67 – Gadget Station (Part 10 of 12)

Video - October 17, 2008

In this video, I cut and fit the door components. I also cut the mortise and tenon joinery for the rails and stiles. A stupid mistake causes a small injury and a bit of a setback, so the last part of the video is dedicated to fixing that mistake.

Discussion

Kip October 17, 2008 8:49 pm

Nice fix demo. I think this is coming together nicely Marc. I do wonder if you ever thought about putting the cloud effect in the bottom rails of the doors as well as the top rails?
Jus tcurious
thanks for sharing the fix I found it insightful.

Reply
Keith October 17, 2008 11:45 pm

Hey Marc, spiral cutter, more $, but totally worth it. I have not had to flip a template on any of my material since going to spiral router bits for flush trim, and no wood torpedoes flying across the shop.

Good fix, I admit that I often struggle with whether or not to repair or start over, and I often end up starting over. It’s not that the damaged part gets thrown out, just used for something smaller. I give away a lot of little bandsaw boxes and pens at holidays.

Reply
WiZeR October 18, 2008 8:12 am

Hey Marc

I know you posted about your injury on the forums, but I can’t believe this happened after my Finger Tearout thread. Oopsy! At least you didn’t nearly loose you’re finger! Brought back some memories watching that.

Nice work on the repair. You really saved your ass ;)

Reply
Mark October 18, 2008 5:59 pm

The high resolution video file seems to be corrupted. I’ve downloaded it twice and I get no video and just noise for audio.

Reply
thewoodwhisperer October 18, 2008 8:59 pm

I just downloaded the file and it played just fine for me. But, as we know with web video, that doesn’t necessarily mean all is well. If anyone else has this issue, please let me know.

Reply
Bill Akins October 18, 2008 9:29 pm

Sorry about the injury but we all need that reminder every now and then. I also enjoyed the fixing a mistake segment. We all have to do that too. Looking forward to the big finish.

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muddler mike October 19, 2008 8:52 am

probably your best episode, Marc. you took the time to show and explain the nuts and bolts of the design, milling, cutting the tenons, and even your injury and repair. no other woodworking show would go to those lengths to give their viewers the true realism of the process.

sorry about your hand, but I’m sure plenty of viewers will be learning from your mistakes. We should make an award in honor of those who took a hit for all others to learn from………hmm…….not a purple heart, but maybe a purple hand award?

:) myk

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Matthew Hills October 19, 2008 9:19 am

Pretty surreal to watch your matter-of-fact discussion about the hand injury… while it was still dripping.

On the woodworking side, was wondering why you went with integral tenons, rather than a domino/floating-tenon?

Matt
(ps–glad the injury wasn’t worse–stay safe!)

Reply
thewoodwhisperer October 21, 2008 9:25 am

Thanks for the comments everyone. I appreciate it.
Matt, there would have been no problem using Dominos for the door frames. The reason why I went with integral tenons might be more obvious in the next few episodes. It has everything to do with the ebony plugs. I didn’t want the plugs to simply be decoration. I wanted them to actually serve a purpose, which in this case was to cover the dowel I used to pin the integral tenon.

Reply
Mark October 21, 2008 11:23 am

I’ve downloaded the “high resolution” file a third time and now it plays correctly. The file size is also slightly different from the first two. I guess there was some problem with the server on the first day (not sending the file header properly?).

Reply
thewoodwhisperer October 21, 2008 11:38 am

Well that sure is weird. But it works now so all is well. Thanks for the update Mark.

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Glen Jasmer October 24, 2008 6:18 pm

Hi Marc
Good job. I look foward to seeing each new video. I was reading the comments after video “10 for the gadget station Oct. 17. Kieth suggested using a “spiral bit” when using a template to rout.
Would it be safe + work to use a template to cut out circles, ovals and other odd shaped curves using a spiral bit without flipping the template?
Thanks. Keep up the good work. Glen

Reply
thewoodwhisperer October 24, 2008 7:25 pm

It is usually safe Glen, and I have done it before. But whenever you routing a very dense wood like bubinga, you need to pay extra special attention and make sure the piece is very secure. Also make sure the bit is very sharp and take light passes. My error was probably exacerbated by the fact that I touched this bit directly on the endgrain, instead of working from the long grain and slowly into the endgrain. Stupid mistake.

Reply
Parker October 25, 2008 12:29 am

Good show. I tend to really value the shows where you show mistakes like the this one for the new information, the humility it shows and the humor that can come from it. I talking about mistakes to the project and not to you here. Please continue to be brave and “keep it real”

I’ve done a lot of fixes myself but epoxy is one glue I haven’t used. I was wondering what kind you are using. There seems to be a bewildering array of epoxys out there.

Reply
Jason Jones August 16, 2012 8:46 am

Hey Marc,

I recently discovered your website and the amazing videos you post, I am a huge fan already. I really appreciate you showing the mistakes and talking through them. I have had something like that kickback happen to me (no injuries thankfully) and didn’t know why it happened. Now I know about cutting the end grain and the precautions to take. Thanks for a great program and all you work.

Jason

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Alex January 13, 2013 11:13 am

I will second muddler mike’s comments – great episode!

Reply

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67 – Gadget Station (Part 10 of 12)

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