Thursday, 19 July 2012

Catching up..

The last couple of weeks have been very wet over here in the UK, but the interest in my work has more than made up for the dreary weather. Some of you have been on 'Google images' and pushed the Olympic torch replica onto the first page.. which is amazing, thank you.

The leather covered bed that I had previously mentioned, has now gone and looked great when it was finished.

This was the bed after a few days work, take a look at what it was like before I started..
It wasn't the most exciting of jobs and repairing the leather was a bit frustrating, as I was getting the colour right, I didn't have much time to work the compound before it would start to cure, so then I would have to mix some more, good fun eh?

On the Restoration page.. in the Previous Work section

I've also been round to see Julian's 1964 split screen VW bus, and it's looking beautiful, there's a final picture added to the camper section.

Take a look...

All the best


Tuesday, 10 July 2012

Julian's Split screen..

Bespoke seating with the best storage...

This gorgeous van belongs to Julian, and the only thing missing is the upholstery.

Julian is having all of the seating and lining work done in leather by
Bromsgrove Auto Trimmers. The intention is to use it for weddings, so a gorgeous interior is a must..

This is what it looked like before I started working on the interior.

Note the masking tape, with lines marked on to show what and where..

First thing Monday morning Pete the upholsterer, and I went through the design of the seating to make it the right height, the depth of seating to work and the angle of the back to be comfortable. The height of the backrest was to sit in a panel detail line, just under the windows.

By the end of the first days work I had the floor down, a master pattern made,
10 backrest sections made and all was good.

and a few days later..   Done..
The cream "Old English" Formica around the bottom,
and in one piece.. so no unsightly joints

The forward seating has the largest storage compartment and as I talked it through with Julian, I suggested that I would line this area out with a soft carpet, for the happy couple to put any items in. That would save things rolling around the floor area.

This corner area is useful for all sorts, the lid/seat squabs have the ply cut-outs screwed to the underside to stop the seats moving around and stiffen them up. It also makes fitting the upholstery too easier, you can't beat a hard base for the upholsterer.

The aft storage floor is not ply lined and good for tools and a jack

Pete and I chose to do the seat cushions with a full, lightweight ply base to make the cushions very crisp and the backrest removable in two parts allowing him to finish the upholstery on the bench and then fit after. I just had to ensure a 2.5mm gap all round each board. This method also allows the base unit to support the whole cushion board and the largest aperture.

Here is the leather covered seating with piping, looks great doesn't it. This photo was taken before the van was completed, so it could only look even more gorgeous later, beautiful.

It didn't take long to do, and by working with Pete, what took me a few minutes longer to do, saved Pete more than double his time..

Hope you like.

All the best


Thursday, 5 July 2012

Olympic torch in wood..

The Olympic Torch section has all of the finished photos, take a look

This posting shows how it was made

Olympic Torch in wood

A few months ago, I was asked by the headmaster of Catshill Middle School, Paul Essenhigh, if I could make a wooden version of the Olympic torch for some sports events they will be having at the school in July, to celebrate the Olympics.

Of course, I said yes..
I had done some research into the torch and started marking out the template on the day that the flame was lit in Greece the other day. I already knew that the torch is 800mm long and weighs 800 grams, so this was a good starting point. After looking on the Internet for dimensions and being unsuccessful with finding any, I looked at the scale of the torch compared to the people holding it. The torch handle was around 40% of the overall length, and the top looked around 115 mm (4 1/2") from the middle of one corner to the other rounded corner of the triangular shape.

and here it is.
Click on the pictures to enlarge

The finished torch, in wood, with an Aluminium tube in the centre, with a shaped Aluminium piece on the top


The timber for this torch will be Medium density fibreboard and pine reinforcement in the corners, painted in gold, using an Aluminium tube down the centre with an Aluminium plate bonded onto the top.

Here is the master pattern for marking the height, width and shape.
I cut out the shape and planned it to a smooth finish

From a piece of 6mm MDF measuring 12220 x 600mm, I cut out seven rough oversize shaped pieces, I kept the off-cuts for trials on the painting later.

Here I am routing all seven from the master pattern. I always had at least two cramps on the timbers at any one time to ensure that their was no movement.

I also made a section of the top that I thought was about the right size..

Two hours worth of marking out the drill sizes and hole positions

So if you wondered why I had made seven sides, one was for marking out all of the holes.
The other six will make two torches, one for Catshill Middle School, the other will be given to Chloe after she plays her part in the opening ceremony.
Glueing up..

I shaped the one corner of the top piece and marked out the holes around from one face to the other to see how the holes lined up... pretty good

Over the next couple of weeks I went and used my pillar drill to get some more holes done, two hours worth on a Sunday, while Lynn and the girls went walking with Clive and Sheila. Then I went to finish them of on a wet Monday, done.

The next thing to do was to fix the sides together using some off-cuts of Pine I had from the Garden room.

Here I have dry fitted the MDF together to see how it's all working out

If you read my Blog you'll know that I don't have a workshop yet, and try to get my work done while the sun is shining...I love this picture

This is the last dry fit, just checked that all was looking good

Planing down the corner joints to ensure flat across the two surfaces

Painting the insides, once together I wouldn't have been able to get the paint in here

After painting in two parts, ready to glue together