Salt Life Hideout

[wmchurch]

Just wanted to say that I've enjoyed reading about your progress. The wife and I are moving back to the Tampa Bay area next month and the first thing on my todo list is to get the garage in shape so I have a place to do "old man stuff". Good inspiration, keep up the good work!

 

[Wingnut65]

Just wanted to say that I've enjoyed reading about your progress. The wife and I are moving back to the Tampa Bay area next month and the first thing on my todo list is to get the garage in shape so I have a place to do "old man stuff". Good inspiration, keep up the good work!

wmchurch Thanks for stopping by the Hideout and for the support. I am making a little progress on new cabinet every day now. I just need to take time to get the shots out of the camera to post the pix and progress report.

Congrats on the move back home. We moved up here from Miami 11 years ago and just love it. We have quite a few GJ members hanging around here. Some day, we will need to have a get together to put faces to the names.

Getting the garage in order sure makes the rest of the settling in go much easier. It was hard working out of cardboard boxes and trying to find tools needed to use inside the house. And in an effort to make progress in the garage, I mounted old cabinets that I brought with me in places that seemed right and would work, but now that I have worked out a plan, will probably need to be moved. Now that you have the time before the move, work out a master plan for the garage. When you get there, do it right the first time. That is before you surf GJ a lot more and find even better ideas and need to remodel your shop to improve it. We all do it and it's not a bad thing. Perfection takes time.

PM me if you need any help with the move in.

 

[Wingnut65]

shopnut we do have a few gators in lakes around our development. When they get 5-6', the County comes in and relocates them to a nature preserve north of here (or maybe to Asylum Lake?? ). I am making sawdust every day for the A/C cabinet and will post progress pix this week.

Yes, Omph, the Bus will run again. Time is starting to lighten up at work as the big project we have been fighting with is out to bid. More projects are in the wings, but that client is more realistic on expectations and deadlines.

I had not thought about a thread on the Bus Rebuild, but that may just be the kick I need to make progress. lol: just like progress in the Hideout thread) The Bus clean-out will be documented. The cabinets I am building now will house some of the items that I have stored in there right now. So, it is a process of which project come first. Kinda like the chicken or the egg, except that both need a biscuit and cheese to go along with it...

The initial bus tear down did find a nest to the left of the engine compartment. I'm sure I have pix from its discovery and disassembly. I don't know mow many more creatures or detritus that are left to be discovered. (I had to look up 'detritus' to know it if I see it. Yep, found and some...)

 

[Ole_Red]

I had not thought about a thread on the Bus Rebuild, but that may just be the kick I need to make progress. lol: just like progress in the Hideout thread) The Bus clean-out will be documented. The cabinets I am building now will house some of the items that I have stored in there right now. So, it is a process of which project come first. Kinda like the chicken or the egg, except that both need a biscuit and cheese to go along with it...

The initial bus tear down did find a nest to the left of the engine compartment. I'm sure I have pix from its discovery and disassembly. I don't know mow many more creatures or detritus that are left to be discovered. (I had to look up 'detritus' to know it if I see it. Yep, found and some...)

If not a thread, you could try out blogger. Thats what I use for my Studes. I would definitely subscribe to that one. Either way I'll subscribe: thread or blog. Love those old buses.

 

[Red Leader]

A bus rebuild thread would be way cool.

As we know, these threads have a habit of keeping us accountable

I was reading in a car magazine that recently a 12-window bus went to the auction block and fetched around $65,000...which may have actually been disappointing to the owner as some have fetched around $100k.

 

[machine_punk]

Looks like you are continuing to make progress! I enjoyed the pictures of the older aircraft...of course you know that I really enjoy anything made with rivets and aluminum. We just took a cruise from Miami...and had the chance to see (and eat) some alligators.

I know in my own shop I feel like I have to make about 4 'invisible' steps forward just to make one tiny step forward that is worth showing on GJ. I'm currently in one of those situations now.

I want to build my light brackets to mount my dental lights on the tool rack I built, but I need a band saw to cut some of the trim pieces accurately. I bought the portable band saw, but I want to build a base for using it like a vertical bandsaw. To do that, I need to make some precision bends in some heavy aluminum. So, I buy the Baileigh combination shear/brake/roll to do things like that. Which requiree building a bench sturdy enough to hold a 1200-pound machine and a spreader bar and hoist to lift it onto that bench. Now, I need to clear a hole in the Stuff filling the garage to put that new bench and machine.

THEN, I can build the table for the bandsaw, which allows me to cut the trim pieces for the bracket and get it done. It feels like I have to get whole sections of the garage put together, just to move forward on my next project.

Looking forward to the AC cabinet and the bus build!

M_P

 

[Wingnut65]

If not a thread, you could try out blogger. Thats what I use for my Studes. I would definitely subscribe to that one. Either way I'll subscribe: thread or blog. Love those old buses.
__________________
1960 Studebaker Lark VIII Regal Longroof http://www.thisoldstude.blogspot.com
1965 Studebaker Commander http://theotherstude.blogspot.com/

Thanks for the suggestion, Ole Red. I had not thought of blogging about it. Although, I have been following your wagon since you brought it home. I am leaning towards a build thread on The Samba where other Bus owners and VW experts can give advice. But I'd also keep a link at the bottom like you have and periodically post an update on this Hideout thread. BTW, I'll be passing thru your neck of the woods in June, but only for a day or so on the way north to catch a boat ride. Can you schedule clear weather?

