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Malcolm's Garden Workshop (The Front Doors)

Roll up, roll up. Here you will find everything from new workshop designs, through builds to completed workshop tours. All magnificently overseen by our own Mike G and his tremendously thorough 'Shed' design and generous advice.

Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby 9fingers » 06 May 2020, 21:44

Nice! :lol:

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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Malc2098 » 06 May 2020, 22:50

9fingers wrote:Nice! :lol:

Bob



No need to go all effusive on me!! :D
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Andyp » 07 May 2020, 07:12

I was thinking about the spacing on the balustrade. If you have an odd number of spindle, you seem to have 9, then isn’t it a matter of placing one in the middle followed by one in the middle between the centre and the end then one in the middle of those and repeat until done.

Or should I stop thinking :)

You’ve made a good job of it anyway.
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby 9fingers » 07 May 2020, 08:09

Maybe you have too much on your mind Andy.
Your method works for 3,7,15, 31 etc but not for 9 I’m afraid.
The formula is 2^n-1
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Andyp » 07 May 2020, 08:31

Ah! I should have tested my theory first :oops:
I'll go back to my hole.
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Pinch » 10 May 2020, 06:44

Beautiful work Malc and an excellent thread. 8-)

Proper job matey.

:text-bravo:
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Malc2098 » 10 May 2020, 09:18

Pinch wrote:Beautiful work Malc and an excellent thread. 8-)

Proper job matey.

:text-bravo:


Thanks, Paul. But don't look too closely when you pop round for a coffee! :)
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Pinch » 10 May 2020, 09:35

Malc2098 wrote:
Pinch wrote:Beautiful work Malc and an excellent thread. 8-)

Proper job matey.

:text-bravo:


Thanks, Paul. But don't look too closely when you pop round for a coffee! :)


I'll 'av 'arf... :D
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Malc2098 » 10 May 2020, 11:00

Pinch wrote:
I'll 'av 'arf... :D



I've got some nice Rebellion Red from the Marlow Brewery where I used to live, and if you're ever up that way on a Friday night, try out there tasting sessions after this lockdown is over. Best free beer ever!

And what about Wychwood Ruby, only £1.25 in the supermarkets, a lovely ruby bitter!
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Malc2098 » 14 May 2020, 16:02

16 balustrade spindles moulded with stopped chamfers and ready for sanding for the long side between newels.

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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Malc2098 » 16 May 2020, 21:41

Long side finished.

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Although they don't come out well in the photo, I left a few bits of wane on there because their colours were stunning, including a deep ruby, and to remind visitors that this wood comes from a tree. :)
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Phil » 17 May 2020, 08:44

Nice Malc 8-)

I can picture an easy chair, bottle of chilled white wine, some snacks and enjoying the view :D
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Malc2098 » 17 May 2020, 10:29

Phil wrote:Nice Malc 8-)

I can picture an easy chair, bottle of chilled white wine, some snacks and enjoying the view :D


Thanks, Phil. I'd go for a nice pint of cellar temperature Palmers 200, rich, malty and full bodied (I was going to say a lot like me, but 2 out of 3 ain't too bad :D ) with a bowl of Marks and Spencers Four Cheese and Onion Combo Mix.


https://palmersbrewery.com/cask/palmers200/
http://www.45spaces.com/crisps-chips-nuts-snacks/l.php?l=four-cheese-onion-combo-mix
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Andyp » 17 May 2020, 11:57

Good Job Malc
Did you consider attaching the balustrade to the those main roof posts?
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Malc2098 » 17 May 2020, 12:42

Andyp wrote:Good Job Malc
Did you consider attaching the balustrade to the those main roof posts?



Thanks, Andy. The deck and the roof posts are independent of each other, totally not connected. The roof is also connected to the workshop roof, too.

This construction was all so new to me that I didn't want one thing to compromise another. So the roof sits on the posts, the posts sit on the saddle stones, the stones sit on individual footings. The decking sits on its own joist supports and is built around the saddle stones. so if the posts move, they don't move the deck; if the deck moves, it doesn't move the stones.

That was my logic. Not sure if it's right, but that's how I designed and built it.
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Andyp » 17 May 2020, 17:30

Makes perfect sense to me and you probably mentioned earlier in the thread but I had forgotten .
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby 9fingers » 17 May 2020, 17:50

I reckon Malc is preparing for earthquakes!
:lol:

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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Malc2098 » 17 May 2020, 21:14

9fingers wrote:I reckon Malc is preparing for earthquakes!
:lol:

Bob


Preparing for them? Worried sick about them!! :o
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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby 9fingers » 17 May 2020, 21:18

Malc2098 wrote:
9fingers wrote:I reckon Malc is preparing for earthquakes!
:lol:

Bob


Preparing for them? Worried sick about them!! :o


Don't worry Malc, the older you get, the less often the world moves for you!
:lol:

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Re: Malcolm's Garden Workshop (Decking Balustrade)

Postby Malc2098 » 17 May 2020, 21:22

9fingers wrote:
Malc2098 wrote:
9fingers wrote:I reckon Malc is preparing for earthquakes!
:lol:

Bob


Preparing for them? Worried sick about them!! :o


Don't worry Malc, the older you get, the less often the world moves for you!
:lol:

Bob


:lol: :lol:

Coincidentally, I had a bit of another virus a couple of weeks back and I now occasionally when I move my head, I become dizzy for a split second before the earth moves back.
Last edited by Malc2098 on 15 Oct 2020, 17:52, edited 1 time in total.
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Re: Malcolm's Garden Workshop (The Front Doors)

Postby Malc2098 » 15 Oct 2020, 16:58

Right! I'm getting sick of having to turn sideways through one half of a pair of double doors at just under 1200mm wide, especially if I'm carrying something and unlocking them at the same time.

