[Woodworkers] Last couple of weeks.....

[Royce Killion via Woodworkers]

On Wed, 16 Sep 2015 08:13:51 -0500, Joe Johns  
<woodwork at twistedknotwoodshop.com> wrote:

> On Wed, Sep 16, 2015 at 6:43 AM, Royce wrote:
>
>> This has kept me busy the last couple of weeks...
>
> ​Royce, Royce, Royce...dude, I'm not gonna allow you to just waltz in  
> here saying the Corncob Art Festival begged you to do something and so  
> you >did this'n that and you only have to tweak one little thing and  
> expect to pirouette outta here leaving us hanging with just that.   
> So...you're gonna have >to spill yer guts.
>
> 1.  What the hell is wiggle wood?

You know that bendy plywood stuff...I have used it a couple of times. It  
is really flexible along the 4 foot dimension of the 8 x 4 sheet...That is  
how
it has been described to me as 8 x 4 instead of 4 x 8.   Anyhow I thought  
of using just thin plywood and that would have probably worked, but I knew  
this would and just went with that...I could get 1/4 or 3/8 thicknesses  
and I went with the 3/8.


>
> 2.   ​Why aren't the vertical ribs on the top section of the far left  
> panel in line with the lower ones (I'm an excellent noticer).

I suppose the 2 or 2 and half weeks would explain that....a couple of late  
nights and poor lighting in the garage....acutally I am happy that
most of them lined up as well as they did. Most of those were just set on  
a quick measurement and because of the curve they were squared
up on the let's split the difference method.

>
> 3.  Didja use SketchUp to model this?

I did not, but I did use a cad program I have to lay out the curve...I  
wanted to have a local print shop to plot me out a full 8 foot curve so it  
would
be easy to lay out the first one, but since I am here in corn cob country,  
they didn't have a program to read my files, so.....because the curve was  
the same  for the entire thing I scaled it down to one  sheet and took  
measuremenst at 6 inch increments and then transferred that to a sheet of  
plywood and then printed a ten inch section of the curve and marked it off  
using my measurements of every six inches.  Worked fine but sure seemed  
like a lot more work than it needed to be, but it worked.

>
> 4.  That's an awful lot of cutting and assembling - two weeks?  You  
> musta been working like a rented mule.  Who'd you have helping ya?

It was pretty much me...a couple of late nights and a little help from the  
wife, but not to bad. After I got the first curve laid out I was able to  
use that for a pattern. The backs of the ribs have just been cut with a  
jigsaw and sanded a little bit, but for the front side I would cut close  
with the jigsaw and then trim the edge with a router so they were all the  
same.  Really jealous of those guys with the cnc router for just a bit.

>
> 5.  'Splain some the more tragic moments like the gut wrenching fear of  
> hauling all the pieces there and assembling them

There was plenty of pain in the butt moments....to move them around in my  
garage I had a couple of small 4 wheel moving carts and had to run them in  
and out of the garage to make room.  The bottom ones got heavy.  As far as  
panic when taking them in...my son helped me load them on the trailer and  
then I just screwed a couple pieces of scrap on the top to make them all  
one piece, and then strapped them down. But....hauling in one load I  
noticed that they sure seemed like they were moving to much....anyway,  
stopped to check them out and it turned out that the strap I used to  
secure them had the free end come loose and got under the trailer  
wheels...pretty much happy I didn't have to remake one.  The biggest fear  
was putting the thing together....like I said I didn't have the space to  
assemble before I took it in so...I was sure counting on everything  
fitting.

>
> In other words...CHRIST, this is epic!  Do tell all (especially the  
> price they paid).

Well when we started my concern was I didn't want the thing tipping over  
and at first they said it could be cabled to the ceiling so I was just  
gonna make it 6 or 8 inches deep and then they decided they wanted it on  
casters so I ended up making the bottom 2 foot wide and it tapers to  
around a little over 7 inches at the top.  I figured they could always put  
sandbags on the bottom, but after getting it installed it seems pretty  
stable. And they finally settled on just furniture gliders on the bottom.   
I believe there is about 25 sheets of 3/4 in ply and 12 sheets of wiggle  
wood in the thing and of course and crap load of screws and staples.  I  
don't know if you can tell from the picture or not, but it is made of 15  
separate pieces. 8, 4 x 8 sections, 4, 2 x 8 sections, 2, 4 x 4 sections  
and a single 4 x 2 section.

As far as price goes, the first estimate was $4200 and then they started  
changing things around so we ended up at $5500.  Not a bad thing, but I  
think this my be my last huge project.

Seems like a lot to me, but I am frugal ( maybe cheap is a better word )

All things considered, they talked to a company that makes custom movie  
screens and they were wanted in the $12,000-$14,000 dollar range.  When I  
went in to look at what they wanted I tried to give them suggestions that  
may have been less expensive but this is what they wanted so this is what  
they got.

While we were in there installing this thing we did talk to a employee  
that grew up not far from our house and he said the last display they had  
in there were artworks from around the world and their shipping bill was  
$25,000 so that made me feel a little better about what they paid me.

Of all things, I am glad my son is close and willing to help, cause I  
would not have been able to do this without him....he's a good kid.

Royce


>
> I'm proud of ya, Royce, ya dun gud!
>--Joe,
> The Twisted Knot Woodshop, "There's never been a classier joint"
> Visit the Twisted Knot Woodshop - http://www.twistedknotwoodshop.com



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