Red Leader, Accountability is what I need. Last year's Barrett-Jackson auction set the record for a 1963 23-Window VW Bus for $217,800. But that was considered a Museum Quality restoration. Anything after that just won't measure up. I didn't hear about the bus that went for only $65,000, but Barret-Jackson had another '63 23-Window bus with camper trailer that went for $128,700. I'm not looking to sell mine, I just want it running again and weather-tight. (BTW, have fun on your vacation!)

machine_punk, it is a vicious cycle of priorities... Step 1 can't be completed until Step 2, 3 and 4 are done and Step 4 needs Step 1 to be completed first. Then someone posts a cool idea on their build and the next thing I know I'm painting all my garage door hardware flat black. Step 5 wasn't even thought of, but it looks awesome! Sorry I wandered, but you get the idea. I can't wait to see your Baileigh sitting on its new pedestal!

I was actually in Miami yesterday for a few hours for a meeting at our HQ. I didn't see any real gators in the Gables, but did fly over the port on the way in. It is a nice place to cruise from and it keeps getting better.

The old planes are in my blood (as the reason for my screen name). I've pounded many rivets on my Dad's '56 C-172 rebuild. Seems my teenage arm was the only one able to fit inside the flaps and ailerons as we closed them. Then a few more on my '49 Navion. Some day I'd like to build an RV-7A or a Sonnex, but only after the Bus is finished. Working with aluminum is so comfortable and the possibilities are endless. As you well know and I love seeing your creations. Keep them coming...

Hideout Update... Stopped at HD on the way home for the hinges for my A/C cabinet and I was all ready to start cutting wood for the shelves. But, I walked in the door to find out I was designated to drive a daughter and wife out shopping at a couple stores. End of the year Chorus concert is Friday night and she needs a specific outfit for the song she's singing. So the progress tonight includes the purchase of four hinges! At least it's something!

 

[Ole_Red]

Thanks for the suggestion, Ole Red. I had not thought of blogging about it. Although, I have been following your wagon since you brought it home. I am leaning towards a build thread on The Samba where other Bus owners and VW experts can give advice. But I'd also keep a link at the bottom like you have and periodically post an update on this Hideout thread. BTW, I'll be passing thru your neck of the woods in June, but only for a day or so on the way north to catch a boat ride. Can you schedule clear weather?

Thanks for following the wagon I haven't done anything to it in quite some time. Life got in the way... as did another Studebaker. Depending on how my schedule works out this weekend, I hope to get a lot done to the 65 and possibly push the wagon out to do some work on it as well. The Samba would be a great place to have a build thread. A lot of incredibly knowledgeable people over there. I've read a few threads over there that were linked from the HAMB that were unreal. I'm looking forward to your progress.

I'll do what I can on the weather. We usually turn the rain on for outsiders so that they don't learn how nice our summers are.

 

[Wingnut65]

Ole Red, I hope you got a chance to make some progress on your toys... I did...


The Captain has turned on the ‘Fasten Seat Belt’ sign. So please return to your seats, Fasten your seat belts, and Get Ready… progress in the Salt Life Hideout continues…
Sit back and enjoy...

A/C Closet Build

This project goes back to the master Plan for the hideout to clean up the clutter at the front of the garage. When I built the paint cabinet, this is what I had for the concept at the front:

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The center paint cabinet has been built (started in Post 50 on page 3) and this phase will be to complete the right side cabinet that covers the A/C air handler unit. I don’t want to totally enclose it to make it difficult to service or replace. So the right side wall will be removable. And since there is quite a bit of space in front of the air handler, the door will actually have shelves on the inside to hold various stuff.

Since it has been way toooo long since the last big project, debris from life has settled in and around the garage. Even though I hate to show these, they are the reality of life…

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The plywood sheets I bought months ago are laying flat on the floor, under the collection of stuff. I could have it leaning against the wall, but I don’t want it to warp in our humid weather.

So, Day 1 of the project was to clean out the garage to get to the wood and to get to the A/C unit. I actually think that took most of the day

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Let see, bicycles with flat tires… research from the girls on the platypus and blue whale… USPS postal tube boxes… old candle… two boogie boards… two scooters... windshield sunshade... box of nail polish… Of this, I can claim one bike and the postal tubes.

OK, it is clean so let’s get started…

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I used 2x3’s for the framing of the side panel. I want the side panel as far to the right as possible to allow space to store some of the stuff back in there. The wood had to be cut to length and have a 1/2” groove routed in to slide the 1/2" plywood side to slide it. The groove will be widened as needed to get it to slide well. (Notice that I can really improvise with my resources to get projects done... And I found the plywood!)

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Here are the routed pieces. The one on the top left is the bottom track…

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…I have a bunch of Teflon sliders that I removed from our dining room chairs. So I deepened the bottom groove so the sliders will fit.

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Here is the back vertical track mounted in place. There was a stud directly behind this so I have a good solid anchor.

