Door #2

Estas Muy Fuerte? - Door#2 - in progress

The incas must have been smiling down on me. I was sure this was going to be the part of the movie where it ends in defeat & I drag a whole bunch of twisted expensive metal to the recyling yard. Stunned that it went together without a fight, & that it actually doesn't seem to want a spring loaded castor on the bottom (a canadian company Darcor make the sweetest machined gate spring loaded castors should it need one). Without any cursing, except for the forehead slapping colossal screwup of welding the top rail in back to front. It's been a long time since my last stupid screwup, so I guess I was just due.

1 week design time, 1 week fabrication time. Got myself psyched up last saturday morning & sat down at my welding table. I rose from my table on sunday night, in some kind of red-eyed inca trance, with most of the sub-assemblies scattered around the new fabrication facility. most ridiculous thing I've ever cobbled up. 7'X7'X4" (thick because I wanted as much insulation as a wall). folds 180. The idea was to keep the structural internal (with the exception of that one flatbar sticking out due to the aforementioned colossal screwup), & the lines as clean as possible. Combination of cold & hot rolled steel. lucked out on the hot rolled, clean & blue.

Not out of the woods yet, lots more weight to add, needs spray foam insulation, cladding on inside & also buffing up, finishing etc, but looking like it may fly (not seeing any sag yet). not the greatest pics, but snapped a few off during the inaugural test drive. A door this size called for the mother of all piano hinges. I mean the mother of all piano hinges.

Beach Time

There's nothing like a day at the beach to forget about your never-ending shop construction project. Great day out with Dan, his big rig & more Elm than we knew what to do with.

Benchroom Door #1

Is this thing finished yet? well there's still a gaping 7' X 7' hole that needs to be filled with door #2; insulation; lighting; the list goes on & on. i'm feeling quite tired. but at least i finally got round to cleaning & sealing the slab, & found a way to insulate the door, so a couple hard fought wins this month.

I sprayed on a water-based Lithium densifier to seal the slab. environmentally friendly, odourless (almost no VOC), scratch resistant & glosses with age/burnishing. Lithium reacts with the lime in the concrete to make silicate which is the good stuff. Epoxy would have looked good too, but besides it's toxicity, it scrathces easily & isn't breathable, so it's not suitable for slab on grade.

There's nothing like building your own doors to bring a construction timeline to it's knees. I riveted the 2 douglas fir panels (cut from my 4X6 stash) on either side of western maple frame (shop-made walnut dowels to peg it center & give me a coat hook, & aluminum spline joint making sure they had breathing room) & filled the void with rigid foam = R7.5. I made the hinges so the door can open 180 degrees & clear the 1" steel siding. Still loving western maple, a dream to hand plane. The front doug fir panel on the other hand wanted nothing to do with a hand plane, the grain was running in & out all over the place, had to bust out the scraper & sandpaper. unusual for fir to show that much disrespect.

Now if I could just figure out how to make a 7' X 7' steel door that also swings 180...

Cable

Stainless steel aircraft cable for cross bracing - http://www.hayn.com/cables/index.html

The bandsaw

1940's Crescent 20". They don't make them like they used to. There's no going back once you've made a cut on a bandsaw that isn't bouncing around the shop floor. Big thanks to Dan for helping with the relocation.

The new 'Wing'

ok she's up. can't wait to see her on google earth. The roof joists are 26' long. There's something primal about building a heavy & immovable object, something you can lean against. Still a long way to slide, roofing, doors, windows, sheet metal etc, etc. and we'll have to see what the building inspector thinks of all this. but the months spent drawing & shop prep'ing the reclaimed doug fir posts/beams/kneebraces paid off. She went together like a jigsaw puzzle, with the awesome help of a young keen carpenter or two. I recommend getting a professional carpenter in & signing on as a 'laborer/wood cutter/materials runner'; a super efficient way to go for the furniture maker. As expected, the minute we started the framing, the storms started rolling in, monsoon season is here.

a little bit of psuedo timber frame joinery, she was designed to go up quickly but still be bombproof, I'm calling her a timber frame hybrid. spent a couple minutes making a water level for measuring the heights of the posts, just like the inca's did, www.buildeazy.com/fp_waterlevel.html - worked like a charm, water is always parallel to the earth!