Things To Make Part 1

Things To Make.

by Archibald Williams.

PREFACE.

The making for oneself of toys and other objects of a more or less useful character has certain advantages over buying them. In the case of the more elaborate and costly articles, it may enable one to possess things which otherwise would be un.o.btainable. Secondly, a home-made article may give a satisfaction more lasting than is conferred by a bought one, though it may be less beautiful to look upon. Thirdly, the mere making should be a pleasure, and must be an education in itself.

To encourage readers to "use their hands" the following chapters have been written. The subjects chosen provide ample scope for the exercise of ingenuity and patience; but in making my selection I have kept before me the fact that a well-equipped workshop falls to the lot of but a few of the boys who are anxious to develop into amateur craftsmen. Therefore, while the easiest tasks set herein are very easy, the most difficult will not be found to demand a very high degree of skill, or more than a very moderate outlay on tools. I may say here that I have been over the ground myself to find out its difficulties for my readers, and that I made an engine similar to that described in Chapter XV (the most elaborate mechanism included in the book) with very simple tools. Some of the items which I had on my original list were abandoned, because they presupposed the possession of comparatively expensive machines.

My selection has also been guided by the desire to cater for different tastes. In some cases the actual manufacture of the thing described may be regarded as the most instructive and valuable element, and may appeal most forcibly to the "handy" boy; in others--the Harmonograph provides a good instance--the interest centres round the experiments made possible by the construction of a simple piece of apparatus; in some the utility of the article manufactured is its chief recommendation.

I feel certain that anyone who follows out the pages of this volume with hand as well as with eye, will have little reason to regret the time so spent. The things made may in course of time be put aside and forgotten, but the manual skill acquired will remain. Nowadays one can buy almost anything ready-made, or get it made without difficulty; yet he who is able to make things for himself will always have an advantage over the person to whom the use of tools is an unprobed mystery.

THINGS TO MAKE.

I. A SAWING TRESTLE

A strong and stable sawing trestle is one of the most important accessories of the carpenter's shop, whether amateur or professional. The saw is constantly being used, and for it to do its work accurately the material must be properly supported, so that it cannot sway or shift. Anybody who has been in the habit of using a wobbly chair or box to saw on will be surprised to find how much more easily wood can be cut when resting on a trestle like that ill.u.s.trated by Figs. 1 to 3.

The top, a, of the trestle is 29 inches long, 4 inches wide, and 2 inches thick. At one end it has a deep nick, to serve much the same purpose as the notched board used in fretworking; also to hold on edge such things as doors while their edges are planed up. Pushed back against the wall the trestle is then "as good as a boy."

[Ill.u.s.tration: Fig I.--Leg of sawing trestle (left). Trestle seen from above (right).]

The four legs are made of 2 by 2 inch stuff. To start with, the pieces should be 24 inches long, to allow for the waste of cutting on the angle.

Cutting the Notches.--Make four marks 7 inches from the four corners of the top, set your bevel to an angle of 70 degrees (or cut an angle out of a card with the help of a protractor), and lay a leg against each mark in turn, the end projecting an inch or so above the top. Move the leg about till it makes the proper angle at the mark, and draw a pencil line down each side of the leg as close up as possible. Since the legs may vary slightly in size, use each once only for marking, and number it and the place to which it belongs.

Lines must now be drawn along the upper and under sides of the top, parallel to and 3/4-inch from the edge, to complete the marking out of the notches.

Cut just inside the side marks with a fine tenon saw, and remove the wood between the cuts back to the top and bottom marks with a broad, sharp chisel, making the surface of the cut as true and flat as you can. Then "offer" the leg that belongs to the cut, its end projecting an inch or so.

If it won't enter, bevel off the sides of the cut very slightly till it will. A good driving fit is what one should aim at. While the leg is in place, draw your pencil in the angles which it makes with the top above and below, to obtain the lines AB, CD (Fig. 2, a).

Bevelling the Legs.-The marking out of the bevels will be much expedited if a template is cut out of tin or card. It should be just as wide as the legs, and at a point 4 inches from one end run off at an angle of 162 degrees from one edge. (See Fig. 2,b.)

[Ill.u.s.tration: FIG. 2.-Showing how to cut sloping joint for trestle leg.]

Draw with a square a line, EEl, across what is to be the inside of the leg.

The template is applied to the end side of the leg and moved up till its sloping edge occupies a position in which a perpendicular dropped on to it from C is 1/2 inch long. Mark the line EF (Fig. 2, b) and the perpendicular CG. The bevel is marked on the other side of the leg, the, angle of the template being at E1 (Fig. 2, a) to guide the saw, which is pa.s.sed down through the leg just outside the marks till in line with CD. The piece is detached by a cross cut along CG, CD. This procedure, which sounds very complicated, but is really very simple, and performed much more quickly than it can be described, yields a leg properly bevelled and provided with a shoulder to take the weight of the top.

[Ill.u.s.tration: Fig.3--End elevation of sawing trestle.]

The leg at the diagonally opposite corner is an exact replica of the one first made; the other two are similar, but the direction of the bevels is reversed, as will be evident after a little consideration.

When all the legs are ready, knock them into place, driving the shoulders tight up against the top, and nail them on. The projections are sawn off roughly and planed down flush with the top. Then affix the tie C at each end, and plane its edges off neatly.

Truing the Legs.--Stand the stool on end, top flat against the wall.