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Since I want the side panel removable, I want to make it easy enough that any A/C service person can remove it to service the air handler. So I want the top to be a slip in and have fasteners only at the bottom. Here is the top track on the left and the front vertical on the right. I cut the heads of two 1/4” bolts. (The AN Bolt took forever to cut by a hacksaw. I chose a zinc-coated steel one for the second, much easier to cut.) I used dowel centers to transfer the holes to each other to align.

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Then I glued the headless bolts into the vertical piece.

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Then I fastened the bottom track down to the air handler plenum base. I used a plumb bob to locate the alignment for the top track.

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Then insert the studs into the holes and one screw into the bottom track and the frame is complete! I will cut the plywood for the sliding side panel and the door when I get the plywood and circular saw out.

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This is how far I got when I was working on my sketches and all the calculations for how I am going to build the shelves for the door, that I realized I did not have enough 1x6 pieces to complete the job. So I needed a run to Home Depot…

So, hold that thought and I will be back soon with the next installment of… cutting, routing, drilling, sawdust… you know, progress!

Oh, the captain has turned off the Fasten Seatbelt Sign. You can return your tray to its upright position and roam around the Journal!

 

[Omphaloskeptic]

Oh Goody, I can't wait for the 'in-flight' movie; what's the title and when does it start?

By the by, those sliding panel tracks might need to be oversize a bit and the panels sealed to prevent swelling from the local humidity. Just my $0.02.

Ya' know Wingnut, if you get carried away with that organization stuff, people might think you've been studying Shopnut's Asylum or even Jack Olsen's 12-gauge garage! lol

 

[Talus]

Read all 19 pages. Great thread! Pics, narration, commentary. This thread has it all!

 

[Wingnut65]

Talus, Welcome to GJ and the Hideout. Thanks for putting up with 19 pages of commentary and ramblings. Thanks for the support. I'm sure some pages are not very exciting while others offer great ideas from my place as well as other ideas that get suggested to me. That is what really makes GJ so inspiring by having a free exchange of ideas to improve our shops.

Omph, I have been working on creative ways of how to fill every nook and cranny with stuff and I think you and shopnut will be impressed with this project. Many of these I ideas I had come up with before I started posting, but he has made some good suggestions for even more utilization of space.

For the weather sealing of the wood, Yes, it will all be painted.

I think the movie will be "Making Chips" followed by "As The Paint Dries".

And to enhance your ejoyment of the in-flight entertainment, I also installed a surround sound stereo system in the Hideout...

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See it on top of the Bus. It is sound with everything else surrounding it... Can't tell from here, but it was playing Rascal Flatts at this time.

Enjoy the music while I work on another update...

 

[Omphaloskeptic]

Aww shucks, I was hoping the in-flight movie would be 'Airplane'; I wonder if any airline has ever shown that flick on a flight? lol

Say, did the 'Bikini Brigade' help you in cleaning up the clutter?

When you decide to go crazy and build the soffit style cabinets around the interior of the garage, you're going to have to book a double-feature set of movies (with cartoons)! Might I suggest the following options? -
'The Money Pit'
'The Magic Bus'
'The Bus Movie' (www.facebook.com/BusMovie)
'Little Miss Sunshine'
'VW Bus Tour: Americana Bohemia - a true story'
'Bass Ackwards: Much Introspection in a Small VW Bus'



....You get the idea.

 

[shopnut]

I have a bunch of Teflon sliders that I removed from our dining room chairs. So I deepened the bottom groove so the sliders will fit.

Great idea to use those sliders Wingnut65. I have a small bin full of them just looking for a project. Let us know how many you end up using along the length of that slot to keep the door supported properly during full travel.

Glad to see you making some progress!

 

[Wingnut65]

O, 'Airplane' would is definitely in the running. It is probably one of my top 3 favorite movies, along with 'Blazing Saddles' and 'Space Balls'. That explains a lot about me, but I don't think I'll ever get over Machu Picchu.

No, the Bikini Brigade has been studying for the end of the year exams, so no major help on this garage project. But one of them did wash my new car this evening.

shopnut, I ended up putting them 3" apart and got 11 in the track. That is the one process photo that I took that didn't come out. I guess I turned the camera off while it was saving the image. When I take the panels apart to paint, I will get a shot of them.

The good news is that the cabinet is about 95% built and really only needs painting and an upgrade to the vertical post anchor screw. I will work on the conclusion post right after intermission...

 

[Shoottx]

Surround Sound

I have the same system in my shop.

Well kinda it is an older version of a Sony outdoors to protect from dust!

 

[tinbender 66]

I like that slider idea. Consider it stolen

 

[Wingnut65]

Omph, On the second half of your post, I still haven't decided on the extent of cabinets or shelves alround the ceiling. But your suggestions for movies are right on track. I've seen a couple, but will definitely need to research the others. And don't forget Fillmore in 'Cars'. Not quite the same, but he's a Splitty as well.

Shoottx glad to hear the sound system works for you as well. It was relatively painless running the wires to install it. I've heard it could have taken most of a day, but I had it up and running pretty quick.

