Update Time!!!
So, I got some sanding belts for Christmas (thanks sister!

) and here is what they go on:
I picked it up for $10 at a ReStore and once I got it home I figured out why someone donated it. It has tons of sparks coming from the brushes and the commutator, including some smoke and sluggish power.
I got it quite a while back and once I learned what it was doing, it got put on the back burner. Well, today no longer! Got it out, took it apart (it was FILTHY inside) and cleaned and reconditioned the commutator including picking out the grooves. I ran it for a little bit to re-seat the brushes, and now its perfect

It tracks great, has good power. Couldn't be happier.
Since I got it up and running, I thought maybe it was time to start on the workbench again! I wanted to sand the 4x4 legs of the workbench before I just threw them together. If you missed the story on these 4x4s, basically...when we moved into the house last August, there was this old swingset back there. Who knows how many years it was up there for. In any case, my brother-in-law and I tore that down and I just had the wood sitting out for about a year, in the rain, snow, etc. Not being one to be wasteful, I decided to use the wood for my workbench project. It took about 2 hours to pull all the nails and junk out of the wood. I needed 8 'legs' for the workbench project, so I used my father-in-law's miter saw (sadly the C-man radial didn't come anywhere close to having the depth of cut) and got about 10 pieces out of them. I'm glad I cut extra...you'll see below
SO! The wife and son decided to go do some shopping with her sisters, so that meant I had about a 2 hour window to get some stuff done out there. I sanded down the 4x4s, not really sure of what I was going to get. Here is how it turned out:
Its got some of the old gray color where it weathered, along with some fresh exposed wood where the grain stood up and was sanded down. I mainly wanted to do this so that I could make cleaner passes on the table router, but this is how it ended up.
Good? Bad? Ugly?
Who knows. I'll be waiting to see what it looks like with some finish on it. If it is absolutely hideous, I'll just paint them black, but I am a fan of cool and unique wood grain, and these legs now definitely are a closer match to the beetle kill pine that will be going on the top.
Now it was routing time. I have my cast iron router table extension now set up on the Craftsman cabinet saw:
I had to fabricate the installation of it on the C-man fence in those 2 hours too
A close-up of the bit I am using:
Once I routed a rounded edge on them, I looked through the grain and picked out this scheme for how they will go together:
I labeled them in a code, hopeless for any other to decipher, so that I knew their order:
Now, my initial design incorporated channels routed into the 4x4s right past the edges of the rounded corners to join the plywood sides of the lower cabinets together (mainly non-structural). Then the plan was to add 2x4s in a staggered square pattern inside to give it the rigidity it needed.
Here is were I made ONE OF THE BEST DECISIONS I've made in a LONG time in the garage

- I forcefully told myself to start on the very back 4x4s as a 'test run', so that just in case anything happened, I could practice first on the back where they would be a little more 'hidden'
Well, I'm glad I did that
I used a 1/2" channel bit in the router and it basically died haha. Here was my setup:
I was definitely burning wood and it was very unsuccessful. I got through 1 with some smoke, and then it choked on the second one.
This was the good one. I noticed that it was pushing the router pretty hard to make that channel, so on the next 4x4, I decided to take a shallower pass. Nope. Nada. No good!
Plumes of smoke rose from the router. Not only that, but the fence on my table saw shifted on the second leg and here is the result:
By
daveamy at 2011-12-27
Yep, ugly ugly ugly!
I don't know exactly what went wrong. It might have been that the bit was dull. I switched to a duplicate bit (non carbide tipped) and the same thing happened. Maybe trying to take off too much material? Maybe my feed rate? Nothing was working.
So...now I had 1 routed leg, 1 destroyed leg, and pretty much couldn't do the others. Normally, this would have been a major piss off. However...remember those 2 other 'extra' legs that I had cut? Ohh yeah!!!
Saved.
This time, I decided I needed another approach. Therefore, I pulled down some 2x2 stock that I had been saving for whatever up in the rafters. I needed exactly 16 pieces (2 per leg) to act as joints to attach things together. Guess how many I had? 17
Here is the basic concept (minus the plywood):
I cut them to length on the table saw, and actually, 2 inches shorter than the main legs. Basically, to get that true 'art deco' look, I wanted to have the main legs go all the way to the ground, but have the cabinet suspended up a few inches. I was originally going to do this on the slots to be routed, but it meant routing about 2 inches short on each pass and doing them all the same. I realized this was impossible when I went to route the second channel on the 1st leg and realized that I had to reverse directions to do the pass...starting from both ends doesn't allow the route channel stopped short of either end...whoops

So that idea went out the water, but since that system is abandoned now, I'm implementing it again. Its hard to explain, but will be clear when I show pictures.
Here are the joiners/spacers/attachers that will be used to hook everything together, 32" and pre-drilled with 3 holes:
I'm hoping maybe I'll get a chance to work on it a little more tomorrow. If so, the task would be attaching the joints, cutting the plywood to size, and actually building the main cabinet. I've got a few other things on my list as well - get the wood lathe going, get the bandsaw going, keep working on the Craftsman tool chest, etc.
No break anytime soon
