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 Post subject: Ammunition chest
PostPosted: Sun Jun 29, 2014 5:11 pm 
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Joined: Thu Dec 31, 2009 2:48 pm
Posts: 974
Location: Cypress, TX
A couple of years ago I posted a build of two ammo chest that I made. Those have long since sold.

I have a new customer that wanted one but he wanted a copper top on it instead or the ornate ironwork that I was doing.

I have been at it for about two weeks and have a lot of pictures. I better start posting some of them now.

Here are two of the older ones I did.

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Here is the start of the new project.
As long as I was setting up to make a chest I decided I would make three of them at one time.
this is cutting to size and doing dovetails.
The bottoms are secured with walnut pegs.


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I made aromatic cedar sliding trays for all of them. It smells really good! :-D

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 Post subject: Re: Ammunition chest
PostPosted: Sun Jun 29, 2014 5:27 pm 
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Location: Cypress, TX
Next is the iron work.
Making handles.

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At this point, I started working only on one chest. I will decide what I want to do with the other two later.

Next is making the hinges, corner angles and hasp. My customer wanted only flat bar with no ornamentation.


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Drilling and countersinking lots of holes. Plus clean up.


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Drilling the holes for the handles.
Countersinking for the hinges and hasp in the underside of the lid.



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 Post subject: Re: Ammunition chest
PostPosted: Sun Jun 29, 2014 5:39 pm 
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Location: Cypress, TX
I did the copper top today. It is pretty involved. It took 122 copper nails.
After set up, I center punch through my template with an ice pick 122 times.
Then I drill through the copper 122 times. Then I drill a pilot hole for the copper nails 122 times.
The copper nails are 1" long but in this case I need 5/8" long. :shock:

So I cut 122 nails to 5/8" length. :-?

After all that, it turned out pretty good. :-D

The brass plates cover the hinges.


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This is where I stand right now.
Next is final sanding and metal cleanup.
Then on to stain (customers request) and metal paint.

I hope you enjoyed the pics. I know I always enjoy yours. :D

Zulu The Photographer


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 Post subject: Re: Ammunition chest
PostPosted: Sun Jun 29, 2014 5:42 pm 
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Joined: Sun Dec 01, 2002 1:01 am
Posts: 1225
Location: Kerrville, Texas USA
Zulu,
What a great job,
the work you do is amazing.

Duan

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Kerrville, Texas

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 Post subject: Re: Ammunition chest
PostPosted: Sun Jun 29, 2014 6:09 pm 
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Location: Skagit Co WA
What type of adhesive did you use to glue the copper to the wood, Zulu?

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 Post subject: Re: Ammunition chest
PostPosted: Sun Jun 29, 2014 6:29 pm 
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Location: Cypress, TX
DennisS wrote:
What type of adhesive did you use to glue the copper to the wood, Zulu?



Dennis,
It's just some Elmer's Wood Glue. Mostly it's to just hold everything in place until I start the next row of copper nails. I let it set about 3 hours.
Zulu


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 Post subject: Re: Ammunition chest
PostPosted: Mon Jun 30, 2014 8:40 am 
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Joined: Thu Sep 16, 1999 12:01 am
Posts: 1935
Location: Forest, Ontario, Canada
Thanks for the pics, Zulu! Nice project. I would be a bit concerned about the lid cupping since one face is covered with an impermeable barrier and the other face isn't, but that depends on the ambient humidity swings in the local environment.

Take care
Bob


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 Post subject: Re: Ammunition chest
PostPosted: Tue Jul 01, 2014 9:01 pm 
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Location: Cypress, TX
Two coats of stain and semi-gloss black on the ironwork.
Clear lacquer next. :-D
Zulu

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http://www.jmelledge.com


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 Post subject: Re: Ammunition chest
PostPosted: Fri Jul 04, 2014 11:48 pm 
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Location: Vacaville CA. USA
Very impresive work. I totaly enjoyed the photos and the process information.

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 Post subject: Re: Ammunition chest
PostPosted: Sat Jul 05, 2014 8:31 am 
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Location: ridley park, PA
The woodworking is really well done, the metal work rocks my socks. Really inspirational post and pics.

Thanks for sharing.

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 Post subject: Re: Ammunition chest
PostPosted: Sat Jul 05, 2014 11:53 am 
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Joined: Sat Sep 06, 2003 12:01 am
Posts: 2033
Location: Mountain City, Texas
Can't express the gratitude for the effort you spend sharing your works with us! You're definitely a consummate and industrious craftsman. Thank You!

Don


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 Post subject: Re: Ammunition chest
PostPosted: Sat Jul 05, 2014 1:06 pm 
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Joined: Thu Dec 31, 2009 2:48 pm
Posts: 974
Location: Cypress, TX
I appreciate all the comments!
I have long made the practice of photographing my projects. I continually send pictures of the work in progress to my customers. All of then keep a folder to stash the pictures in and all really like seeing what goes on.
Plus, I am certain that it gives some relief to someone who just made a large downpayment (50%) to someone on the internet that they don't even know.
I welcome their comments and it makes them feel a part of the process.

I always like seeing the pictures here of the work others do and want to repay in kind.
This is a good group and I think we all learn a little from everyone here.

Hopefully, I'll be doing final assembly on the ammo chest next week and will be posting more pictures.
Stay tuned. :D
Zulu

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http://www.jmelledge.com


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 Post subject: Re: Ammunition chest
PostPosted: Wed Jul 09, 2014 1:10 pm 
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Location: Cypress, TX
The ammunition chest is finished. :D :D
All the screws are slotted brass. I just can't make myself use phillips head screws in something like this.
I'm pleased with it.
Enjoy the pics.!
Zulu


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http://www.jmelledge.com


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 Post subject: Re: Ammunition chest
PostPosted: Wed Jul 09, 2014 1:50 pm 
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Joined: Sat Sep 06, 2003 12:01 am
Posts: 2033
Location: Mountain City, Texas
All I can say is WOW! The clocked screws punctuate the precision and detailed execution of a Master Craftsman's project.

Don


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 Post subject: Re: Ammunition chest
PostPosted: Wed Jul 09, 2014 4:09 pm 
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Joined: Mon Sep 14, 1998 12:01 am
Posts: 5495
Location: Tyaak, Victoria Australia
Zulu, I have a question, and its by no means a nitpicking one, just curious.
I was admiring the welds on the handles, and how neat they were done, and started wondering how they would have been
done is days of yore. Would they have been fire welded, or peened over?

Just curious, your work always amazes me.

Eric


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 Post subject: Re: Ammunition chest
PostPosted: Thu Jul 10, 2014 8:36 am 
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Joined: Thu Dec 31, 2009 2:48 pm
Posts: 974
Location: Cypress, TX
eric wrote:
Zulu, I have a question, and its by no means a nitpicking one, just curious.
I was admiring the welds on the handles, and how neat they were done, and started wondering how they would have been
done is days of yore. Would they have been fire welded, or peened over?

Just curious, your work always amazes me.

Eric



Eric,
I can only assume that a blacksmith hammer welded things together. Heating white hot and beating two pieces of metal together will form a bond.
I have never tried it.
Zulu


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 Post subject: Re: Ammunition chest
PostPosted: Thu Jul 17, 2014 1:04 pm 
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Joined: Tue Oct 21, 2003 12:01 am
Posts: 4407
Location: Northern Maine and out of the city.
Hey Z , the type of work your doing reminds me of the church steeple days of laying down copper roofs and such.
We did everything in copper standing seam and ledge work to large 6' high crosses.
Nice work man :-D


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