TB66, feel free to pilfer all you want. On my two-level sliding door cabinet that I built, I keep putting candle wax along the bottom edge of the doors to get them to slide. I was concerned that a 3x6 half inch sheet of plywood may need a little more than wax to get it to slide. I came up with the idea when I removed all these sliders from the feet of our dining room chairs because they would catch on the edges of the tile we have. I went with felt pads and a small nail well recessed and have no problems with the chairs. But I couldn't see throwing away 24 Teflon sliders. Now I still have leftovers for another project.

 

[Wingnut65]

I'm still working on the next installment for A/C Closet Build, but wanted to give a little insight on a cool tool that I find very useful in my shop. So I have come up with a new segment fot the Salt Life Hideout build thread, for a lack of a better name...

Cool Tools: Radi-Plane

I found this in my Dad's tools and I have used it on every wood project I build... It's the Radi Plane. It is used for quickly rounding over the edge of a piece of wood. I used it on the top board here.

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The secret to it's ease of use is the brass angle that sits flush on the corner of a board, and the two cutting blades that put a consistent and uniform radius on a corner. The first blade removes a little wood and the second removes more and puts about 1/8" radius on the corner.

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Here is an action shot... (visualize this sliding back and forth...) It can be started in the middle of a board, or at the end. BUT... Watch the grain of the wood! It is best to go with the slope of the grain. Once in a while, not all the time, I've pulled a strip of wood up with the blades when going against the grain. Nothing a little glue can't fix. I find it easy to use by sliding back and forth several times and not try to remove all the wood in one pass.

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Then I hit the edge with a sanding block to even everything out. I am satisfied with the finish of the edge for my cabinets and shelves. To me, it gives a much nicer edge than the sharp 90 edge that I usually knick up before the project is completed.

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So, a little insight to a tool I have in my tool box that I really use a lot. It gives me a much more consistent edge than using a sanding block for the whole edge.

I have no idea where my Dad bought this, but I've seen them available on-line new for about $25 or about $10-15 on eBay.

Thanks for listening. We will return to our regularly scheduled programming shortly...

 

[Wingnut65]

In this thread, you will see that I have I can improvise with a limited assortment of tools in my garage to be able to build the projects I need. I do not have a table saw due to lack of space, so I improvise. I also have a small Craftsman router table that is too narrow for some projects, so I improvise. I manage to get a lot done with what I have and hopefully you may consider that you can do almost anything you want with what you have on hand. Let’s get started…

The A/C Closet Build Continues

OK, So I left off when I didn’t have enough 1x6’s to build the shelves of the cabinet. So I used my new IS Utility Vehicle to get some lumber.

See, it fits!

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I have always taken full advantage of amenities in cars. But since this did not come with fold-down seats, a pass-thru will work just fine!

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I was extremely careful with protecting the interior surfaces. Four 1x6 x 8’ and two girls fit perfectly. (Good thing Mrs. Wingnut wasn’t watching to see how I got the wood home…)

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So with the wood home, I needed to figure out exactly how big the shelves needed to be. But first, I had to figure out how the hinges would be mounted to find out how much space I had left for the shelves and two end panels. So, I got a scrap piece of 5/8 plywood that I will use for the door and a scrap 2x2 to mount the hinge to (this will be a 1x6 in the actual build.) Notice how the door looks like it will open almost 180 degrees… Looks can be deceiving.

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Hinge spacing and alignment worked out well the first try.

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But the hinge pushes the cabinet off the frame about 1/4", so the decision was made to recess the hinges fully into the cabinet side panel. This may also close off the gap from the door panel to the frame that is also the width of the hinge.

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In order to get a good solid and secure fit for the shelves, I want to route a groove in the vertical sides for each shelf to fit into. Then I can have glue on three sides, instead of just a ****-joint with screws. So, the router came off the table and the base reinstalled to be able to make the slots.

I cut both side panels to length and aligned and clamped them together so the shelves will be the same spacing. I clamped a 2x across the board and to the router table to act as the guide.

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Be sure to measure the offset needed from the edge of the bit to the edge of the baseplate. I set the depth to 1/4" so there would be enough space to glue the shelves in, but not deep enough to weaken the side panels.

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Next was to recess the hinges. I could use a hammer and chisel to cut them in since I don’t have a hinge jig, but I figures it would take longer than to make a jig myself than to cut out four hinges and make them perfect depth the first time. Besides, it will give me a chance to try some router template bushings that I have never used yet.

So, here is my hinge jig that I made from some scrap 1/4" plywood. Now I know what you are saying… That’s too small to be able to clamp down. Or, That is so small that it won’t support the base of the router. I can hear you know, and you are correct (says the voice of experience…) BTW, since this will be a utility cabinet and these hinges will be almost hidden, I wasn’t too precise on the size of the recesses beyond the hinges.

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And, since the jig is soooo small, I had to use small finishing nails to attach it to the frame. No problem with holes, I will have screw holes to fill as well. I used a 1/4” bit and cleaned out the area of the hinge.

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Test fit = Success!

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And the hinge sits flush! Mission Accomplished!

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Here is the router with bushing and bit, the hinge jig and a finished recess.

