Projects
This project was built more than 10 years ago and still occupies a corner of our living room. It was an interesting project in that it was my first attempt at laminating and bending the runners. Three of these were built with one being donated to a charity auction.
This table and chairs was a 2012 Christmas project for a great grand-daughter. The table and chairs are my design. The legs were made on my hand built router milling machine that can be seen on my Shop/Equipment page. The finish is a water-based Minwax Polycrylic. This project was my first attempt at spraying this finish. The gun was HVLP with no thinning of the finish material. I applied three coats, let it dry for 24 hours, sanded it with 400 grit paper, and applied a finish coat.
This is my first attempt at power carving. I have a Foredom Model SR with maximum RPM of 18,000. The shoe carving started as a block. It was rough cut on the bandsaw and a large forstner bit made the initial cut into the heel area. I have found that the Foredom has other uses in the shop. For example, completing round overs in tight corners when I cannot get into corners with the router round over bit.
The design for this chair came from a chair a friend’s wife was given decades ago when she was a little girl. We were able to make cardboard patterns with the original chair in tact. This was our first attempt at caning. It was a chance to learn something new and the results were very good. We actually ended up building six of the chairs. Mouseover the photo for another angle of the chair.
This is power carving #2. After carving the shoe pictured on this page, my next project became this maple leaf. After locating a line art picture on the internet, I started with a block of oak. All carving was completed with the Foredom power carver. It was a good “filler” project……I worked on it between other projects or while I was waiting for glue or finish to dry .
This is power carving #3. While I was serving in the Iowa Senate, I came up with the idea of doing a carving of the state. It now serves as a candy dish on the living room coffee table.
This was a winter project from several years ago. During a typical Iowa winter it seemed right to build a sled. As you can see, it has not been tested in the snow. Mouseover for another angle.
My work table is 64” X 60” and is 39” high. The top is maple with the frame made from two sheets of ¾” plywood cut into 4” wide strips and laminated together. All joints are mortise and tenon. The table is very stable. The 39” height was decided on after much thought, with input from my back. Mouseover the photo for a close-up of the leg and support joints.
Over the years, I have made my share of picture frames. This is an example of some of my work. Mouseover the picture to view a closeup of the birch inlay and the corner joint.
In the late 1960's, our sons had a Playskool Tyke Bike that they rode. A few years ago when we had a new grandson join our family, I had to build one for him to ride. This is my version, as best as I could remember the one our sons enjoyed. Mouseover the picture of another angle.
A few years ago, we did some updating in the house. Included in the updating was the replacement of two cold air return registers in the dining/living room area. When I went to purchase the registers, I was unable to buy exact replacements. The solution to the problem was to build replacements with oak to match to the other wood features in that area. The registers are constructed in two parts so the frame mounts to the wall and the grill is mounted on the frame with no exposed screws. Mouseover for another angle.
A friend that does a lot of hiking into secluded lakes to fish, was looking to reduce the load for the hike. He came up with the idea of replacing the stock on the 12 gauge shotgun that he carries for protection, with a pistol grip. The band saw and Foredom power carver were utilized to make the pistol grip for the shotgun. Mouseover for another angle.
The candlestick telephone project was an opportunity to spend sometime on the lathe. Because of the design of the candlestick phone, it seemed like a natural. The project is stained with India ink with sprayed lacquer. Mouseover for another angle.
A number of years ago I wanted a display case for two lever action rifles. The case pictured is the design I put together. It was built from air dried walnut and lined with red velvet. Mouseover the picture for a second view.
Recently a friend came to the shop wanting a wall display unit for his golf ball collection. The pictured unit is the result. Mouseover the top photo and note that the right face frame is remove-able allowing access to the glass. The glass can be slid to the right to add or change the arrangement of the collection.
Early last summer, one of our son's and his family started building a new home in Lawton. Plans called for 4 bedrooms, 4 car garage and many extras. I was handed a picture of a kitchen they liked and asked to design and build the kitchen. The design and all detail drawings were completed in Sketchup. A friend, Fred Chadwick and I then started the build. All cabinet cases are melamine with poplar face frames and door parts. Blum soft close hinges and soft close drawer slides were incorporated into the hardware portion of the design. Finish is Sherwin Williams ProClassic with top coats of Minwax Polycrylic clear satin. Door frame and drawer face frames were milled on the General I-Carver 40-915X CNC machine. Mouseover the picture for a closeup.
