Between 485 & 705 SQ/FT Denver MCM garage expansion

[Ronin22]

First off, I hope my fellow GJers are staying healthy.



The short answer is: I don't know. The car was an aborted restoration project that was in the POs garage for over a decade. It really looks like someone got mad and took it out on the poor grill.

The grill is now apart and it seems that I have some time on my hands to straighten out the bars.

Poor car/grill.
Looks like it's in a good/caring home now

 

[kwyjibo]

One bit of good news: I have some bits of a slightly less beat up second grill. I have replacements for a couple of the really bent slats.

Also in my forced isolation I've finally started the audio cabinet. Luckily I collected most of the hardware and finishing products before being limited by any further restrictions

 

[BoilermakerFan]

two days man... is the audio cabinet done? I'm trying to be patient, but this whole "social distancing" thing has me going stir crazy and my patience is thin.

 

[kwyjibo]

two days man... is the audio cabinet done? I'm trying to be patient, but this whole "social distancing" thing has me going stir crazy and my patience is thin.

You're worse than my wife! She waited until today to ask about it.
Actually, I've been busy reapplying the Penofin to all the cedar. It's amazing how dry the wood is after the winter - and how much nicer it looks with new oil. I'll post a photo later.

Back to the cabinet. I'm still having an internal battle over some of the details for the design and the time spent oiling boards is good for thinking. I'll post an update for that at the end of the day

 

[Arclitgold]

Pics of the cedar!


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[kwyjibo]

Oh **** - I forgot to take a photo of a half-oiled board to show the difference. I'll be oiling again tomorrow, so I'll make sure to get an in progress shot. Here's one of a section of wall when I finished

I spent some time on the cabinet also

I'm not too happy with the edge banding. The trimmer took some chunks off. Using a razor blade made a smoother edge

 

[BoilermakerFan]

You're worse than my wife! She waited until today to ask about it.

 

[nicholam77]

I've always had issues with edge banding trimmers. Even paying close attention to the grain direction they never seem to leave a perfect edge, at least the one I've used.

Re:the cabinet, how did you go about attaching the middle dividers attached to the bottom panel?

Love it when this thread gets updated, everything looking great!

 

[kwyjibo]

Hi Nick, I tried the trimmer that is basically a little plastic handle with a couple blades embedded in it. And, yes, it's frustrating to have it catch and tear, even when being extra careful with the grain direction. It took longer, but just carefully trimming with a razor made a much better cut for me.
The joints are all dadoes and rabbets. The dadoes are generally made with two passes of the router. I found that there's a big variation in the thickness of these ply sheets - like up to 1mm.

I remembered to get a photo of the mid-oiling cedar.

The color is much deeper again with the oil. You can see in a close-up photo how dry the wood got in one year

 

[kwyjibo]

quick update, but very motivating
I tested out the finish for the audio cabinet. First time using a gel stain (this one's from General Finishes) so I tried it on scrap. Looked good so I moved on to one of the ends and internal divider. The grain looks way better than I had hoped. Now I just need to get more of the components completed

 

[nicholam77]

Thanks for the info on the cabinet, looks very clean. I'll have to try a razor blade next time. Router works well, too, but kinda yucks up the bit if you're using the adhesive backed stuff. That gel stain looks awesome, it gives it a great color! I'm a fan of General Finishes water-based poly, but it's a bit boring to use for everything, so I'll have to look into that!

 

[BoilermakerFan]

looks great!

 

[mmsheb]

That gel stain looks awesome. Really brings out the grain.
Mike

 

[wendle]

This might be a poor excuse for a first post, but I've been a cabinetmaker for 30 years and some of the above description of edge strip drama is hard for me to read

The easiest, neatest way to trim back timber veneer or melamine edge strip is with a file - but you use to the file to push the excess back, rather than actually file it.

If you hold the file against the face of the board (at the left hand end of the edge strip) as if you were going to file it, then rotate it CCW until it's at 90° to the edge (assuming you're right handed here), then rotate it maybe another 20-30°. Then as you push the file up into the edge strip it will kind of fold the excess back off and move forward ready for the next stroke.

This will leave it flush, but sharp, so finish off with the file in a conventional manner, or sand, or whatever.

Probably a terrible description, but if you try it you'll work it out.

Hope this helps someone...

 

[kwyjibo]

Thanks for the comments guys.
@wendle - yours was a great first post. I looked into the file technique, I'll give it a try. On my last trim job I used a 1" chisel - it was easier to control the cut than using a naked razor blade.

 

[kwyjibo]

Just as I was submitting the last post, the UPS guy was delivering a box of these:

I decided a while back to name the garage: WERK1851.
One of the translations from German of "Werk" is factory. The one that is most meaningful to me is Werk 1, a historically significant building at Porsche. So to commemorate the occasion, I designed a T-shirt based on the cover of the 911 factory manuals.

 

[250]

Cool!

 

[Arclitgold]

Nice shirts! Keep it coming. Sounds like Denver got a bit more snow recently; I bet you’re tired of it at this point eh?


