WALL SHOWCASE
PROJECT DETAILS:
-- Coming Soon --
MATERIALS:
MATERIALS:
- -- Coming Soon --
TOOLS:
- -- Coming Soon --
CONSTRUCTION:
- -- Coming Soon --
PICTURES:
Sunday, May 10, 2015
BOOKSHELF
PROJECT DETAILS:
The bookshelf was a simple project similar to letter box. It was for books but can also be multi-purpose to contain toys, dolls, show piece items.
MATERIALS:
MATERIALS:
- Plywood - 6 x 4 sheet, 18 mm thickness
- Plywood - 6 x 4 sheet, 3 mm thickness
- Laminate sheets - 8 x 4 sheet, 0.8 mm thickness (choose color of interest)
- Sand paper - 180 and 120 grit
- Fevicol white wood glue - 500 mg
- Fevicol sythetic rubber (SR) - 500 mg
- Wooden reaper/band - 1 inch thickness (length need to calculate from plan)
- Nails - headless type and regular type (1+ inch long)
- Screws - 2 inch long (20 pieces approx.)
- Paper sticking tape
TOOLS:
- Round saw machine with wood cutting blade
- Big hand file for smoothing cutting laminate
- Laminate cutting sharp knife
- G - Clamps - 4 no.s
- Hammer
- Screwdriver
CONSTRUCTION:
- Cut the 12" plywood sheet to the specifications given in plan below:
- Cut the 3 mm sheet to a rectangle of size (30 inch + 24 mm) width x 28 inch height
- Laminate both sides of the cut plywood pieces. The regular technique of fevicol white + SR application does the trick.
- Drill 2 holes in pieces D and E measuring 12 inches from the top and 1 inch from either sides.
- Next, lay the pieces on a flat surface and horizontally align pieces A,B and C in between D and E. Simply screw the sections D and E now through the holes we drilled in previous step.
- This will take form of the bookshelf now and the final part is to nail the back panel of 3 mm plywood to close the backside. Fix the 3 mm back panel using headless nails.
- Next apply reapers across edges of plywood with fevicol white. Hammer a few headless nails to hold in place. Reapers come in various designs as well, so choose as per your taste. I chose a rounded surface design.
- Sand the reaper with sand paper and then paint or polish it to look good. Or just varnish it to get long life.
- Thats it ! bookshelf is ready
PICTURES:
My Tool Box
Initially when I started collecting tools, I had a tough time knowing what parameters to look for, brand, etc. Chinese machines for drilling, cutting which I purchased with much skeptism do work well, however nowadays with online websites its easier to get hold of quality tools.
The best brand in this area for machines is "bosch". Even if it costs a little bit more, the quality and finesse are unmatch-able compared to black and decker and other brands out there.It took nearly 5 years to collect all these tools as they were not bought at same time. When the need came, I used to search online refer woodworking books or watch youtube videos to get Ideas on what tool to buy.
Investing in these tools saved a lot of time which would otherwise be spent in manual labor.
The list of tools and machines used in my toolbox:
(Round saw machine with wood cutting blade)
(Big hand file for smoothing cutting laminate)
(Laminate cutting sharp knife)
(G - Clamps)
(Manual Planer)
(Electric Planer)
(Electric Drill)
(JigSaw)
(ScrewGun)
(Carpenters Level)
(Measuring Tape)
(Toolbox)
(Manual Planer)
(Electric Planer)
(Electric Drill)
(JigSaw)
(ScrewGun)
(Routing Machine)
(Carpenters Level)
(Measuring Tape)
(Toolbox)
LETTER BOX
PROJECT DETAILS:
Letter box was intended to meet its purpose, however I wanted a box that can have sufficient space to hold magazines and bills, large envelopes, etc. For security reasons a key-lock was also provided.
MATERIALS:
- Plywood - 6 x 4 sheet, 12 mm thickness
- Laminate sheets - 8 x 4 sheet, 0.8 mm thickness (choose color of interest)
- Sand paper - 180 and 120 grit
- Fevicol white wood glue - 500 mg
- Fevicol sythetic rubber (SR) - 500 mg
- Key lock - cylinder type
- Wooden reaper/band - 1 strip
- Nails - headless type and regular type (1+ inch long)
- Paper sticking tape
- Cabinet Door Hinge - 2 pieces
TOOLS:
- Round saw machine with wood cutting blade
- Big hand file for smoothing cutting laminate
- Laminate cutting sharp knife
- G - Clamps - 4 no.s
- Hammer
- Screwdriver
CONSTRUCTION:
- Cut the plywood sheet to the specifications given in plan below. The center piece (10" x 18") must be cut twice.
- Cut the laminate sheets in this same way as plywood specifications. This will cover the inside of the letter box. The exterior will be cut after the assembly.
- Now we will take each piece of plywood and its corresponding laminate and stick them together one by one.
