Studio711.com – Ben Martens

I’ve mentioned the Modern Rogue YouTube channel in some past “Best of YouTube” posts and they’re still going strong. In fact, they recently built a huge new building on their property to ramp up their production capabilities. At one point, Brian mentioned that he thought it would be neat to add fan submitted stuff to some of their buildings on the property. I don’t know if he was serious or not but it seemed like a good excuse to try making a sign on the CNC.

Since Brian has a fire eating stage show and they do a lot of fire stuff on the YouTube channel, I decided to start by burning the wood with a torch. Then I used the CNC to carve their logo into the board and I finished it off with some spray polyurethane to keep the black ash from getting all over.

A mutual friend helped connect me with them to get a mailing address. I shipped it off and thought that would be the end of it, but a couple weeks later, they did a special Instagram post to show it off and say thank you!

Elijah has been asking for a treehouse for quite a while. Despite my best efforts, I can’t find a good spot to put one in our tiny yard. So much of it is covered with French drains, irrigation lines, etc. But I still wanted to give him something fun to play in and to climb on.

I was putting him to bed one night when I looked up and realized that the vaulted ceiling in his room left a lot of space above his bed. So I chatted it over with Tyla and then build a platform above his bed.

Since this will probably be torn down and thrown away in 6-8 years, I wanted to keep it simple. I used Jay Bates’s bunk bed plans and basically cut out the bottom bunk. The whole thing was designed to fit around his existing bed.

The 2x4s and 2x6s that I got from Home Depot were pretty bad. After a lot of picking, I was able to find some fairly straight boards but they were going to require a lot of sanding. So I had the bright idea of running them all through the planer to skim off a little bit on each side. That worked well but man did it make a huge mess! There’s no way my little shop vac could keep up with that so I just let the chips fly and cleaned up the mess later.

Elijah stayed in the shop for a lot of the build. It was fun to have him helping and seeing how it all went together.

I wasn’t looking forward to painting that beast but I didn’t want to leave it looking like dimensional knotty lumber so I finally pulled the trigger (pun intended) on an HVLP paint sprayer. I chose a fairly simple one from Rockler but it still has a detached turbine unit. I originally thought I’d move the loft into the back yard to paint it but the forecast was calling for rain. So I tried setting up our pop up kitchen tent thing in the driveway with tarps underneath and on the sides. That wasn’t terrible but the loft was too big to be able to spray comfortably. I did the primer but them moved it back inside to do the paint by hand. I’m looking forward to trying the spray again on something smaller. The photo below shows the setup before I added the final two walls of plastic. The side of the loft facing down did not need to be painted as it was going to end up against the wall in his room.

This loft is starting out very simple but I’d love to build a little house up there at some point. We’ll see how much he uses it. His favorite part right now is the bar I added on the bottom for him to swing from. I think we will definitely need some pillows or a pad up on the top. It’s hard on our knees!

 

As a thank you for letting us come up to Maine, I made a sign to leave at Camp Ticawa. It features their original logo which I had drawn a long time ago to make shirts (that shirt store is still alive!)

This was by far the most complicated thing I have done on the CNC to date. I spent hours tweaking the SVG file and even longer in Fusion playing with the toolpath to get it just right. In the end I did one pass with a 1/8″ endmill and then went through a second time with a vee bit to clean up the edges and do all the smaller areas. For the wood I glued to 1×8 pieces of pine together, filled in the seam with wood filler and then painted it with a nice blue enamel paint that we had previously intended to use on our front door. I was going to fill the letters with white paint, but the raw pine looked so nice that I just left it that way.

Now it sits in a place of honor between the ear rock and the butt rock! If any Ticawa fans are interested in getting their own version, please contact me. I’m happy to chat about making one of you or giving you the files so you can make your own.

This is the last year for our planter boxes along the driveway. We decided to pull them out but we still wanted to have a few strawberry plants around. The back yard seemed like a good place to help avoid the deer so I put together a simple design for ladder style planter boxes. The whole thing is on wheels for now so we can move it around, but eventually the plan is to put them along the fence. I might have to move one of the plants to make room for it.

The structure is made out of 2×6 cedar and 1×10 cedar. The boxes are lined with plastic with some drain holes drilled through and then covered with landscape fabric. I also had some of the old fence stain laying around and since it’s going to be up against the fence eventually, I slapped on a quick coat.

If I made them again, I’d probably make a few changes to try to decrease the cost a bit, but overall I think these will serve us well for years to come.

Evergreen Lutheran High School in Tacoma has a fundraiser auction every year. Every year I think about making something and then fail to do so. This year I made it under the deadline by about two hours.

