production run commenced!

Dan Noren

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the optical illusion cutting board production run has commenced! friday i picked up all of the walnut and maple at logs to lumber. yesterday i spent several hours planing them smooth. today's task is to cut all of the parts needed. the walnut is all good straight grain, and the maple has a fair amount of figuring to it. more pics to follow....
 

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today's progress. i wasn't sure if i was going to have enough short lengths of maple after cutting all of the longer lengths. but with the leftovers from ripping the longer lengths to width, i had enough. the walnut was just beautiful, but the maple had some real ugly spots, and it was fun to cut around them. but, all in all, everything is cut to length, and ripped to width. tomorrow, while the wife :blah: is in school, i can start in with gluing up the blanks.
 

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started the gluing up of the blanks yesterday, starting with the big blanks for the chevron boards. then, with the last one done, i started in with the bulge board blanks. hopefully i can start in on the smaller board blanks tomorrow.
 

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I was in bed bath and beyond sunday with my wife, she had to get some gifts.

I walked over to check out their cutting boards and prices.

I was surprised at the nice quality and good looking boards and the prices were reasonable, considering everyone has a 20% off one item or 5 dollars off a sale coupon.
 
with the bulge board blanks glued up, it's on to the angle board blanks.
 

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busy day today, started when i went to pop's right after work this morning, around 5:30, and finishing up around 8 tonight. first of all, i've a list of 22 items that i need to do, and i got about half of it out of the way today. the first task was to cut another 280 maple and walnut plugs, as i had not done a head count, i didn't have enough plugs. each board requires 120 of each, maple and walnut plugs. now i have enough. went home and caught a short nap before taking the wife :blah: to school, then caught another three hours, as she demanded that i get some sleep. after that, i went back to pop's and commenced to working on fixing the first of next year's state fair projects, a cutting board for herself as a gift for a friend of hers, and get the last of the board blanks out of the clamps. good thing i have the drum sander, as it handled the lion's share of sanding the cutting board blanks. the ones for the bulging ones, and chevron ones are quite heavy. then it was take a break, work on something else (her board), and then back to sanding. after i got her board out of the clamps, i flattened it out on the planer, then did the cuts. i then took everything inside and showed pop how the board that took first place was made. he found it quite interesting when i told him about flipping every other strip to get the pattern, then turning them up on edge (edge grain board, my first). then it was out to the garage again to glue it up and put it in clamps, and some final sanding, then a bit of clean up. can't wait to hit it again tomorrow!
 

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went right to it again. sanded until nice and smooth. then started with the cutting. started with the tapering boards, then the chevron, and finished up with the bulge boards. tomorrow the gluing up starts.
 

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still going! glued up the tapered and chevron boards. lost one of the chevron boards due to a bit of an angle that crept in and couldn't be salvaged. well, 2 out of 3 ain't bad. starting to work on the setup of the bulge boards tonight. i figure the only way to get the holes drilled accurately for the plugs is to lay out where they will go before gluing up the blank, then gluing up the blank in stages, 3 strips at a time, then glue those assemblies together.
 

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today's fun continued....
 

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spent some time on sunday night laying out all of the plug locations in the bulge boards. tomorrow i start drilling the holes, then gluing in the plugs. then its gluing up the blanks in stages, then final sanding.
 

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busy morning this morning. re-covered one of the cushions on the couch, as a hole had developed over time. then helped the neighbor (neighbour for our brit friends) with his flat tire. then poked locator holes for all 720 holes in the bulge boards. just got back from pop's house, having drilled all said 720 holes. tonight will be taken up with gluing in the plugs.
 

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Awesome writeup, Dan, Thanks! :thumb:

still going! glued up the tapered and chevron boards. lost one of the chevron boards due to a bit of an angle that crept in and couldn't be salvaged.

Can't quite picture this... :huh: Do you mean there was some slippage when gluing up? No chance of just making it a smaller one?

all 720 holes

ditto what Vaughn said... :eek:

I assume these are just on one side of the board, or are you making them double sided?

...art
 
art - just the one side.

after the wife :blah: and i got back home last night, i figured that i would put the plugs in one of the boards. now i have to find my flush cutting saw, and trim all these lil devils down. with that done, i can glue up the strips in stages.
 

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