The panel was not flat, but I guess it comes pretty natural after glueing up to cupped boards. At first I traversed it with the scrub plane, and then when it was flattish I started going with the grain.
After a bit of workout, it was nice and flat.
I dry assembled the carcase of the chest, and after checking that it was square, I traced the outline of the bottom onto the bottom panel.
According to my sketch it will look good if the bottom is protruding on all sides, just something like 1/4". This could technically be achieved by adding a small piece of moulding, but I didn't bring any moulding planes with me, so I had to think of another way to make this small detail.
The plan was to make a groove near the bottom of the carcase, to house the bottom, That is pretty traditional.
In order for the lower part of the bottom to protrude I had to make a rabbet along all the sides of the bottom.
Then on the remaining full thickness part of the bottom I had to make a groove, so I would end up with a thin piece of bottom that would fit into the grooves of the carcase sides.
In my mind this worked very well.
Design flaw No 1
I normally stick to the grooving before dovetailing, but I didn't do it this time because my original idea was to simply make a rabbet and then nail the bottom on.
Due to my interlocking groove idea, I had to make a set of grooves without messing up the dovetails, so I wouldn't get a groove that would be visible from the outside of the chest.
On the sides it worked really well, since I just cleared the tails.
On the end boards I found myself needing to make a stopped groove - as in stopped in both ends. I tried using my grooving plane, but it pretty quickly became evident, that this tool was not intended for making that kind of grooves.
My solution was to use a utility knife for defining the sides of the groove. I adjusted the iron of the grooving plane so it protruded a little less than 1/4" (5 mm to be exact). That made it possible for me to use the grooving plane as sort of a router plane.
It took a bit more time than I had expected, but the grooves turned out well.
Design flaw No 2
If you need to make a groove on the side of your rabbet, be sure not to make the rabbet wider than your grooving plane can handle..
This flaw was discovered after I had finished planing the almost 3/4" wide rabbet all the way around the bottom.
I think that I might be able to tackle it sort of the same way I did with the stopped grooves. But I decided to call it a day and not risking to mess up things by keeping on working too late.
After imposing those additional challenges on myself, I would like to explain why I changed the design in the first place:
I wanted to make sure that there would be no crack between the sides and the bottom if it should move with the seasons. Therefore I got the idea of housing the bottom in a groove.
And making one bottom, and then glueing on a decorative bottom seemed like an idea that required too much work. Guess I was wrong about that.
Flattening the bottom.
A stopped groove.
Note the protrusion of the iron on the plane.
The bottom with rabbets.
Jonas
ReplyDeleteI really enjoy reading your posts and your problems solving. To me that's the fun part of woodworking, solving problems on the fly, for I always work without any real plans, just doodles :-)
Bob
Hi Bob
DeleteThanks for the kind words.
I am glad to know that I am not alone on this one :-)
The process of making something out here is definitely more important than the outcome, since it is basically a way of recharging my own batteries. Off course it is nice when things go smoothly, but it is also challenging to be able to overcome a problem.
I would like to work to a "real" plan sometime, but I think it will have to be while I am at home, because out here I am very limited in materials and tools etc. So it makes more sense to make up the plan as I go along out here.
Brgds
Jonas