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Woven Wood Doors, Part IV Parts Is Parts4/10
Part Four - Parts Is Parts
We had a fabulous snow come down hard and heavy on a Saturday morning, and the shop was quiet and heavy with 4” of wet snow on the roof. The sun was out from noon on, and cast a remarkable light in the shop. There are times when it is magical in the shop.
As our shop is small, I generally work several half days during the week, giving Justin full access since he is ‘key personnel’ and very productive. If I can help, I’m there, but it is about 50-50 whether I’m help or bugging him. We will sort thru the tasks and assign them to he or me as appropriate. I have always worked Saturdays and Sundays as that is my time to advance a project, get caught up, walk in circles and mumble, whatever.
So this Saturday was especially nice since we have a beautiful stack of wonderful parts, the job was back on track, and we had a clear path in front of us.
A holding jig was made for sanding with a R/O at 150 grit. It held 8 blocks at a time and in the window light, it was easy to judge accurately what was going on. They were fit onto tongues once again and then clamped to hold in the other direction.
Splines were made and sized to be a loose, almost snug fit in the blocks. We planned on using epoxy, and it likes a thick glue line, so did not need to be clamped. So I built up a rail to hold the blocks vertically while I buttered the splines with glue and slid them in place. 240 splines, that is. They fit well and did not want to creep around as I laid the blocks flat to set up.
Looking over my shoulder, turning off the lights on Sunday afternoon, the parts were all lined up on the bench like so many dominoes. Sanded, cleaned up and splined, ready to be fit into a large panel and then into the door.
David (& Justin, for execution of work?), while I have not much standing in this line of business, I just want to say briefly that this thread is notable in my view in that, while not the only story of its kind I've read here (this is a place to look at the details of processes, yes? Not just about bragging rights on final results?), this is the only story I have seen (and admittedly my view is limited) and remember that delves into lower level details (while not the lowest level of agonizing minute details, I imagine, as one must still maintain hard-earned trade knowledge in-house to keep the order book and stakeholders happy), and including passes and fails, of the shop processes to create something of value to a lucky patron able and willing to pay the price. Yeah, sounds like salesman talk, sure. Just saying your thread is much appreciated.
Hope you keep this going through the whole process (seems like thats your plan). Its great to see someone take the time to document.