WWA Info Exchange

For Woodworkers By Woodworkers
It is currently Fri Mar 29, 2024 7:47 am

All times are UTC - 5 hours




Post new topic Reply to topic  [ 17 posts ] 
Author Message
 Post subject: Ammunition chest
PostPosted: Sun Jun 29, 2014 5:11 pm 
Offline
Veteran

Joined: Thu Dec 31, 2009 2:48 pm
Posts: 1146
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.

Image

Image



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.


Image


Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image




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

Image

Image

Image


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Sun Jun 29, 2014 5:27 pm 
Offline
Veteran

Joined: Thu Dec 31, 2009 2:48 pm
Posts: 1146
Location: Cypress, TX
Next is the iron work.
Making handles.

Image

Image

Image

Image

Image

Image

Image

Image


Image

Image



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.


Image

Image

Image

Image

Image

Image

Image

Image

Image




Drilling and countersinking lots of holes. Plus clean up.


Image

Image

Image

Image

Image



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



Image

Image

Image

Image

Image

Image


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Sun Jun 29, 2014 5:39 pm 
Offline
Veteran

Joined: Thu Dec 31, 2009 2:48 pm
Posts: 1146
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.


Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image



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


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Sun Jun 29, 2014 5:42 pm 
Offline
Veteran
User avatar

Joined: Sun Dec 01, 2002 1:01 am
Posts: 1305
Location: Kerrville, Texas USA
Zulu,
What a great job,
the work you do is amazing.

Duan

_________________
Duan Packard
Kerrville, Texas

dum vivimus, vivamus


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Sun Jun 29, 2014 6:09 pm 
Offline
Veteran
User avatar

Joined: Sat Jan 14, 2006 10:44 am
Posts: 3951
Location: Skagit Co WA
What type of adhesive did you use to glue the copper to the wood, Zulu?

_________________
Nullum Gratuitum Prandium

Cheers - Dennis


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Sun Jun 29, 2014 6:29 pm 
Offline
Veteran

Joined: Thu Dec 31, 2009 2:48 pm
Posts: 1146
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


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Mon Jun 30, 2014 8:40 am 
Offline
Veteran
User avatar

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


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Tue Jul 01, 2014 9:01 pm 
Offline
Veteran

Joined: Thu Dec 31, 2009 2:48 pm
Posts: 1146
Location: Cypress, TX
Two coats of stain and semi-gloss black on the ironwork.
Clear lacquer next. :-D
Zulu

Image

Image

_________________
Zulu's website
http://www.jmelledge.com


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Fri Jul 04, 2014 11:48 pm 
Offline
Veteran
User avatar

Joined: Thu Feb 21, 2002 1:01 am
Posts: 1375
Location: Vacaville CA. USA
Very impresive work. I totaly enjoyed the photos and the process information.

_________________
my projects

That's not a goof...It's a design feature.
Dewayne


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Sat Jul 05, 2014 8:31 am 
Offline
Veteran

Joined: Thu Sep 20, 2007 4:55 pm
Posts: 2371
Location: ridley park, PA
The woodworking is really well done, the metal work rocks my socks. Really inspirational post and pics.

Thanks for sharing.

_________________
"To all those who work come moments of beauty unseen by the rest of the world." Norman Maclean


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Sat Jul 05, 2014 11:53 am 
Offline
Veteran

Joined: Sat Sep 06, 2003 12:01 am
Posts: 2056
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


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Sat Jul 05, 2014 1:06 pm 
Offline
Veteran

Joined: Thu Dec 31, 2009 2:48 pm
Posts: 1146
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

_________________
Zulu's website
http://www.jmelledge.com


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Wed Jul 09, 2014 1:10 pm 
Offline
Veteran

Joined: Thu Dec 31, 2009 2:48 pm
Posts: 1146
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


Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

_________________
Zulu's website
http://www.jmelledge.com


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Wed Jul 09, 2014 1:50 pm 
Offline
Veteran

Joined: Sat Sep 06, 2003 12:01 am
Posts: 2056
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


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Wed Jul 09, 2014 4:09 pm 
Offline
Veteran
User avatar

Joined: Mon Sep 14, 1998 12:01 am
Posts: 5497
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


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Thu Jul 10, 2014 8:36 am 
Offline
Veteran

Joined: Thu Dec 31, 2009 2:48 pm
Posts: 1146
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


Top
 Profile  
 
 Post subject: Re: Ammunition chest
PostPosted: Thu Jul 17, 2014 1:04 pm 
Offline
Veteran

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


Top
 Profile  
 
Display posts from previous:  Sort by  
Post new topic Reply to topic  [ 17 posts ] 

All times are UTC - 5 hours


Who is online

Users browsing this forum: No registered users and 38 guests


You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot post attachments in this forum

Search for:
Jump to:  
Powered by phpBB® Forum Software © phpBB Group