Lighthouse Shutter Order

[OzarkSawdust]

I finished the shutter order for a lady today. What a job! She wanted each side 14 1/2" wide and 26" tall...My saw is a 16"...

I did learn some new tricks though. First I had to drag the saw out in the middle of the shop to have room around it. Then I designed the shutters from a shelf bracket I found on line. Went to Rapid Resizer and blew it up to the measurements and printed the 6 page pattern. I figured if I could get one to come out right I would flip it over and use it as a templet.

Not having a jointer and planer, I had a cabinet maker friend make me two blanks with 1 x 8s edge glued. Then came the trouble. I did the layout and double checked the measurements before cutting, thank God, to find the pattern was 1/4" off one way and almost 3/8" off in another spot! Back to the computer. Checked the input numbers and printed it on plain paper...still off. So I increased the measurements a little and printed . The trouble spots were now OK...but a different spot was not!!

At this point I went out and check all the measurements of the 1/4" plywood trial I did. Close enough to use as a template and I could "wing it"...LOL.

I also found out I really needed three hands...  So I took an art brush, dropped it through the entry hole, used it to line up the blade slot in the table. and held the large blank with a 4" quick clamp. Then I removed the brush and could top feed the whole thing and tighten the bottom blade clamp, remove the quick clamp and cut ! Then repeat for the next hole! Kind of crazy...but it worked slick. 

Glad to be done with this project! She is going to prime and paint them to go with her kitchen...so I don't have to finish them!!

Two things came out of this project, besides a learning experience.

1. I got that big cutout, between the lighthouse and the side frame, out almost intact today. I checked it and I can cut a puzzle dog from the scrap piece and sell it!! Bad news is I didn't think of it yesterday and cut that piece into smaller pieces getting it out.

2. This afternoon as I was working on it the lady calls me. It seems she does fundraising for local cancer victims. She wants me to come up with a trinket box to put a picture in the lid and a CUBS logo on it. It will be filled with the money she's raising for a lady with breast cancer who will be going through chemo in a month or two after a Mastectomy. 

So I get a triple play for this project! And probably a chance to be involved for other cancer patients!

Edited August 14, 2020 by OzarkSawdust

[Rockytime]

They look terrific! Nice work.

[OzarkSawdust]

25 minutes ago, Rockytime said:

They look terrific! Nice work.

Thanks Les!

[wombatie]

They may have been a nightmare for you but you did an awesome job.   Just don't let anyone else see them. 

Marg

[John B]

You took a long road to get there but the journey was well worth it. They look very nice.

[Tomanydogs]

If there’s a will there’s a way. Glad you found it. Well done they look great. 

[amazingkevin]

Tough dogs are le

[amazingkevin]

Glad you found the trick to make life easy for you!!!

[OzarkSawdust]

7 hours ago, wombatie said:

They may have been a nightmare for you but you did an awesome job.   Just don't let anyone else see them. 

Marg

Thanks Marg! I'm half afraid someone else will want some! In 2 weeks I'm showing my work at the fair. The customer is going to paint them and give them back for the week so I can display them with the rest of my work. 

Edited August 15, 2020 by OzarkSawdust

[OzarkSawdust]

4 hours ago, Tomanydogs said:

If there’s a will there’s a way. Glad you found it. Well done they look great. 

Thanks! If it's impossible...scrollers will find a way!!