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[gearhead1960]

Just as I was submitting the last post, the UPS guy was delivering a box of these:

I decided a while back to name the garage: WERK1851.
One of the translations from German of "Werk" is factory. The one that is most meaningful to me is Werk 1, a historically significant building at Porsche. So to commemorate the occasion, I designed a T-shirt based on the cover of the 911 factory manuals.

Can I order a large please? In orange, if possible.....

 

[kwyjibo]

We had rain that transitioned to snow yesterday, so all the trees were white when we woke up today. I am getting tired of the snow. Unfortunately the blossoms on the apricot tree probably will die... again. So another year of no fruit.

After re-oiling the cedar boards around the courtyard I started some of the final touches of the pergola. One thing is to 'cover' the walkway out of the back of the garage. Another way of thinking of it is that it's a 2' connection between the pergola and the garage. I ordered four more of the fancy hidden fastener joist hangers for the cedar slats. So until they arrive, the framework will just sit like this.

The T-shirts were a test run of the logo - single ink color (white) on dark shirts. I modified the logo, most obviously by adding two more colors to reflect better the theme of the garage. The printer has reasonable pricing on multicolor screening (around $24 depending on quantity) so I'm planning on another run using the 3 color image on light blue shirts. If anyone is seriously interested, let me know.

 

[5280 JB]

Can't wait to see more of the audio cabinet after the gel stain - it really makes the grain pop!

 

[gearhead1960]

The T-shirts were a test run of the logo - single ink color (white) on dark shirts. I modified the logo, most obviously by adding two more colors to reflect better the theme of the garage. The printer has reasonable pricing on multicolor screening (around $24 depending on quantity) so I'm planning on another run using the 3 color image on light blue shirts. If anyone is seriously interested, let me know.

That color combo has me hooked....put me down for that one....paypal account?

 

[kwyjibo]

Thanks for the encouraging comments.
gearhead1960, I sent you a PM
No updates from the weekend. We're trying to keep some sense of normalcy in the house, so minimizing "work" during the weekends.

 

[964haus]

I may have missed it but what are you using to finish/seal your plywood cabinets? I built some over the weekend (attempting to do the same as you but with far less skills) and I'd like to through a Minwax/poly or something to protect the raw plywood.

Thanks!
m.

 

[kwyjibo]

I may have missed it but what are you using to finish/seal your plywood cabinets? I built some over the weekend (attempting to do the same as you but with far less skills) and I'd like to through a Minwax/poly or something to protect the raw plywood.

Thanks!
m.

I'm using Minwax polyurethane. Unlike most decisions where I overthink it, I started using the Minwax stuff because it was on sale at Lowes when I was there for something else. It seems to work fine so I kept using it. I decided to try something different for the audio cabinet so I recently bought a quart of General Finishes gel. It's not that I'm dissatisfied with the Minwax, just experimenting.

btw, I never made cabinets before starting on these. No laminating. No rabbets/dados. I'm still learning, but for me, that's the point. Have fun with your build and good luck

 

[kwyjibo]

I've switched between working in the single and tandem garages more times than I can remember. It takes most of a day to move all the tools, lumber, seats and other car parts between the garages. And I've done it again. I hope this is the last time. My wife's car is now parked in the tandem so that I can work on the single. More on that later.

Before I could get back to work on the audio cabinet, I had a nice surprise yesterday: the joist hangers were delivered. I hadn't even got a shipping notice and they came way before the date the online seller indicated. I had already cut and oiled the boards so it was done in no time. I don't really expect the two boards to do much except block some late afternoon sun. Actually the connection to the garage does make the pergola more stable.

 

[Growlertdi]

such a simple thing, but also a very nice detail.

I hope this doesn't change your insurance classification from a detached to attached structure.

 

[kwyjibo]

such a simple thing, but also a very nice detail.

I hope this doesn't change your insurance classification from a detached to attached structure.

When I started this whole thing a few years ago, the insurance co said it wouldn't matter. I'll go back to them with photos of the completed pergola to make sure there isn't any question. At worst, I can unscrew and repaint.

I haven't done much in the garage for a few days. UPS damaged my last shipment of hardware for the audio credenza so that has been stalled for a while as I wait for the replacements. Like a lot of other people I've been spending a lot of time reorganizing and cleaning
In the meantime, here's the grill for the '71

Unfortunately I can't say that this is the same one pictured earlier. I got this off one of the forums. I haven't given up on the original, but now I know that I have a straight one for when the time comes to install... in a few years.

 

[Trapps]

...I haven't given up on the original, but now I know that I have a straight one for when the time comes to install... in a few years.

I love that you have a long term vision and roadmap! The place is looking great!

 

[Arclitgold]

Awesome. Keep it coming!


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[5280 JB]

That 911 decklid grille is a work of art unto itself!

 

[ODIS]

Would agree with 5280 JB on that engine grill. Money well spent on an item that will give you pleasure every time you look at it without all the calories you would spend trying to get all of the individual parts perfectly aligned.

Thought mine was a candidate for correcting, but, in comparison to your original, think the one on my ‘71, is in “character” with the car.

View media item 102598
BTW, enjoy reading about all of your great work on the house and cars. Very nice!

 

[kwyjibo]

I love that you have a long term vision and roadmap! The place is looking great!