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Now on to align the hinges… The hinges need to be aligned vertically so the pivots are in line. If they would be off a little, the wood cabinet would twist and warp ever time it is opened. So I used a 5/8” spacer where the face of the cabinet will be. The second piece of plywood is to make sure the hinge aligns with the outside edge of the cabinet face. (Sorry if that sounded confusing, maybe I need some sleep)

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Once the hinges were all recessed, I needed to find out how long the shelves needed to be. So, I clamped the hinged frame piece in place, set the other end panel on the right side and measured between them for the shelf size.

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Since the shelves will extend inside from the face of the door, the rotation of the door will cause the edge of the cabinet to hit the frame of the sliding panel. So, a little algebra, a calculator and the Pythagorean theorem determined the distance I needed for the hypotenuse of the shelf. Basically, if the length of the shelf diagonal would be the same as the back side, then the door will clear. It turned out that I needed to cut the shelves at a 3 degree angle to make it clear.

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To assemble the shelves, I drilled three holes in the middle of the shelf recess for screws.

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A dry fit with one screw per shelf confirmed that all the wood was cut correctly.

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I set the shelves in place to make sure all the clearances were correct before I glued everything in place. Two hinges will hold this up! And notice that the 180 degree door swing will be so nice to allow clearance for the air handler

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Close the cabinet and all looks great!

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The algebra worked perfectly! There is an 1/8” clearance to the frame.

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Great work, so I thought…




Please come back again to find out how to cut plywood without a table saw… How to make 3/4” Teflon sliders fit into a 1/2" wide track… And, that the length of a hinge screw really does matter…

Until the Next Episode of The Salt Life Hideout, Goodnight and may the good news be yours!

 

[Omphaloskeptic]

Wingnut, this cabinet project is coming along nicely. Thanks for taking us along for the ride. Have you considered adding a third hinge to help support the loaded shelves and help resist door sag/twist? I think your routed hinge pocket looks just right, but if you need to, I've found that light weight tar paper (or similar) makes for good hinge backing shims.

Use that Radii Plane on every hard edge which will receive paint; you'll find the paint really doesn't like sharp corners for coverage. I have that tool and it really comes in handy for a nice finished edge.

 

[Red Leader]

Awesome project! That will go a long way into making your place look a lot cleaner.

At first when I saw the result of your project I was thinkin' ...hmmm, I'm wonder'n if them shelves are gonna sag a little if he puts some stuff on em! But then I read your comment about plywood. I'm glad my brain is still functioning

Keep up the great work!

-Dave

 

[flybefree]

Jeff, in all my years of inventive engineering I have never, until this day, seen AN bolt jointer in a cabinet build. Well done.

Shaun

 

[Wingnut65]

Thanks guys for the comments. This cabinet has been in my mind for over a year. Took a little creativity to work out the sliding panel idea to allow access to the A/C unit, but engineering the rest is just cutting each piece to fit where I think it should go.

O and RL, there are actually four 4-1/2" door hinges on the side of the shelf to carry the loads. That and 5/8" plywood glued and screwed to the shelves and I think I can climb the shelves if I need to. For the test fit, I only installed two hinges and I think there were only 2 screws in each side.

FBF, I have a box of AN bolts from my Dad's garage that probably weighs 8-10 pounds with various sizes and lengths and conditions. Since we bought them in bulk at Oshkosh in the early '80's, I have no record or documentation for any of them. I would be hesitant of using them in any plane, at least for a critical location. So, I have plenty to use where needed. But after almost 10 minutes to cut the head off, I decided to get another type for the second bolt.

Thanks for coming along for the ride. Hopefully I can post the last installment soon.

 

[Wingnut65]

Finishing The A/C Closet Build

Engineering a project that has never been designed before takes thought, creativity, design, motivation, supplies, tools and Math. Yes, the dreaded Math from way back in school! But not only Algebra like I used in the last post by using the Pythagorean Theorem, but real actual math. Like 2+2=4…

And it is helpful to know that a 1x6 is actually closer to 3/4" x 5-1/2”. And it is understood that routing out 1/4" of the 3/4" thickness will definitely not allow for the manufacturer provided #8 x 1” hinge screws to fit in the hinges without problems. But then also the thickness of one side of the hinge, plus 1/2" of wood, still will not let an #8 x 3/4" wood screw fit in the modified 3/4" piece of wood. It’s a math thing… See:

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I put the 1” screws in the bottom before I remembered that math is critical to a good looking project. Then I got the 3/4" screws and got a similar result. But, not knowing exactly what I will have in the cabinet, I figured the 1” screws would hold better and all I needed was a backer to cover the hinge area and to enhance the screw holding ability.

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Then I realized how this actually looks and that, even though it is just a little block of wood, it does take space out of the cabinet width for storage of larger items. Maybe I shouldn’t be concerned, but I have decided to solve the problem with my Craftsman grinder… Those 3/4” long screws aren’t anymore…

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The bottom is the unmodified, full-length 3/4” screw and the others will now pass my approval for installation. My rationalization for this thought is that the point of the screw is only used for driving the screw in. It really does not have any holding strength for pull-out where the screw tapers. That, and the fact that there are 4 hinges with 4 screws per hinge for a total of 16 screws used for holding up the cabinet. That should work.