I only had five days to whip something up so I decided to completely steal an idea from Nick at 6_8woodworks, and make some ornaments out of laminated scraps. Thankfully I had enough interesting pieces of the right sizes to make a few at the same time.

Since I have that shiny new CNC sitting there, I whipped up a drawing and was able to cut out 3 identical ornaments relatively easily. The only real trick was making the cut into Puget Sound wide enough for my 1/8″ bit to get in there. As I cut each one, I rotated my stock piece to get a slightly different pattern on each one. I finished them off with a bunch of sanding, boiled linseed oil, and some twine through a hole to hold it onto a Christmas tree.

I don’t expect these to raise a huge amount of money but it will be fun to see other people put a price tag on my woodworking. I almost exclusively make things for myself or as gifts so there’s no real price tag involved.

After making a simple zero clearance insert with my new Shapeoko 3 XXL, I wanted to try something else fairly simple but slightly more challenging. Ever since I installed our Ecobee 3, I’ve wanted to replace the white plastic plate that goes around the thermostat. But building something that has a nice shape and fits well would be a challenge so I dropped it in my “if I ever get a CNC” project list.

To get started, I grabbed a photo of my model online (there are a lot of slight variations through the years!) and traced around the outside in Inkscape. I used some cheap 1/4″ MDF as test pieces on the Shapeoko and after 4 attempts with tweaks in between, I had a good fit around the thermostat.

Then I added a lot more complexity. Instead of just being cut out, that original hole that I designed became a pocket in the material. I added in a hole all the way through the back for the wires and two more for the mounting screws to pass through. That all went pretty smoothly but the tricky part was making room for the vent on the bottom of the thermostat to exhaust air but not making the vent bigger than it needed to be. I’m still not convinced I have that designed as well as I could, but it got to the “good enough” point after 4 attempts in 3/4″ pine.

For the final cut, I milled up some walnut and put it on the CNC. The first attempt went ok but ended up failing near the end. Despite slowing down the program to account for hardwood, I think I was still a little too aggressive and I might have had the router carriage adjusted a little too loosely. The second attempt went slower (about 35 minutes instead of 20 minutes in pine) but it came out perfectly. I finished up with some sanding and routed a chamfer around the outside using the router table. I finished it with a coat of boiled linseed oil and mounted it on the wall.

This project really made me feel the value of the CNC. It was awesome to tweak my design by fractions of an inch and have a completely new part in under half an hour. It’s a lot easier to experiment than if I was trying to do this all carefully by hand.

Fun fact: about 80% of the way through this project, I was installing a test plate and when I put the thermostat on, it didn’t turn on. Of course this was the last thing I was doing before going to bed. After some panic and opening up service panels on my furnace, I found a fuse that had blown. The next morning, I called my favorite HVAC expert, and verified that replacing the fuse would work. After a quick trip to the store and $2, I was back in action, but boy was that a cold and stressful night! Always turn off your equipment before working on it!

When Tyla’s dad was in the Navy, he served on the USS Hector fixing clocks. He ended up with one of the clocks from the ship and for his birthday this year, the kids got it fixed up and running again. It sat on a counter in their house until I snagged it and mounted it for his Christmas gift.

I was able to make it with some scrap walnut and maple, but just barely. After I had it all done I realized that I should include a place to hold the winding key. It was kind of hard to work that into the design so I carved out a spot on the top where it can rest. I took the piece of maple to work to use the laser engraver there. The clock has two keyhole mounts routed into the back so hopefully that will be enough to hold the heavy clock onto the wall.

Merry Christmas, Don!

My woodshop is the third bay of our garage so I basically have one long wall to work with. It has always been a catch-all spot where I storage random sheets of plywood and generally dream of what might go there some day. It was time to stop dreaming and make use of it. I find that in my workshop I repeatedly get stuck in indecision. It’s silly because I will be making it all myself and I can just change it later if I decide I want to. Pick a path and go for it!

I saved some money by not building actual individual cabinets but rather each cabinet shares a wall with the one next to it. It was going to be a LOT of plywood, so I started by drawing the whole thing out in Sketchup, figuring out what pieces I’d need to cut and then I used a free cut list generator to help me optimize my plywood usage.

Part of the plan was to make a more permanent place for my miter saw to sit. The cart that I built in 2015 has been working great, but I’m tired of having it be in the way. With this new plan, the miter saw sits lower than the other cabinets so that wood rests flat across the saw onto the top of the cabinets. At some point I’ll put some T-track into the top of the cabinets to add a stop block with a tape measure for quick, accurate cuts on the miter saw. Normally you see these built with outfeed support on both sides, but I don’t have enough room for that. And while I’d prefer to have the outfeed support on the left side, this made more sense. The garage door is on the left so if I have to cut a really long piece, I can open up the door and get some extra room.

