TWO WEEKS LATER. In fact, it’s been so long, with the interim so eventful, I barely recall the subject matter alluded to in the March 29 post. However, today, I have a different subject to relate to you.
Part of my take — right or wrong — on this exercise is that we participants ought to present current works IN PROGRESS. A sort of a semi-formalized What I Did Today. Being a procrastinator, I’m going to lag that a bit. But I think I have an excuse. I was up until 3AM fighting with the machinery and software to transfer photos from my phone to my computer. (If anybody knows a transfer utility superior to Air Droid, please enlighten me. For me, it keeps losing the WiFi connection and failing of transfer. The photo set for today’s post totals out at 43MB. I’ve no idea why, even at WiFi speeds, that should take long enough to time out.) So my post TODAY is about what I did YESTERDAY. For what I did TODAY, tune in TOMORROW. (Or maybe later, depending on how well I can keep to this schedule. Past performance being a reliable indicator of future results. (Or however that goes.))
Swennyway. What I did yesterday was build a shelf. For my wife Toni (whose birthday was Monday, BTW) to go on the exposed brick chimney above her desk in the Study at Casa d’Alger. So, as a spoiler, here’s what it looks like, now finished. Process shots next. (Click to embiggen. Click all the little pictures if you want to see them bigger.)
The whole thing stems from when Toni started collecting things VW. Well, no, I suspect it goes back to the eighties when we collected Lladro porcelain figurines. We have a large stock of cats, flappers … I think there’s a ship under sail in there. Birds, bunnies, rocks, ashtrays (not so many of those since both of us quit smoking). Tux, the Linux penguin. A rubber duckie. Mugs and mugs full of pencils and markers. And, here lately, Toni’s been developing quite the garageful of bugs and buses. And neat, framed art — photos and prints.
It’s started to get a bit crowded over there. So Toni started looking for corbels. I was picturing a pair of nice acanthus leaves, or an owl or a gargoyle. But she ended up with some nice, Shaker-esque brackets. Seven inches tall by five deep. With dadoes cut top and back and screw eyes mounted in the dadoes.
Meantime, let us consider the field. As you can see in the pic above (and the left and right ends, herewith), there is casing molding either side of the brick, covering the seam between the brick and the drywall. Og and I selected this and the dentil molding that runs around the ceiling line of the whole room (or will once it’s done). It’s triple-fluted, so the placement of the corbels is critical. It would have been nicer if they had been the same width as the molding, but you do with what you have. The downside of this is that it becomes obvious that the two pieces — the molding board and the corbel — were not made to go together. If they had, either there would be a table cut into the molding to bed the corbel or the flutes would have been stopped short of the corbel’s position. However, simply mounting the corbel on the molding, with the flutes continuing under it doesn’t look THAT bad. And the upside is that there is a well-centered trough in which to position the mounting screw, which makes the mounting easier.
Before mounting the corbels, I set a six-foot level across the space and drew a line on the moldings to serve as a guide to everything. Then I measured the corbels to make sure I was setting the screws in the right place to position the tops level to each other and the base line. Good thing I did that. On one, the keyhole for the mounting screw was centered 13⁄16” down on the other, the drop was 1¾”. I also noticed to my chagrin that the manufacturer had neglected to include a bracket for the shelf in the top dado. Seemed a rather dumb design decision to me, but, hey — they’re selling, so it must work for them. I’ll never buy another anything from that manufacturer and I doubt they’ll miss me.
Having marked the drops, I set the screws and drove them in with the drill, leaving the heads proud (and testing with the brackets periodically, adjusting with a hand screwdriver). I take a moment to note here that the idiot teenager who designed these things specified flat head screws, rather than the application appropriate round or pan head (with or without washer).
Then the action moved outside with a collection of tools and a six-foot number one grade white pine one by six bought previously. I cut it to length. (Love my Diablo blade — a quick spritz of WD40 on the running blade helps fora cleaner cut and helps keep the blade clean.) 57 inches was our rough measurement to determine needed stock, but the actual length turned out to be 56¾”
Once cut to length, I wanted to chamfer the top edges on three sides (not the side against the wall. My router is a Bosch 2¼ HP beast that weighs a ton but is suprisingly easy to handle and quite nimble on the wood. It handles like a dream when its running. The spinning motor has enough mass to have a gyroscope effect, making the thing tend to want to stay steady. I pulled it out of storage for this project and was surprised when I opened the case to find that I’d put it away with the chamfer bit already locked up and height adjusted to a cut depth appropriate for a ¾” board. It was the work of a couple of minutes to finish the edges.
We’d agreed not to put any kind of sealant or finish on the shelf because of Ditto. Birds don’t take well to the volatile organic compounds that are outgassed from paints and varnishes, not to mention solvents, so you don’t use them in areas where birds are — or even nearby. (And that includes deodorizers.) So the final step in building this shelf was to sand it smooth and clean — free of blemishes and splinters. Not too hard, since I’d started out with white wood to begin with. I put a quarter-sheet of 320 grit sandpaper in my Bosch orbital pad sander — another power tool that’s a dream to use — and smoothed the face and edges, softening the corners as I went. I spotted and smoothed one place where the router had chattered a bit and missed another one. I bet nobody else will ever see it.
Next time, a pretty jewel of a piece.