: Back to Blogging

Hello to my Lumberjocks followers. After taking several months break, I have decided to go back to blogging again. Since I was going in many directions when I last posted, I decided to take some time off and get things sorted out. After over 1800 posts, I thought it was a much-needed rest.

I have decided to continue blogging but on a central site that would do better to encompass the many types of things that I create. I felt that while Keith is continuing to do scroll saw patterns and I am continuing to make wood surfaces for painters, a lot of my posts were in relation to not only those subjects, but also painting and even needlework. Posting on the WordPress site will allow me to reach those who are interested in what I do on a larger scale.

I hope you decide to subscribe to my WordPress blog. I have made some great friendships here on Lumberjocks and have missed talking to you each morning. But as I always say – life is like a kaleidoscope – forever evolving and changing. In order to be successful in our lives, we need to be able to adapt and change, too.

The new address for my blog is here: https://sheilalandrydesigns.wordpress.com/2018/03/14/604/

I hope to see you there.

Have a great day!

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