Now that the cabinet was framed together, the next was to cut the plywood for the face panel and the sliding side panel. Since I do not own a table saw, I improvise with my Floor Saw! This is standard procedure for cutting plywood here. Just gotta remember to have 2x spacers on the floor and the saw blade depth less than the spacer height. No problems so far and no damage to the RaceDeck yet.

Cutting to the correct width…

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…then rotate and trim off the end.

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With the shelves still mounted (with only 2 of the 4 hinges…) I measured where the face panel will be mounted in relation to the hinges

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Then used a jigsaw to remove a notch for the hinges. This will allow the face panel to be pushed further to the left to cover the gap at the back of the unit to the anchor frame.

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I set the plywood face down and set the shelves on it, making sure the hinges fit well. With the shelves in place, I used a pencil and traced the outline of the shelves onto the plywood. I didn’t get a picture, but the reason for this was to locate and drill pilot holes for the screws in the center of each shelf. This assures a direct hit when I screw in from the opposite side.

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I turned the shelves over, put wood glue on each shelf, set the plywood in place and aligned with the hinges, countersunk and then installed all the screws into each shelf. FYI, I just used 2” coarse thread drywall screws.

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Done! (Picture taken as I watched the glue dry. Exciting, isn’t it?)

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Now I need to shift focus to get the sliding side panel installed now that it has been cut to size. The problem is that all my spare Teflon sliders are 3/4" diameter and the groove I routed in the bottom frame is only 1/2" wide. I put a few of the sliders in my generic no-name vice. A couple minutes with the 80-grit sanding block…

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…and edges were flat. Flipped them over and did the other side. I can’t tell if this picture shows this side or the other side, but they both got flattened!

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I drilled pilot holes about 3” apart and installed a total of 11 sliders

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Since I didn’t measure each slider to make sure they were all exactly the same thickness, I also cut the back corner of the sliding panel a little to help it slide over any uneven sliders.

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Then it was very easy to slide the panel into the groove.

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Installed the front frame piece and screwed it in place and Mrs. Wingnut helped hold it in place as I installed the shelving unit, one difficult screw at a time…

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Before you ask, Yes, I realize I could have run the shelves much higher. But I’d never be able to reach anything without a ladder. And, I have plans for that upper section that is actually much deeper for more storage. (shopnut does have an influence on people for creative storage ideas…)

It was only after mounting the door then that I realized that something was off just a little… the cabinet rubbed the side panel and would not close! Could have been all the weight of the shelves with door face panel… Could have been that measurements were taken with using only 2 screws in each of only 2 hinges for the mock-up… Mrs. W started to guesstimate where the problem was when a daughter came out to the garage. I suggested they both go in and solve the younger’s problem. When she came back, the door closed perfectly. But it wanted to stay opened a couple inches, probably due to the 1/4” depth that I set the hinges instead of a little less depth.

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No problem… I had a couple of these left over from not needing them on the paint cabinet. Only one was needed to secure the empty cabinet shut. I may need to install another at the top when it is loaded.

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Then the cabinet closed and stayed shut.

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Here is how the hinge cut-out turned out. And it conceals the gap that could have been there.

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Last night I was able to get a coat of paint it. And this really makes me realize I need to paint the A/C duct as well.

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The only thing I have left to install is a threaded insert for the removable front piece for the sliding side panel. I want a metal-to-metal anchor instead of just a drywall screw and hoping it hits the same hole every time.

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So, the cabinet is almost completed. (Heres a Red Leader To-Do List..) Items left To-Do include:
- Finish sanding and painting several more coats
- Have a cold one and watch the paint dry
- Install a furring strip across the face to hold the items onto the shelves when the door is opened.
- Complete the upper storage idea I have for over the top of the air handler unit
- Fill the cabinet with stuff.

Not sure when I will get a break from Life to be able to complete these items, but I will keep you posted as I continue my work.

Thanks for riding along on this project. Just another adventure in the Salt Life Hideout!

 

[Wingnut65]

Two Design Issues…

Here are two items that I had to deal with, one worked out as planned, one didn’t…

My air handler unit has a PVC overflow pipe extending down to the floor. If I have water on my floor, I need to clean out the condensate line… I originally pictured a cut-out in the door to allow the pipe to extend out. But when the paint cabinet was built and extended past the face of the return air plenum below the unit, the problem was solved. The door also extends past the face of the plenum and the pipe remains as-is. (photo looking in along the bottom shelf)

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Second Issue…

If you recall in the last post how pleased I was that the shelves allowed for a 180 degree door swing will be so nice to allow clearance for the air handler?

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Well, reality set in… The A/C duct above had other plans.

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If I need to, I can modify the ductwork a little without decreasing efficiency of the unit. But that is for another day…


EDIT... I forgot to mention in the last post, when Mrs. Wingnut left the garage, I removed the sliding side panel and moved the top track over 1/2" or so and reinstalled everything. When she came out a few minutes later, she was very surprised to see the cabinet actually closed. I actually think she may have been impressed with the quality of the project...

Well, she could a been!



.