This is the “work” side of the kitchen island. On the left end is a roll out that houses two trash containers. Included in the island are the dish washer, sink and a below the counter top microwave oven. A push of a button on the face of the microwave opens the slide out drawer. Items to be microwaved are then set into the drawer, the same button pushed and the drawer closes. Settings are then made to complete the microwave process. Mouse over the picture to see the drawer open ready to receive items to be microwaved. Mouseover the picture for a closeup
An update to one of our bathrooms brought this project to life. The case is oak plywood, finished inside and out. The carved feature was added to the raised panel doors and drawer fronts. Mouseover the picture to get a better look at the door fronts.
Part of our responsibility on the new house was to design and build a vanity and linen closet for the main bathroom. Again, the design started from pictures and was completed with detail drawings in Sketchup. Oak was the material of choice for both units. The linen closet features a fold out clothes hamper. Blum soft close hinges were utilized on both the vanity and linen closet. The finish is India Ink with Minwax Polycrylic clear satin top coat. Mouseover for an additional view.
Part of our responsibility on the new house was to design and build a vanity and linen closet for the main bathroom. Again, the design started from pictures and was completed with detail drawings in Sketchup. Oak was the material of choice for both units. The linen closet features a fold out clothes hamper. Blum soft close hinges were utilized on both the vanity and linen closet. The finish is India Ink with Minwax Polycrylic clear satin top coat. Mouseover for an additional view.
A hand rail was needed for the hallway opening to the steps down to the lower level. Material selection was oak, stained to match the hand scrapped flooring with a surface finish of Minwax Polycrylic for durability.
Another feature for the open concept living area is a “wall mount” for the 55” TV. It was decided this should be a feature on the largest wall in the open area. Again, a “something like this” picture was found with final layout in Sketchup. Cedar was selected for construction, with the unmilled surface being utilized as the face for a somewhat rustic appearance. The “face frame” is mounted at a 15 degree angle adding depth and a little added perspective. Mouseover the picture for an additional view.
Project planning allowed for time to machine Christmas gifts for the family. This is an image of blocks made for grandson Kellen depicting his name.
In 2011 a router milling machine was built in the shop. The router milling machine can be viewed by clicking on the Shop/Equipment tab at the top. At the time the machine was built, the drive gears were cut on the bandsaw with many hours devoted to sanding. With the addition of the CNC machine, replacement drive gears were machined on the CNC. AutoCad DWG files were imported into the ArtCam software and the replacement gears imaged in the photo are the result. The router milling machine now operates slightly smother with the CNC cut gears. Thank you to ShopNotes for making those DWG files available.
Another CNC project. This project was machined in the the relief toolpath mode. With a little paint applied, you see the finished product. Mouse over the picture and have a look at the project fresh off the CNC.
The CNC was a big part of a recent kitchen design and build. The completed drawer fronts were constructed by using the CNC machine.
A recent project request came from a family that lives south of Lincoln, Nebraska. They wanted a desk built for their daughter's bedroom, that matched her current bedroom furniture. The project material is poplar and birch plywood. Solid material for shop projects is purchased at Dunham Hardwoods in Dunlap, Iowa. Sheet goods are purchased at Daniels-Olsen located in Sioux Falls, South Dakota. Mouseover the picture to see a close up of a drawer unit.
Over the past few years I have been making frames for Nick Bogenrief owner of B & B Art Glass in Hinton, Iowa. The photo to the left is an example of the work and design that goes into the fine art that Nick produces in his studio in Hinton. For more information, you can reach Nick by telephone during regular business hours at 712-947-4572. Mouseover the picture to the left for a look at more detail of the craftsmanship that is typical of a B & B art piece.
Sometime back, our grandson, Kellen acquired a duckling as a pet. It soon became apparent that housing would be required and it would be expected that it should be at several levels above the usual. After much consideration, the photo at the left reflects the final design and build of the much needed "Duck Condo". It became necessary to include, but not limited to: insulation, heated floor, freezer style walk through door and a satellite dish in the event television would be added at a later date. Mouse over the picture for a closer look at the satellite dish......the dish was put together after I made a trip to a kitchen cabinet and came up with a decades old melmac saucer.