Funny, my wife would probably characterize me as stubborn and a hoarder

Awesome. Keep it coming!


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That 911 decklid grille is a work of art unto itself!

Would agree with 5280 JB on that engine grill. Money well spent on an item that will give you pleasure every time you look at it without all the calories you would spend trying to get all of the individual parts perfectly aligned.

Thought mine was a candidate for correcting, but, in comparison to your original, think the one on my ‘71, is in “character” with the car.

BTW, enjoy reading about all of your great work on the house and cars. Very nice!

Thanks for the encouraging words
I completely agree about the grill. I think the grill is one of those things on a 911 that nobody notices when it's "right"; but when it's "wrong", it's obviously wrong. The original grill on my '71 was in character with the rest of the car, too. That was the problem .

A couple things keep me from going completely insane during the quarantine. The first thing is keeping busy with projects in the house and garage. I'm still waiting for some hardware, so I forced myself to clean and organize the tools. My friends know that I don't like to spend time cleaning, but I do my best to keep things organized and functional. Normally I only polish tools when the project is done and out of the garage. So I was surprised when I found myself cleaning my small roller. Here's an example

The second thing that keeps me sane are the periodic socially distant visits by friends. One stopped by when exercising his cl350. A few minutes after he left, the 2002turbo pulled up. I haven't seen him since early Feb when we crashed the BMW club event at Air and Space museum.

 

[sean Buick 76]

Great job on all the projects!

 

[BoilermakerFan]

I was wondering about the console. I have an order stuck in China. Shipped 3/24. Hasn't moved since 4/1. They claim the freight forwarder is having trouble getting it out on a flight because of CV-19. I told them BS.

 

[Bakafish]

Thanks for swinging by my thread earlier! I am so envious of all your stuff A classic (green!) Porsche has always been on my wishlist, the house and the exterior, all that garage space... I'm torn between the idea of restoring some classic bit of kit (which I know I have neither the time, space nor the energy to actually do this) or some modern angry pixie infused techno cart. For now I'm trying to get the house in shape. I really like your exterior treatments, no way I can steal them with the paucity of space I have though.

Would love to see your actual build process, especially with the cabinetry. I know it is tedious to document when you are in the thick of it, but a lot of us neophytes can use all the help we can get. I suspect you are probably hiding some Festool stuff, show us your lime green pride

I haven't done any laminate work at my house, but I did do some work on my wifu's clinic. I bought the pricy little unit pictured below. It uses precision ground ceramic blades, mine is the 0.3 mm chamfer. They sell various sizes, and it is sharper than a bee's behind. The 'blades' are on both sides and come flush to the front, so it can do inside corners easily, and all registration is done from the ceramic blocks themselves, it glides along easily and is super precision.

The (shirt) design looks great, looking forward to the details, I may be tempted to get one!

 

[kwyjibo]

Thanks for the positive comments. Despite all the extra home time recently, I still haven't gotten around to exploring all the threads on this forum. I have to admit that I usually do a drive-by posting, but every once in a while a title catches my eye. I'm a bad forum citizen.

I don't consider myself a woodworker. I enjoy making things but I'm nowhere near the skill level of a dedicated woodworker. More of a hobby that grew out of necessity. I've learned a lot from books but mostly from the internet, which has an abundance of instructive sites that I think do a much better job than I could to explain techniques. So basically, I don't post too much about the in progress because there is much better out there.

I do have a few Festool products (as many others, because of Gregor!): tracksaw, domino cutter and router. I'd love to use some serious power tools, like a table saw, router or lathe, but I just don't have the room for them. I don't think my wife will give up her garage spot and I already have more project cars than I do indoor storage. Maybe I should build an addition to the addition... The one larger machine that I may pick up is a drill press.

I've never really shown the garage in wood configuration. But for the last couple years whenever wood is involved, this is what I use to cut, shape and/or join. Here's my cutting station - sheet foam insulation and Festool tracksaw on the floor. After all the Baltic birch ply, cedar, OSB, T1-11 and etc. I finally replaced the original Festool blade when I started on the stereo credenza

My "MFT" is a slat bench. The slats are spaced just far enough apart for the bar clamps. The router gets the most use on it

But I also have it shimmed up at the end for 90degree clamping, like cutting the domino slots.

It's crowded in the garage right now because we're storing some plants inside - it's been about 20F for the last few nights. I had planned on bringing the targa home to start work on it, but I need the room to work on the credenza.

 

[fourmotioneer]

Enjoyed reading through your thread today. My buddy worked at Centerline in Lafayette for 4 years and he had quite the steering wheel collection too. I think anything below 30 is sane...

 

[nicholam77]

Interesting concept on the clamping bench, I had not seen that one before.

Since you've built a lot of cabinets at this point... can I ask, do you use any accessories for the track saw for repeatability? Like rail square or parallel guides? I'm working on making a track saw cutting station right now but for me that's the major downside when used alone -- it's difficult to get repeatable or truly square cuts.

Can't wait to see more progress on the credenza.

 

[Arclitgold]

Yeah thanks for the garage shots! Can’t wait to see more updates. And please share some targa content as well!


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