- Spread fevicol white on one side of a plywood piece with a card board strip or brush.
- Spread fevicol SR with a brush on the laminate piece and wait for 30 secs to dry a bit.
- Once dried, sandwitch both plywood and laminate together and then apply pressure so that they stick together. Pressure inside out so that air bubbles get released.
- Stick the edges of the laminated plywood with paper tape tightly.
- Now, do the same for all the remaining pieces and stack them together suitably.
- Once stacked, clamp them together with G clamp and let it to dry for a day.
- After drying, lets start assembling each piece together.
- Starting with the 18" x 7" piece, place the unlaminate side facing down on floor. Then place the remaining pieces around it to form a box shape. The triangle portion should face up and laminated sides inwards.
- Drill holes in sides one by one and nail them together to join.
- Now place the 22" x 8 " piece on top of the box and hinge it from both sides. apply fevicol white and nail through the wooden reaper around the edge of this plywood. Sand and scrape off unwanted material.
- The box should now be functional.
- Next, measure the exterior dimensions of the box and cut laminates matching the specifications. Apply fevicol white and SR procedure as earlier and stick all the laminates to plywood.
- Finally fit the key lock through the round hole on the top and the letter box is ready !!!
PICTURES:
Door Hinge
Key Lock
Side View
Finale !
Friday, May 8, 2015
T.V. / Computer Table
Background:
This was the first project I got inspired with, a T.V. / Computer table.
Before I dive into the details of the construction, a little background on the beginnings.
As months passed, I decided to buy an LCD TV and was really excited about it. The feeling after purchasing your first TV with your money was beyond words in those times. Anyway, to cut short the long story, quickly the lack of a table was realized and I thought I'll buy a table for the TV.
Having busted my budget on the TV, searched for frugal means to buy a table however everything was beyond reach or didn't satisfy the utility I hoped for. Then out of the blue it struct to me why not attempt to build one from plywood. Curiously went to the nearby hardware/plywood shop across the road and asked the price for a sheet of plywood. "1250 Rs for 8x4 sheet saab" was the answer.
This blew out my mind as the tables I inquired where all quoting 5k and decided to buy the sheet and make the table in DIY mode.
Challenges:
Buying plywood was only begiinning of the problem but then came transportation. An auto obliged to carry it on the rooftop after accepting a nominal fee of 150 Rs :D. All neighbours, watchman in the society starred at me while I carried it to my room. I replied that it was for supporting my bed :)
Now came the major challenge, "how to cut the sheet ?" I ran down to the hardware shop and bought myself a hand saw and thought to myself "yea, i's a piece of cake, will cut it in no time". The gruesome reality came later when it took nearly a week to cut through all the pieces I wanted to make the box !!! The cuts were jagged and had splinters coming off the sides which made it appear quite dangerous as well.
Read up online on how to remove splinters and went to buy a "file" to shave off the splinters and make it smooth edged.
Assembly:
Once all the pieces were cut, edge trimmed and sanded out, the next part was assembly. For this bought some long iron nails and hammer and joined each pieces one by one to arrive at the final box shape. This phase was time consuming and required multiple hands to hold at perfect angles and hammer nails through.
Wrapping it up:
Once the table was ready, it was really gratifying to bear witness to the fruit of labor. The only problem was that it was not painted not laminated (did not know how to do it back then), so bought a white table cloth and covered the table making it look neat.
Lessons Learnt:
Though it was first attempt, the following lessons were learnt as a result of the experiment:
- Never use hand saw to chop off a large sheet of plywood. It consumes lot of energy and time
- Hand sawing without a guide leads to jagged edges and splinters on the sides
- Plywood has 2 varieties, "block board" and "wood ply. The former has blocks of wood sand witched in 2 layers of plywood. The latter has layers of plywood sand witched together.
- Block board was used in this project and it proved to be a bad choice as its tough to join the pieces together with nails. Instead plywood should have been used.
- Plywood has specific thickness to be careful off, 3mm to 12 mm thickness range are there. More thickness, the more rigid the wood will be. The thinner the more it will bend.
- In this project 6 mm ply was used but it was not the ideal choice as later it was susceptible to bending and sagging.
- Based on the thickness, type, and material of wood used the price of plywood sheet varies.
- Sheets are available in 8x4 or 6x4 or sometimes shops may sell cut pieces that are left overs
- The frame of the box should be in thick plywood where as the back panel should be only 3 mm board.
- Instead of putting a cloth over it, painting or lamination should have been done.
- Instead of nailing the pieces, screws or nut-n-bolt joint should have been used.
- Instead of hammering holes with nails, a drilling machine should have been used
- Instead of hand saw, an electric jig saw or round saw should have been used
Ok, that's all about the first project. hope you have fun reading about it.
Feel free to post your comments about it.
Feel free to post your comments about it.
Subscribe to:
Posts (Atom)