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PostPosted: Tue Oct 16, 2012 7:55 am 
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That's incredible work. Very interesting.

Thanks.


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PostPosted: Wed Oct 17, 2012 6:03 pm 
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Location: Cypress, TX
Here is what I got done today.
The 3/8" washer was heated red hot and dropped on the frozen copper rod to a predetermined place.
It's purpose is so I can tighten the rear nut and not have the copper bar slip.
Besides the copper top, the hasp is the hardest thing to get right. After installation of the tang, the copper rod is hammered over to prevent slippage of the tang.
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The handles are bolted in place. The nuts and washers are covered with a wooden facing, countersunk to accept the copper washers to hide the nuts. They will be secured with brass screws.

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The tray slides in place and trays in position. Brass screws are used to secure the slides.
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I made dividers in one side to hold 3" charges. They are easily removed in case someone has charges of a different size.
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Note the "prop pole" in the picture. When finished, the top will not open more than 85 degrees. This is intended to make the lid close unless someone was holding it open. That way it is not subject to firey debris raining down on an open chest lid. That could cause some consternation. :shock: :shock: :shock: :shock: :shock:
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Tomorrow, I go get the piece of copper for the top. The installation is a very time consuming process. It involves over 300 copper nails. Each nail hole must be predrilled with a pilot hole.
Stay tuned for these pictures. They will be cool.
Zulu


Last edited by Zulu on Sat Sep 16, 2017 2:06 pm, edited 1 time in total.

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PostPosted: Fri Oct 19, 2012 7:07 am 
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I started on the copper top.
I used a 52" X 29" piece of 16 oz. per square foot copper I got for $80.
It was my intention to take more pictures than I did but the copper installation is very frustrating and I missed a couple of pictures that I should have taken.
Here is what I got done yesterday.

The new copper sitting on the box.

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One edge of the copper clamped in place. Drilling pilot holes through a template I made.

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Copper nails installed. Getting ready to make the first bend. Bend is done with a block of wood and a mallet. Then finished with a long strip of wood and clamps to get a sharp edge.

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A different template is used to drill the side holes.

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Side holes finished and nailed, the copper is pulled over the top of the lid and glued in place.

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I should have had a couple of more pictures here but I missed my chance.
Both sides are nailed. I am getting ready to cut the copper to final length and nail the underside.

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Underside nailed. Both ends still have to be done.

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The above work took me five hours. :shock:
The ends have to bend over the curved top of the lid. It gets harder. :cry:

I'm not sure if I will work on it today. It is my birthday. I turned 60. :-? :-? :-? :-? :-? :-?
What's the deal with that? :confused: One minute you are hanging around young and dumb, and the next minute you are hanging around old and dumb. :shock:
I will have to ponder this today.
Zulu


Last edited by Zulu on Sat Sep 16, 2017 2:11 pm, edited 1 time in total.

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PostPosted: Fri Oct 19, 2012 8:52 am 
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Location: Aurora CO
HOLY COW! That's a job and a half for sure. Looking good though. How many copper nails do you go though on one of these?


Oh, and HAPPY BIRTHDAY! Take some down time and relax, you've earned it.

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Frank
WWACOAUX#1
"I love the smell of Sawdust in the morning, it smells like, victory." Image
WWA'ers I've met: Popeye, Ed Avery, Stephen Wolf, Rockfish, Rodedon


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PostPosted: Fri Oct 19, 2012 9:21 am 
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There will be well over 300 copper nails in the lid by the time I'm finished. And everyone of them needs a pilot hole. :shock:
Zulu


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PostPosted: Fri Oct 19, 2012 8:35 pm 
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My wife asked me today what I wanted to do on my birthday. I told her that I did whatever I want to everyday of the year. Today is no different. Everyday must be my birthday. :D
I went to my shop cause that's where I love to hang out. 8)

Finished the copper top. Here is how the ends came together.

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Template in place to mark the holes.

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Holes marked, drilled and nailed.

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Finished copper top.

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7 hours total in the copper top. :shock:
Now final sanding and finish.
The next pictures you will see will be the final product.
Zulu


Last edited by Zulu on Sat Sep 16, 2017 2:16 pm, edited 1 time in total.

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PostPosted: Sat Oct 20, 2012 12:12 am 
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Location: san clemente, ca
Just to have the patience to move this project along is overwhelming.

Thank you so much for taking the time to document your progress. Can't wait for the finished product.

