Another pic heavy update from July 4th break. I had 5 days off of work so I got a few things done!
Fortunately I fit in some relaxation too.
Kayaking with the wife in Cannon Falls, MN.
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Crappy pic but saw about 5 bald eagles including some fledglings. Fitting for the 4th.
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Did a lot of grilling. Including pizzas.
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Went to Cars + Coffee. Highlighting some of my childhood favorites: Ferrari 360 Modena with factory BBS CK's, Dodge Viper, and E30 M3.
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If those headlight wipers aren't German over-engineering I don't know what is.
On to the important stuff.
Front Door:
The house progress continues. We had the front door to our house replaced over the weekend by a handy man. Didn't feel like doing it myself. But I did paint it, and trim it out.
Hideous old door for comparison:
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The new one is steel so surface prep was key along with the right roller.
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I was worried anything but a spray gun would look bad, but it turned out fantastically smooth.
Also when I got the door from Menards the stock guy accidentally crushed the corner when lifting it upright. I didn't want to return the door and wait for a new one so I just glued it.
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Once installed there was a gap between the brick mould and our vinyl siding so I got some of those PVC wood grain "boards" I used for the exterior garage light mounting plates and ran them through the table saw and miter saw to trim out the outside:
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Still needs caulk and paint but here is the final look:
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Of course the inside needed new casing:
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As with every task it seems it's never a simple plug and play. The new door was just a hair wider so I had to cut back the baseboards by 1/4 inch each. Scored them with a Dremel cutting wheel and then hit them with a chisel. Worked okay. Didn't take a completed pic, but I'm sure everyone's seen a door before
Garage / Shop:
I got a router! Dewalt 618.
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And it's first task of course is a router table! After evaluating a number of pre-made options I decided to make my own. It's going to fold down from the wall so it's semi-permanent but also space-saving. Got the plans from a Rockler article:
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I glued two MDF sheets together for the core, and flushed them up with the new router:
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Nice and square.
Then I cut oak sides to rough length:
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The laser makes easy work of rough dimensions.
Then I doubled them up and glued together:
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I only have enough clamps to do one glue-up at a time so doing all 4 sides took most of a day.
I laid them out and made markings based on how they lined up vs. straight measurements.
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Then cut to final length in the crosscut sled. It was very precise.
The instructions said to attach the sides to the core with biscuits. I don't have a plate joiner so I got a cheap doweling jig instead. It sorta did the job, but I did not like it at all. I won't be using it again for anything nice because it's almost impossible to hold steady and drill at the same time, and difficult to clamp. Would not recommend.
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During glue up I realized the pipe clamps I borrowed from my dad were a few inches too short to clamp the long side!! Should have dry fit them first. Oh well, learning things all the time.
I'll be using Rockler's plate so to cut the middle out I drilled 4 holes with a Forstner bit and then a jig saw.
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Template with 1/4 plywood and double-sided tape:
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Again used the new router and flush trim bit to route out the rest of the hole for the plate:
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It's a pretty close fit. The corners aren't perfect like they would be if I bought Rockler's pre-made template for $10 but it's good enough.
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Another thing I skipped was proper leveling screws. I liked the idea of the Kreg plate levelers but for $20 figured I could just make my own out of plywood:
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So yeah, there's the finished product at this point:
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Next will be sanding the oak flush, giving the edges a round over, and then building the plywood cabinet and MDF fence.
More to share soon...