Shopsmith Forums

Just catching up a bit on tedious things... Again a heck of a lot of hole-plugs to install, but it's worth it for a tight box when new hardware comes along. The SS horizontal boring mode makes the hole-plugs go fast.


The frame&panel new front cover (on the left) worked out to have some of the best joints I've done in a while. I had used the SS table-saw for slots, and the SS Overarm Router for tenons. More hole-plugs shown on the drawers and sides.

Very nice work! It is a pleasure to see

Also - agree on your choice of tool applications. Same choices I would make.

nuhobby, do you align the grain of the plugs with the grain of the repaired panel and then finish the whole thing?

How do you keep the panel from looking like M&M's are all over it .....

That is beautiful!

Thanks, Dick, I do grain-align the hole-plugs, but it's not super critical since these plugs are 90% covered by the replacement latches and corner-pieces. The replacements don't have identical hole-locations as the originals, so I have to plug the holes. I do like planing them flat; it's just fun!

The front-panel is a completely new fabrication, so no M&M plugged-holes will be there .

I also like planing down very old oak like this. I saw a word in the guitar-making literature, "Torrefied Wood." Something about really old/aged wood like this works differently with tools, and reportedly sounds better on guitars. There's even some companies trying to pre-age their guitar wood!

Chris

The next session was some "Rout and Replace" work -- better done before assembly.

The back rail of the Top Till had a really bad edge from wear and tear, so I put in a replacement strip:

The front rail of the Top Till had a big dent on its bottom side, so I routed out a spot:

Here is an indulgence. I have 4-5 E.C. Atkins antique saws, made here at Indianapolis decades ago. One of them has been 'pimped' with a whole new, fine-gauge, fine-set saw plate. Using it to rip a little repair stock piece:

Now the repair spot is planed down and selective gluing has started. A lot of the left side of the carcass is now glued, but the right side is loose-fit until I establish and install pivoting hardware on the new front-panel:

Happy woodworking!
Chris

Oh heck, I had to take a break from what was already a slow project. Plus, I'd bought a couple more carcasses "on the cheap" during these many months. I had to move all this stuff aside just so I can think straight again.... The Gerstner needs finishing, and there are 2 cute little Union chests in line behind it!

A little closure on the latest chest: I got so busy and behind, that I decided to sell it off. The new owner took the "mended bones" I provided, and finished the job details. He was tickled with the custom front panel (which was my main project satisfaction anyway!):
Chris

I got away from these Chests 3-4 years ago since I was getting overwhelmed. But lately I scooped up an oddball small Black and Decker chest for a circa 1942 valve-grinding tool (missing in action....).

I am altering the thing, having some fun. It's a bit less complicated and fussy than a true Gerstner ...
happy woodworking,

Chris

I went to the trusty Overarm Pin Router, which has been my main rabbeting method for 10 years....

Now I have enough parts to make a ship-lapped new back assembly:

Here I'm in the middle of another distraction on a saw-handle Frankenstein project. But the chest-in-progress makes a nice backdrop:

More later!
Chris

Chris,
As I have been following your work on the B&D chest I am enjoying the work you put into rebuilding these old carcasses. I spent about an hour this morning reviewing the posts from the beginning and you have been at it for close to 6 years, probably longer.
I love the old Gerstners and you have done a wonderful job bringing them back to life. I got a chance to visit their factory, which is quite small, and was amazed at the new chests they have in their display room. While 99% of the chests I have seen are oak, the showroom is filled with chests made of cherry, walnut, maple and other hard woods. The same quality is used in the new ones and they were unloading a tractor trailer of oak while we were there.
The old building is awesome with the smell of fresh sawn oak hitting you as soon as you enter the front door.

Good luck with the current rebuild and thanks for sharing your progress.
Wiley