Doug


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PostPosted: Sat Oct 20, 2012 8:42 am 
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There is still more to do. :shock:

As of right now, I have 68 hours in the project.
I still have to;
final sanding
apply finish
paint ironwork
install ironwork (about 150 screws all with a predrilled pilot hole)
polish copper top
make and install leather belts on top of the copper (used to hold tarps)
install planking on the inside of the lid to hide the ribs ( another 80 copper nails)
apply linseed oil to the interior of the box including trays and dividers
Maybe another 15 hours, making around a total of 83 hours. This will be the fastest one I have built. My first one took around 125 hours. There are untold things that have to be figured out. This is my fifth chest and I have most of the kinks worked out of the process.
It's a lot of work, but as anyone knows who has done a long project, it is very rewarding.
Zulu


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PostPosted: Mon Oct 22, 2012 11:21 am 
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Location: Tallahassee, FL
Awesome work.

I often have thought about accurately recording my time on a project. In fact, I have tried it a few times. But, after noticing the clock has been running for hours and I have yet to make any sawdust or shavings, I give up on that idea. Worried I would be too discouraged by the results.


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PostPosted: Mon Oct 22, 2012 9:53 pm 
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Thinking time definately counts towards a project. My advantage here is that this is my fifth chest. I already know what to do. I also have the benefit of my written notes from previous builds.
That really goes a long way in keeping the build hours down.
My first chest took about 125 hours to finish.
Wewill see where I end up here but I suspect it will be around 85 hours.
Zulu


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PostPosted: Mon Oct 29, 2012 2:31 pm 
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I'm Back!!

Finally got it finished! :D
84 hours total. A new record for me!
Here are some pictures.
Painted the metal work and stained the outside of the chest. I decided to stain it because I wanted to. Good enough reason for me. :-D
Pardon all the junk in the picture. I suspect most of us have a place like this. :oops: :oops:
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Installed five oak planks in the lid with 80 copper nails. This brought the nail total to over 300. :shock:

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After three coats of clear satin lacquer, the metal work went on and everything assembled. over 150 slotted head screws in the metal work each put in with a pilot hole and an old fashioned screwdriver. Never use Phillips head screws in a project where they didn't exist in the original.
Everything inside the chest was coated in boiled linseed oil. I like this finish in the inside. Maintenance is easy. A light sanding and a recoat of oil will make it look brand new again.

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Note the black hinge stop to the right of the brass plate. The stop keeps the lid from opening more than 85 degrees. It will close on it's own without the prop pole.

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My lovely assistant made this chest cover for me. It is canvas with leather trimmings and brass grommets for tie downs.

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This is the end of the pictures.
If there is anyone out there who is contemplating building a limber chest, you ought to bookmark this thread for reference. If I had some pictures like this to go with my first build, they would have come in very handy. I believe there are about 120 pictures in this thread.
This was fun to do. It isn't always easy to remember to grab the camera when you should but it was worth it to have this reference for myself.
My lovely assistant is working now to get some pictures up on my website. I will post the link when she gets it done.
Hope you enjoyed the show!
Zulu


Last edited by Zulu on Sat Sep 16, 2017 2:29 pm, edited 1 time in total.

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PostPosted: Mon Oct 29, 2012 9:27 pm 
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OUTSTANDING!!!!!!

That is an amazing build and beautiful results. Right down to the orientation of the screw heads. WOW, that is really something!!!!!!!!!!!! 8) 8) 8) 8) 8)

_________________
Frank
WWACOAUX#1
"I love the smell of Sawdust in the morning, it smells like, victory." Image
WWA'ers I've met: Popeye, Ed Avery, Stephen Wolf, Rockfish, Rodedon


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PostPosted: Tue Oct 30, 2012 7:34 am 
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Orientation of screw heads actually is not proper. Tightening a screw to the actual torque recomendation is proper.
I did it so all screw heads would shed water. A limber chest has the possibility to be caught in the rain.
Zulu


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PostPosted: Tue Oct 30, 2012 8:27 am 
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The limber chest is for sale and can be seen now on my website at

http://www.jmelledge.com/LimberChest.html

While you are there, please browse through a few pages. There is a lot of cool stuff to see. My site has over 90 pages now thanks to my lovely Web Mistress. 8)
Zulu


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PostPosted: Wed Oct 31, 2012 5:38 pm 
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I sent a link to this thread to the guy that bought my last limber chest.

Now he wants a price to build a limber. :shock:
A limber is what holds the limber chest. Six horses pull the limber with the cannon attached to it.
I have built two of them. Both at he same time.

I am still thinking if I want to do another one. They are very involved. :-?
Zulu

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Last edited by Zulu on Sat Sep 16, 2017 2:36 pm, edited 1 time in total.

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PostPosted: Wed Oct 31, 2012 6:12 pm 
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Zulu - having followed your post from the beginning, I for one don't think you're charging enough for the chest.

Phenomenal work.
Doug


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PostPosted: Wed Oct 31, 2012 6:27 pm 
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The End.
Thanks for looking.
Zulu


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