Edwardacollett's Blog

Preparing for Construction…
June 9, 2010, 5:24 am
Filed under: Materials, Process | Tags: ,

To save money (and then have to put out more money to fix problems) I broke down my design from being large circular objects into four sections each. now that they have been cut i have to machine the corners to that they creat a lap joint and as such can be bolted together.

Firstly I had to make a horizontal cut at the end of each segment using the table Saw set to the correct depth and length from stop, (as there were two different length cuts I had to make sure I didn’t cut them at the wrong lengths. To do this I set the saw twice and cut in two stages.

Horizontal cuts, waste material clearly marked

Horizontal cuts, waste material clearly marked

After this horizontal cut was made I had to make some vertical cuts. Using the Re-Saw with a particularly sharp blade and set to the exact right distance the cuts were made. All pieces would now fit together with out any further problems.

virtical cuts for lap joint

virtical cuts for lap joint

Now that most problems have been resolved I have to sit back and work out the order in which all segments go together in regards to construction…


CNC routing Problems…
June 9, 2010, 4:49 am
Filed under: CNC Routing, Materials, Process | Tags: , , , ,

After I recieved all of the cut ply, then had them re-cut… I found further problems.

It turns out that cutting all of the Laminex coated ply was damaging to the bits and as such whent through a handfull of the Companies cutting bits. When each bit became blunt it obviously failed to cut as well… meaning many edges of the laminex were chipped and damaged. This actually wasn’t a huge problem as I had to put a rounded edge on all the pieces anyway due to them being sharp.

I soon realised however, that the small holes at the coners and ends of each piece were alsocut incorrectly… although I had the drawings and computer design files all correct… having the holes small (by only 0.1-0.3 of a mm) ment that none of the rod that I had bought would actually fit through them… a problem as the stainless steel rod only come in certain sizes…, I had two options, one of which was to make the steel smaller, through machining and sanding, the other, to make the holes slightly bigger, or in fact the right size… Another problem was that when the Stainless steel rod was inserted into the routed holes, there was the danger of them chipping the Laminex. To solve this problem I countersunk all of the holes so that the Laminex would stay in one piece.

I decided to go with making the holes bigger. To do this i needed a particular drill bit: 8.1 mm in size. I managed to source such a drill bit through an engineering supply shop in Canberra.

countersinking holes

countersinking holes

holes re-drilled to correct size

holes re-drilled to correct size

$7.85 and 4 hours later and all holes are drilled back to their actual size…

Next stage is working out how to actually put it all together!

The CNC cut Materials have arrived… however…
June 7, 2010, 2:24 pm
Filed under: CNC Routing, Materials, Process | Tags: , , , ,

And so I receive a phone call to say that the first half of the CNC cut materials are ready to be picked up. However there were some problems with a handful of pieces.

Two of the large circular pieces were cut incorrectly, damaged and needed to be re cut…. meaning that I would need to purchase more material… at a hefty cost of $274 for the sheet (He offered to cut them for free) The two pieces that were damaged happened to be two of the face boards for the cabinets… Seeing as i was unable to get the same Laminex coated marine ply (as I got it for cheap of our masters student) I had to buy ordinary hoop marine ply, i decided to get the three front panels all recut so that they would all match when constructed.

The reason they were cut incorrectly was because I tried to cut too many pieces out of the limited material I had (obviously to keep it as cheap as possible) when the pieces were cut though, the ply sheet they were being cut out of lost its rigidity and the cutting bit began to wander… as shown in the pictures.

The top is not straight!

They cut this one a little wrong...

Although It’s unfortunate that there were two pieces cut incorrectly, the problem was solved within 24 hours with all pieces collected and ready to be worked on in preparation for construction.

Components CNC cut and ready for further work...

Although, it turns out the CNC cut holes are too small

problems continue…

Machining process of timber for the six draws…
May 31, 2010, 3:13 am
Filed under: Materials, Process | Tags:

Now that I have my CNC routing underway, it is time to move on to more pressing matters… The material for the draws. I was a bit cloudy when it came to what material I would use to make the draws. I had a limited amount of time, was already looking like the project was going to cost a fortune and I had almost run out of the recycled/reclaimed old growth Oregon… After speaking to Rodney for a few short minutes it would be decided tha I would try to use Oregon for everything when it came to the draws… front, back and sides (although the running edge of the draw would be a harder material such as a high quality pine or Victorian Ash off cuts)

I got into contact with the Timber merchant again and headed out there to find some more Oregan, which I did. The beam that Gordon found for me was one of four and came out of an old RAAF base, (used to hold the roller doors apparently). The beam was covered in lead based paint and sitting in a puddle.