 

[shopnut]

Before you ask, Yes, I realize I could have run the shelves much higher. But I’d never be able to reach anything without a ladder. And, I have plans for that upper section that is actually much deeper for more storage. (shopnut does have an influence on people for creative storage ideas…)

I was actually bracing for a nasty ladder joke - thanks for being kind, buddy

It's all looking good. It's no fun when it works out without a little tweaking, is it?

I've been pouring a cup of 50/50 bleach in my condensate line every 6 months or so for about 20 years now to keep it mold/algae free (and free flowing). The HVAC guys say to pour just hot water down there - not sure if the bleach is causing a problem or not. Anybody know?

 

[Red Leader]

Coming together really nicely Jeff!

After the closet and duct work, whats next?

 

[Omphaloskeptic]

Don't ya just love building something and then finding out they don't make fasteners to fit your combination of materials? Been there, done that, bought the T-shirt!

Your cabinet project is looking good, your almost done; have a cold one to treat yourself.

 

[Wingnut65]

shopnut, no need for ladder jokes. We are past that and you are on to more lofty ideas!

For cleaning the line, I just use a jug of pool chlorine to pour a little down the condensate line. My problem this weekend when my floor did get wet, that the 12" of line from the air handler to the clean out was actually clogged. That was a new one to address...

RL, Thanks, Dave. Next will be the cabinet to the left of the paint cabinet that will cover the water heater area. I had been planning the same concept, but will need to review all options as I see how much of my stuff will actually fit into the A/C cabinet. Hope you can get back to your project!

I agree, O, even when the factory supplied parts or accessories need to be modified to work properly. And even sometimes the fasteners are what I planned to use just won't work. After I installed the threaded insert, I realized that 1) the 2" 1/4x20 screw I bought is too short, and 2) the idea of using a finish washer under the head won't allow the cabinet to close and hit the magnetic latch. Tonight I will countersink the screw as deep as I need to make it work. So I learn...

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[flybefree]

Jeff,

Can you just pull down the door and cut it so the shelving part swing free and the top part could just open until it hits the duct work?

Shaun

 

[Wingnut65]

Shaun, I hadn't thought about separating the sections, but that may be a possibility. I have the last step of this project to build a shelf over the air handler for some big bulky items, namely our ice chests. Otherwise that would also be wasted space.

I'll have to figure out if having two separate doors will be a problem for getting anything out. It would definitely help getting access to the A/C unit.

Thanks for the idea.


And for all the visitors to Garage Journal who are not members, this is the exact reason why we post our garage makeovers and projects for all to see. Someone in another part of the country, or the world, can see an opportunity that we may not have noticed. He speaks up, throws out an idea, and BAM!, an opportunity for an improvement has been made.

We welcome all visitors to GJ and to the Salt Life Hideout, but also invite you to become a member and join in our discussions. I'll even cover the cost of the free membership, myself. Take the plunge. Jump in. Lurk no more!

And now back to our regularly scheduled topic...

 

[nkachur]

and speaking of lurking, I just realized that after following your thread for the last few month that I have never said boo...

Boo !!!!!

Anyways your garage is coming together and I must say the chair sliders are an inovative twist.

 

[Shoottx]

From the pictures it looks like the swing out shelving unit swings out under the air handling unit. If it is cut the top of the door off. then the opening storage unit will work. For the top you can either afix it as a solid panel, hinge it from the top to swing up.

Or you could move the hinges to the other side of the door and have it swing open the other direction.

Many solutions to a problem. As a friend of mine says "it not that craftsman don't make mistakes, it is mistakes become design features of the project."

 

[Wingnut65]

Thanks for coming out from behind the curtains, nkachur. Hope you can get your roof panels finished before the wet season really hits. I hope some ideas that I have come up with or stolen from someone else, will help you in your shop as well.

From the pictures it looks like the swing out shelving unit swings out under the air handling unit. If it is cut the top of the door off. then the opening storage unit will work. For the top you can either afix it as a solid panel, hinge it from the top to swing up.

Or you could move the hinges to the other side of the door and have it swing open the other direction.

Many solutions to a problem. As a friend of mine says "it not that craftsman don't make mistakes, it is mistakes become design features of the project."

Thanks Shoottx for the suggestions. I like the idea to cut the top off the door as you and FBF have suggested. Mounting it as a fixed panel will not work since I still have storage space over the air handler that I want to utilize. Swinging it from the right would mount it on the removable sliding side panel frame and would just be too awkward to work around. Swinging it up has merit, but I'd have to get a latch to make it stay up. The easiest may be to keep it swinging where it is.

As for making mistakes into design features... one of the world's greatest architects wanted a clock on his front porch. It was a 7-day, 2-sided clock he had in his home in Boston and had weights for each day of the week. In order to fit it in his living room and extend thru the wall to the porch (thus, 2-sided), it had to be mounted up high. Although he had to cut a hole in his living room floor for the Saturday and Sunday weights, the clock was mounted near the ceiling of the living room. But... the ceiling of the porch was actually lower. So, the craftsman that he was, he added this design feature to the ceiling of his porch.

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As an architect, it really makes me feel great that one of the world's greatest architects can turn an 'Oh ****' into a cool design feature.

Thanks Shoottx for reminding me to tell this story in my build.