I used 3/4″ pine plywood (~$35/sheet at Home Depot). I’ve used that for most of my shop projects and I’m always impressed at how nice it is for the price. The tops of the cabinets got two sheets of the plywood. It adds a bit of cost but it really strengthens the top and makes the cabinets feel more solid.

The first step was cutting each of the vertical pieces. These were basically just rectangles with a notch cut out for a toe kick, but there were two complications. First of all, I had to cut out a notch for the foundation wall. Secondly, the garage floor isn’t level. I wanted to spend a little extra time to make the top work surface be level to avoid hassle with the drawers later. So each of the vertical pieces was going to be a slightly different height. Instead of trying to get that perfect, I left each one about an inch short. Then when it came time to mount them in place, I would hold them at the right height, slide a piece of scrap plywood up next to the bottom and screw the scrap into the vertical divider. So the cabinets are screwed into the studs and then rest on the floor.

I don’t know if I’d do it this way again or not, but to space out the vertical dividers, I cut a bunch of pieces the with of the cabinet and pocket holed them into the dividers. On the plus side, it made it easy to assemble each section one by one and keep them all evenly spaced, but on the down side, it was a lot of screwing and cutting.

You’ll see that not every opening is the same width. I went with 3″ multiples since that’s what normal cabinets use, but I tried to add in some variety for storing different things.

After adding the top (YAY! Finally a place to put some tools!), I ripped down some 2x4s to make a face frame. Hiding the plywood edges looks nice but it also helped me make perfectly rectangular openings which pays dividends down the road when it’s time for drawers. The laser level was instrumental in getting the top of the cabinets level and also at this point in the process when I was making the dividers perfectly vertical and the horizontal face frames perfectly flat.

Now it was time to make the drawers. A LOT of drawers. 20 to be exact. Again, I probably could have gone an easier route, but I chose to assemble the drawers by using dadoes. This gives a bit of additional glue surface and helps to keep things square during assembly. Unfortunately my little shop vac can’t handle the dust collection duties for dadoes so it repeatedly slogged up the hose inside my table saw. I finally just gave up on dust collection with the dadoes, disconnected everything, and cleaned up afterwards.

Most of the drawer sizes were pretty standard, but there were two special ones. One of them is full height and my plan is to use that for scrap hardwood storage. I have a bunch of smallish pieces and I had previously been standing them up in a trash can. The other one holds my planer. That planer is pretty heavy so I ended up using a double set of drawer slides which seems to be working well so far. If it starts to sag I can always kick a block under the end of the extended drawer when I’m using the planer. I don’t know how well both of these special drawers will work in the long run, but it’s easy enough to take them out and add standard drawers later.

Speaking of drawer slides, that part of the project can really break the bank. I have bought some very cheap slides from Amazon in the past and had good success so I went that route again. This time I got Promark full extension slides along with some mounting screws.

After the above photo, I finished off the last six drawers and now it’s fully functional. I moved on to some other projects, but soon I will add drawer fronts. Those will help to hide the uneven spacing of the actual drawers and bring them up flush with the face frames. I’m planning to design and cut some drawer pulls on my new CNC machine as well.

This was a huge project and it was a pain breaking down 13 sheets of plywood, but man I’m loving it! I have a huge new work surface and so much storage. Building drawers takes a lot of extra time and money, but I find that they are a lot better than deep shelves because you can actually use the whole depth instead of forgetting what’s behind the first row of stuff.

Elijah came in at the end of this post and wanted to help so I’ll close out with his thoughts. “I just really like those cabinets. I love them. I just really love those cabinets. They’re so great. They’re just so great. That’s all.”

I’ve made a project in the woodshop every year of Elijah’s life. That’s kind of a hard trend to break. The first year was a table and chairs and ever since then, I’ve made something from the Wood Magazine construction sets (end loader, dump truck, semi lowboy and dump trailer). I stuck with that theme this year and made the skid steer. I was crunched for time and it was a small project so it seemed like a good fit. Thanks to Tim for giving me some scrap maple so I didn’t have to make a run to the lumber store. Follow him on Instagram under the @woodscreekwoodworks account.

The project went pretty smoothly, but, again, I felt like the instructions could have been better. There was too much precise cutting and hoping that stuff lined up later. Why not just leave it all a little long and then flush it up later? I need to get better at building stuff in my head to recognize these opportunities.

I bought the kit that provided all the hardware and wheels and it came together pretty quickly. With these toys, I’ve learned to mill up lots of extra wood so that I can have another crack at it when things go wrong and that skill proved useful here.

Some day I won’t be able to post this stuff early, but for now, Elijah doesn’t read my blog so I can show you a picture early. Merry Christmas!