Machining up Orgon

Machining up Orgon on table saw

After we cut it in half and machined it up to a respectable state we realised that it was really good timber as it had really tight grain. It looked as if the tree would have been several hundred years old when it was cut which is amazing.

detail of Oregan end grain

detail of Oregan end grain

detail of Oregon end grain

detail of Oregan end grain

I had plenty of Timber to use for all of my draws and as such began to machine it up, it had to be ripped and cut to all the right lengths before being laminated in pairs so that I could get the full stock requirement for the draw fronts, making sure the grain was as close to quarter cut as possible (to maximise stability). I glued them all up in two sets of clamps using tight bond as the glue of choice as it will not expand in to all of the bolt or nails holes like polyurethane glue does.

glue up of Oregan using Tightbond glue

Glue up of Oregan using Tightbond glue

All of the timber has been machined to within mm of the final dimensions and is being left to sit in the workshop untill I am ready to use it.

Other process continue…

May 31, 2010, 2:33 am
Filed under: Images | Tags: ,

I was asked, after several of my friends had viewed my work, what I was actually making… so I hope these help to clarify… there will also a perspective drawing added soon…

Drawing of cabinet from side

Drawing of Cabinet set from side, showing detail of slats and screws.

front view joined

drawing of front view of cabinets

Top ciew joined

Top view drawing of cabinets

CNC Routing finally underway…
May 31, 2010, 1:18 am
Filed under: CNC Routing, Images, Materials, Process | Tags: ,

Laminex sheet 1, file ready for cut

After many hours of looking into a computer screen and several days of delays the completed illustrator files were handed over to the CNC routers so that they could start their job. Once the files had been delivered I purchased two sheets of 19 mm Marine ply and arranged them to be delivered directly to the CNC routers the following day at no extra charge. Previously in the week one of the masters students in the workshop came to see me regarding some left over materials he had from a previous project, (2 sheets of 3040/1220/20 mm white gloss laminated marine ply) and asked if I would be able to use them. Seeing as I was looking at laminating some segments anyway I decided to take him up on his offer as it would save me many hours of glueing time, and offer him $300/sheet (they were custom-made at a price near $400 so I saved a worthwhile amount of money)

The CNC router cutting time is charged at approx $100/hour, all pieces are cut three times (two major cuts and 1 minor ‘clean up’ cut). Expected total cost was said not to exceed $600… I will try to hold them to that if it goes over price, as im sure it will.  They should be ready for collection in the next 3 days.

The total cost of Marine ply and cutting stages of this project will end up being approximately $1800 which sounds like a lot of money… because it is… however, it must be kept in mind that I am realistically making 3 cabinets and when looking at it after dividing costs into thirds, $600 for the Marine ply and cutting process per cabinet is actually pretty good.

The next process will be milling and machining the last off the stainless steel.

I’m looking forward to starting construction on the cabinets though, but think im going to have to clear some space…

The machining process continues…

CNC Routing Process…
May 23, 2010, 1:23 pm
Filed under: CNC Routing, Materials, Process | Tags: , ,

For the last week or so I have been working on getting the computer designs of all the individual pieces that I need to get CNC routed. This also has come with problems, after I completed the 1st lot of designs and worked all of the multiples of them into the Marine ply sheet size… the total number of sheets came out to 6 sheets, resulting in about $1600 worth of materials… I decided to then re-work the design once more to try to minimise the amount of material needed… At the same time, another masters student in the workshop let me know that he had 2 sheets of 20mm white Laminex coated marine ply that he had left from a previous project and that I should offer him a price for them. His sheets were in fact almost a quarter bigger than a standard sheet  I was looking at using. I offered him $300/sheet (Saved approx $80 a sheet)

By re-working the designs, and with the extra material on the larger sheets, i have managed to get the material costs to approx $1140 saving close to $460.

In the next day or so, the goal is to meet with the CNC Routers, ask them to help me finalize the computer drawings, get these drawings ready to use, order and arrange the delivery of Marine ply to the CNC routers and finally have it all cut and collected by the end of the week.

The budgeting process continues…