BTW, Anyone recognize the architect or the building???

.

 

[Wingnut65]

So no guesses on the quiz??? I guess we really didn't like tests in school either.
HINT: He was one of our Forefathers! (US Residents Only...)

Quick weekend update... Cutting and painting.

Last week, Flybefree and Shoottx made a suggestion on how to improve my cabinet. Well, Saturday I took the cabinet down and cut the top panel off so the door will open fully. Part of the Bikini Brigade helped to hold the cabinet as I removed the hinge screws. (Sorry she was out of uniform, but she was studying at the time I needed her.)

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I cut the panel off and repainted the whole cabinet another coat or two. Then reinstalled. Yep, it swings open now much further than before.

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I even marked out where the paint band will be on cabinets and installed a handle in the middle of the band.

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I know the right side vertical is not completely plumb (don't tell anyone...) but I needed to move it out about 1/4" so that the shelves have adequate clearance to be able to open and close. Problem solved.

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I also painted both sides of the side panel and all its framing. See the hi-tech painting system that I implement for these details...

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Now I need to find the right hinges to mount the top panel. If I can use the same hinges as I used for the paint cabinet, then the panel will look like a fixed panel and not a door.


.

 

[Mavawreck]

Looks great! My only worry is with your water heater and making sure that it gets the proper amount of combustion air. Chances are that you will be fine with the proposed holes at the top and gap at the bottom. However, typically when I see a lower efficiency combustion appliance installed in a closet the vents are at the bottom. I do not know if this is for any particular reason, possibly it makes use of the natural convective current to help the unit draft where the air comes it at the bottom and rises as it gets hotter.

 

[flybefree]

Jeff,

You know I heartily approve of putting those yougin's to work! I like your painting system...it's not just a roller people, it's a system of systems...you got your roller, your roller cover, roller pan, sheet of scap board, one trash can, and another trash can...plus rags and stuff. It's complicated...just send him some money and quick asking questions.

Shaun

 

[LPete3]

Wow, wingnut, that is a very creative way of using every space available. I don't have a garage yet. Working on that and collecting tools so when it happens I will be ready. I enjoy reading and seeing the awesome ideas that everyone comes up with. I just hope I can remember some of them when the time comes.

I believe the architect is Thomas Jefferson and the building is Monticello. Awesome place, been there a couple of times.

 

[Wingnut65]

Looks great! My only worry is with your water heater and making sure that it gets the proper amount of combustion air. Chances are that you will be fine with the proposed holes at the top and gap at the bottom. However, typically when I see a lower efficiency combustion appliance installed in a closet the vents are at the bottom. I do not know if this is for any particular reason, possibly it makes use of the natural convective current to help the unit draft where the air comes it at the bottom and rises as it gets hotter.

Thanks Mavawreck for the concern and comments. I plan on having plenty of air circulation around the water heater. I may even copy the upper vents from the water heater panel over to the upper air handler panel. There is plenty of space behind the air handler and ductwork for air circulation. And, if I notice any changes in the water heater performance, I will add more vents.

Jeff,

You know I heartily approve of putting those yougin's to work! I like your painting system...it's not just a roller people, it's a system of systems...you got your roller, your roller cover, roller pan, sheet of scrap board, one trash can, and another trash can...plus rags and stuff. It's complicated...just send him some money and quick asking questions.

Shaun

This painting system is a honed and polished system. And if I have too many panels to fit on the garbage cans, I mean painting supports, then the stools get used, then more 2x's on the floor to spread stuff out.

That scrap board is actually the removable side panel that is shown painted in the other pictures. But now that you mention it, that would make for a perfect table when I need to spread out parts for a project or more hors d'oeuvres. Thanks for another great idea, FBF!

As for the Jr labor, just wait until your 42" Fan Club is a teenager. With that many years working in your place, all you will need to tell him is that the tractor's read axle bearings need to be re-packed and he will be off to get it done. Start to teach them early and they will not be afraid of work when they need to do it.

Wow, wingnut, that is a very creative way of using every space available. I don't have a garage yet. Working on that and collecting tools so when it happens I will be ready. I enjoy reading and seeing the awesome ideas that everyone comes up with. I just hope I can remember some of them when the time comes.

I believe the architect is Thomas Jefferson and the building is Monticello. Awesome place, been there a couple of times.

AND WE HAVE A WINNER!!! LPete3 has nailed both questions correctly. And anyone who has been to Monticello will hear the story of the clock. Since there is a hole in the floor, the tour through the basement will see the lines on the wall for Saturday and Sunday weights for the 7-day clock.

LPete3, first of all, Welcome to Garage Journal. Thanks for the compliments. This is a great place to get ideas for your garage transformation, when you get one. It took me a little while before I realized I should take notes as I surf these pages. Now, when I see a photo of something that I like, I right click, copy and paste to a Word document with a name of who posted it so I can give them credit later. I should also save a link to where I stole, I mean found it, but the name helps. And, you will find that a neat idea on one page will show up in another, but with a twist or other improvement. We help each other out with ideas to improve their project, which in turn can also improve our own project. Glad you found us and I hope we can trade some ideas. See ya in the tool aisle.