Measure off a 20-inch perpendicular from the wall to the outside corner of each of the two upper legs. (Fig. 3.) Lay a straightedge from mark to mark, and draw lines across the legs. Reverse the trestle, and do the same with the legs at the other end. Then turn the trestle on its side, and draw lines on the other outside faces of the legs, using the lines already made as guides. If the operation has been carried through accurately, all eight lines will be in a plane parallel to the top. Cut off the ends of the legs below the lines, and the trestle is finished.

II. A JOINER'S BENCH.

After finishing his sawing trestle the reader may be willing to undertake a larger job, the manufacture of a joiner's bench--if he does not already possess a good article--heavy and rigid enough to stand firm under plane and hammer.

For the general design and detailed measurements he is referred to Figs. 4 and 5, in which the dimensions of each part are figured clearly. The length of 5 feet, width of 2 feet (exclusive of the back E), and height of 2 feet 7-1/2 inches will be found a good average. If the legs prove a bit long for some readers, it is a simple matter to lay a plank beside the bench to raise the (human) feet an inch or two.

In order to give rigidity, the struts S1S2 of the trestles at the end and the braces DD on the front are "halved" where they overlap the legs and front so as to offer the resistance of a "shoulder" to any thrust.

[Ill.u.s.tration: Fig. 4.--Front elevation of Joiner's bench]

Materials.--The cost of these will be, approximately: wood, 12s. 6d.; [12 Shillings. 6 Pence] bench screw, 1s. 6d.; nails and screws, 1s.; or 15s.

in all. It is advisable to show the timber merchant the specifications, so that he may cut up the stuff most economically.

If the wood is mill-planed before delivery a lot of trouble will be saved, as no further finish will be required, except perhaps at the top corners.

In pa.s.sing, one should remark that the boards used should be of the widths and lengths given; while as regards thickness the figures must be taken as nominal, as in practice the saw cut is included. Thus a 1-inch board would, when planed, be only 7/8 to 15/16 inch thick, unless the actual size is specified, in which case something extra might be charged.

Construction.

The Trestles.--These should be made first. Begin by getting all the legs of exactly the same length, and square top and bottom. Then cut off two 22-inch lengths of the 6 by 1 inch wood, squaring the ends carefully. Two of the legs are laid on the floor, one end against the wall or a batten nailed to the floor and arranged parallel to one another, as gauged by the piece C, which is nailed on perfectly square to both, and with its top edge exactly flush with the ends of the legs.

Next take the 3 by 1 inch wood for the struts, and cut off a piece 32 inches long. Two inches from one end of it make a cross mark with the square, and from the ends of the mark run lines towards the end at an angle of 45 degrees. Cut along these lines, and lay one of the edges just cut up against C, and flush with the outer edge of L1 (Fig. 5). Tack the strut on temporarily to both legs, turn the trestle over, and draw your pencil (which should have a sharp point) along the angles which the strut makes with the legs. This gives you the limits of the overlaps. Detach the strut.

The marking-gauge now comes into use. Set it at 3/8 inch, and make marks on the sides of the strut down to the limits, pressing the guide against what will be the inner face of the board. The ends must now be divided down along the gauge scratches to the limit mark with a tenon or panel saw, the saw being kept on the inside of the mark, So that its cut is included in the 3/8 inch, and a cross cut made to detach the piece and leave a shoulder. The strut is "offered" again to the legs, and a mark is drawn across the bottom parallel to the ends or the legs for the final saw cut.

Nail on the strut, pressing the legs well up against the shoulders. Its fellow on the other side of the legs is prepared in exactly the same manner; and the second trestle is a duplicate of the first, with the exception that the directions of the struts are reversed relatively to the C piece, to preserve the symmetry--which, however, is not an important point.

[Ill.u.s.tration: FIG. 5.--End elevation of joiner's bench.]

Back and Front.--The only operation to be performed on the front piece B and the back G is the notching of them both on the inside faces at the centre to take the ends of the bearer F, which performs the important function of preventing any bending of the top planks. Lay the boards together, top edges and ends level, and mark them at the same time. The square is then used on the faces to give the limits for the notches, which should be 1/4 inch deep and chiselled out carefully.

Draw cross lines with your square 3 inches from each end of both pieces, on the inside, to show where the legs are to be. Bore holes in the boards for the 3-inch screws which will hold them to the legs.

Attaching the Trestles.--Stand the trestles on their heads and lay the back and front up to them, using the guide marks just drawn. A nail driven part way in through one of the screw holes, and a batten tacked diagonally on the DD lines, will hold a leg in position while the screws are inserted.

(Make sure that the tops of the legs and the top edges of B and G are in the same plane.)

Affixing the Braces.--The braces DD, of 3 by 1 inch stuff, can now be marked off and cut exactly down the middle to the limits of the overlap.

Screw on the braces.

The bearer F is next cut out. Its length should be such as to maintain the exact parallelism of B with G, and the ends be as square as you can cut them. Fix it in position by two 2-inch screws at each end.

The bench is now ready for covering. Begin with the front board, A1. Bore countersunk holes for 3-inch screws over the centre of the legs and half an inch from the front edge, 1 foot apart. Arrange Al with its front edge perfectly flush with the face of B, and tack it in place by nails driven through a couple of screw holes, and insert all the screws. The middle board, A2, is laid up against it, and the back board, A3 (bored for screws like the front board), against that. Screw down A3.

You must now measure carefully to establish lines over the centres of CC and F. Attach each board to each of these by a couple of screws. All screws in the top of the bench are countersunk 1/8 inch below the surface. Screw the ledge E, of 4 by 5/8 inch wood, on to the back of G, with 2-1/2 inches projecting. This will prevent tools, etc., slipping off the bench.