Wood_Ogre builds 14 ft Koa Kaholo Kook Box

better than a copperhead serial

http://www.youtube.com/watch?v=Mq9DUjLDjco&feature=related

at the avenue theatre on

san bruno avenue in the portola

or maybe it was at the

visitation valley community center.

notice the workshop scene at 1:40

look familiar? Yes the secret

wood ogre laboratory hidden

in the remote homesteads

where the magic happens

at all hours of the day and night

while watchdog robots

and silent start routers 

ply the moons gravity

and tidal whims in fluid bodies

on the quest of splitting

the atmospheres of air and water.

 

The frames are my favorites

the flex allowance

in the forebow are genius.

 

…ambrose…

 

hit it mark 

8 to the bar.

you gotta love this guy

http://www.youtube.com/watch?v=Mq9DUjLDjco&feature=related

fighting it out with a cnc machine

…ambrose…

The fingers are cut useing the inlay router guide with the large bushing removed

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures158.jpg[/IMG]

the fingers for the bottom panels are cut .Fingers are on the right, the jig is fastened to the wast side on the left.

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures155.jpg[/IMG]

sockets are cut with large bushing

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures156.jpg[/IMG]

when everthing is alined and clamped ,the panels , template and a backer ply are fastened to the work bench with wire brads so nothing can move when routeing.

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures157.jpg[/IMG]

Finger joints cut with a inlay collar and bit are so tight that if you tap them together with a hammer you can not get them apart. So I sand each finger 12 passes with 60 grit sand paper to loosen them up for the epoxy glue. The strength of the joint is in the glue.

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures159.jpg[/IMG]

Masking tape is layed over the fingers and sockets.

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures160.jpg[/IMG]

The masking tape is cut with exacto knife. With the tape there is no mess to clean up after glueing

[[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures161.jpg[/IMG]

Epoxy glue is brushed on joint. and then the joint is tapped together with a rubb er mallet. Wax paper under and over then it is weighted with bricks and lead untill dry.

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures162.jpg[/IMG]

The race is on !! The EYEs are neck and neck 951 to 959 ! Are they the same eyes, or different ? Any one got any EYEdea of what I am talking about ? Look around, see what you can see , then let me know what you find out !! I'm going to shove this thread down your throat if you like it or not ! So look out cause if you aren't reading this thread I will poke your eye out with a sharp stick !!!!!!!!!

I got a big pile of bricks beside my shop door .They are one of the most used clamping tools for wood board building . My wife steals them for the garden, I steal them back. Heres the bottom panels clamped down with bricks !!

 

 

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/markspictures163.jpg[/IMG]

women !!...and bricks.....I've had this happen to me....Hilarious....although now I think she would rather throw em at me ..lol

After glue up tape is removed from finger joints no clean up needed and no glue smears !!!!

 

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures164.jpg[/IMG]

With the 3 bottom panels glued up it is time to trim the back panels to finish size with back half template.

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures165.jpg[/IMG]

 

Template is flipped over to outher side of panel and allighned with center line and trimmed to finish. The same thing is done with the front half of the board.

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures166.jpg[/IMG]

4 oz cloth stretched over inside of panels. I glass the inside panels before assembling the board.

 

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures167.jpg[/IMG]

Ambrose , I see that you are watching this post so I will not poke your eye out with a sharp stick !!!

watching closely

includes evading

eye poke stick.

somtimes known as

poke eye stick

observers are vulnurable

from either front or back

of stick or operator…

…ambrose…

Im back with more worthless garbage to shove down your throats !!! The front  is split and over laps so one side has to be held up with a couple blocks.

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures168.jpg[/IMG]

glass cloth is cut down the middle

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures169.jpg[/IMG]

The glass cloth has to be pulled over to cover the overlap.

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures170.jpg[/IMG]

The side panels are flat so they are easy to glass. I seem to allways do a perfect glass lam on the insides and then do some screw up on the outside where it shows

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures171.jpg[/IMG]

Flaws on the outside

are easier to fix.

Genius strikes again.

…ambrose…

flaws on the inside

especially in tall girls

are well concealed .

Ogre,

I'm glad to see that the resident Poi Dog, is still on duty in your shop.   More photo's, please!

Teddy the dog is kool. Ive learned to step around him and not on him!  Will put up pictures as I can. Teddy is still a young dog so I hope to have many good years with him. He is my wifes dog but I am Teddys human as he is in the shop with me every day all day, while my wife goes off to work.

Aftere cutting the sides useing templates the sheer clamps were sawed on table saw and cut to length and ready to glue.

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures173.jpg[/IMG]

sheer clamps glued and clamped to top edge of sides

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures174.jpg[/IMG]

Sheer clamp beveled with a wooded hand plane. bottom edge of plywood beveled with trim router.

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures175.jpg[/IMG]

Side panels, frames, and bottom panels were loosely fastened together with wire and a couple strap clamps

[IMG]http://i144.photobucket.com/albums/r195/Wood_Ogre/Koholo%2014%20Kookbox/markspictures176.jpg[/IMG]