So, I had Grantlands Timber supply me with a load of freshly felled 4 x 2 larch back in May. I cut it to convenient lengths and seasoned it round the back of my workshop. I covered it over with all sorts of offcuts.

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While waiting for the guitars' lacquer to cure, I decided to get out and start milling it for the pair of front doors.

I've never made proper doors before, so I've tried to keep it simple with the ledge and brace pattern.

This is the bit I can't get over, it's like being back at school in the woodwork class, but bigger! Plane face side, plane face edge. I now use the PT instead of the No 5.

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Now, to be economic, I wanted the ledges and braces to be sawn from the Ex 4x2 or 100x50 I should say. By planing out any sawmill errors and any curls that had found their way in, I was losing width. I theoretically would have liked the ledges and braces at 30mm and the TGV battens at 20mm to make up the 50mm width on the stiles and header. Ha! Fat chance!

In the end, I settled for 22mm for ledges, braces and battens and therefore 44mm for the stiles and header. So everything got thicknessed to those dimensions.

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Next on to the mortices and out came the mortiser. It's only a baby one, so I take it really easy, but the result is not too bad. I was doing haunched mortices for the header and I don't know the name for the ledges, but their tenons were half of the ledge thickness.

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I've only got videos of the tenon cutting on the table saw with a flat top toothed blade (for my not so informed as you lot Facebook friends and rellies) so you'll just have to settle for how it went together.

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Oo. I forgot to mention. I treated myself to a new toy for the workshop. You can see from the photos it's only about the size of a single car garage, and sometimes when I'm using the mortiser, the router or the bandsaw, they are not the same height as my bench, cabinets or saw table. So I bought a scissor lift for motorbikes. It's hydraulcly operated with foot pedals and it's been brilliant. I can just about lift the mortiser on to it and set it to the height of the saw table. It's been the infeed table, the outfield table and even my stool. It's got some pretty naff cast iron wheels on it, but I'm swapping them over to a Coldene twin set shortly.

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Back to the WIP.

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The swifter ones amongst you will not only have noticed that the doors are not the same width, but also the stiles are of different widths. The wider door will be the one that gets used generally and the little one will only be used when big stuff needs to be moved in or out.

The wide stiles are for the overlapping rebates that double doors need to close against each other.

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Now here is where I've messed up a bit because I spent ages on Sketchup planning the overlap, I just couldn't get my head round removing two rebates and only reducing the overall width by one of them :oops: , But I didn't research the security market for rebate kits for sash locks. It seems they only come in 13mm or 25mm rebate sets. My rebate is 22mm, half the thickness of the doors. I would appreciate any ideas apart from the obvious, which I might end up doing, because I have been generous on the door widths.

Out came Sketchup again when I had to work out the width of the TGV battens including their expansion gaps etc.

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And I moulded the battens with these bad boys!

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And the outcome?

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And the tops of the battens got teed and veed, too.

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(357.48 KiB)


Next came cutting and fitting the braces.

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And then screwing them all together.

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(203.69 KiB)


I added hinge braces for the tee strap hinges already on the long term temporary doors.

9C288CE3-F8B6-4810-9E98-A212AF6A6C9A.jpeg
(188.78 KiB)


And that's as far as I've got while I research the lock industry a bit more. They ain't 'alf 'eavy!
Last edited by Andyp on 15 Oct 2020, 17:31, edited 1 time in total.
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Re: Malcolm's Garden Workshop (The Front Doors)

Postby TrimTheKing » 16 Oct 2020, 13:34

Very nice mate! I like the look of those a lot and those chamfers really make them!

They going to be painted?
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Re: Malcolm's Garden Workshop (The Front Doors)

Postby Malc2098 » 16 Oct 2020, 14:08

TrimTheKing wrote:Very nice mate! I like the look of those a lot and those chamfers really make them!

They going to be painted?


Thanks, Mark.

I'm minded to paint them with the Barn Paint the same colour as the cladding. The grain should show through. The doors are under the decking roof so don't get rained on. Then I'm minded not to paint the insides at all, 'cos I like looking at them. :)
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Re: Malcolm's Garden Workshop (The Front Doors)

Postby Malc2098 » 20 Oct 2020, 20:26

I've forgotten how fiddly it is fitting the rebate set for a sashlock on double doors. First routing the the proud part of the rebate, then mortising for the lock. Then routing the proud part of the rebate and shallow housing the striker plate. And them doors are heavy. My shoulders keep telling me!

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(354.23 KiB)


Security bolts tomorrow.
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Re: Malcolm's Garden Workshop (The Front Doors)

Postby Andyp » 21 Oct 2020, 07:20

Nice.
cheers

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