Assembly day.

With all the holes pierced for the pegs, it's finally time for assembly. The rain is holding off, so I'm going to do it outside.

Even with all the pre-fitting, it can still be a struggle to get all the pieces together. The idea is that the offset of the holes will pull all the joints together. I am going to give it a trial squeeze with sash clamps, before I put any pegs in. That way I can see if there needs to be any final adjustment of the shoulders.

All of these parts are from gnarly English oak, and even though they were straight and true when I first planed them, some have moved and twisted. This kind of construction allows for that and as long as you can get the tenons part way into the mortices, once they all tap home, the whole of it miraculously transforms into a straight thing. Sure enough, the shoulders of the top rail/stile joint needed squaring up.

Time to gather the pegs. One final check to makes sure all the holes are in the right place.

And then bang them in. It's a very satisfying process, as the pegs squirm through the offset holes, pulling it all tight.

Then back inside, as the sky is darkening with potential rain.

This chest will be taller than most at 35.5"/900mm, for two reasons. It's going to be a combined tool chest and workbench, with space underneath to slide my other toolbox (which is a WW1 British soldier's kit box, I believe). That height is ideal for me to work at.

Another oddity with this chest, is the brackets; because it's going to be a workbench/toolbox, I've upped the amount of pegs by a factor of 4. Period brackets often had only one peg, these have 4 each. It's going to take a lot of punishment, so I want it to be as strong as possible.

Where the rail carvings run onto the stiles, I have left this unfinished, so I can take those final cuts now the front is joined. I have to trim off those pegs first.

Exeter Box

Peter Follansbee is going to be making this box soon. I thought I might beat him to it, but he's much faster at this stuff. Plus the board I need for the top is still a log,

I went to take the photos back in March, and meant to send them to him then, but time slipped away. Anyway, he's got a whole load of pictures winging their way across the Atlantic as I write. Happy carving Peter. I think he's using white oak. When I make it, it will be from this English oak, that rolled in recently.

The box is lovely Exeter strapwork. Our favourite.

At once simple, but complex.

Front carving mostly done.

 

Front carving mostly done. Mortice and groove the back of the stiles, for the side panels and rails, groove the back of the bottom rail, for the floor boards and then ready to drawbore and join.

More Oakum and lime mortar and other hot things.

Today's installation. 2.4 x 1.9m window in Accoya. 28mm argon-filled DGUs. It's not listed, but it is a traditionally built barn, with lime mortar masonry, converted to a house. When it was converted, the window that was put here, was sealed with expanding foam and portland cement, causing the window to rot and damp problems inside. This new window has been sealed with Oakum and lime mortar, which should help with the damp issues. Wet hessian outside curtains, to protect the mortar while it cures.

Draining beads to give the window it's best chances against the weather. Osmo + to protect the dark oak stain.

In the main worksshop this week, with the window in production, and a few other jobs on the bench.

My new(old) Multico morticer. If you need to use a machine, use an accurate machine...

....do it once..........and free yourself up for handtool work!

If you use old machines, you need accurate hand tools to maintain them. I love this adjustable spanner, all the way from Buffalo, NY. It stays where you set it!

Talking of tools, making some is getting closer. The forge is now up and running, and what a forge it is! Gas with the possibility of using coal, and with the lid on, a kiln.

And with a few adjustments.

This chest is being designed as I go. The panels to each side  need something else to the carving. It's only now, with the trial assembly, that I realise what it is.

Not a huge adjustment; the leaves in the top part, needed more definition, and detail. And of course, having raking light, with the chest front in it's intended, vertical orientation, helps a lot.

And just another gratuitous photo of the central panel.

I now have to decide the design for the stiles. Enough foliage; I am thinking something with birds.

I want to be clear, that the design of this chest, is not copied from any single piece. It is, rather, a collection of different motifs, from various East Devon style chests of the 17th century, my favourites, if you like, and obviously, influenced by my hand and eye.

Bottom rail. In the flow.

On with the bottom rail. Chalked out first, with charcoal to show where the joints will be.

In with v-gouge.

Giving us this.

And grounded.

A few adjustments to make, but you get the idea.

Getting into the groove.

With the carving mostly done on the top rail and muntins, time to get the plough plane out, and cut the grooves into which the panels will fit.

Chopping out the mortices.

Tenon sawing the shoulders.

And a trial fit of the parts so far. I would normally have all the parts carved before assembling, but as I don't know exactly how the bottom rail will look, I want to see how the existing parts look.

I am pleased with it so far.