Archive for category Hobbies

The importance of safety in everyday things

There is a reason I love building physical objects with wood. It shares many basic engineering principles of building good software. For example, planning to group similar tasks to enable as much batch processing as possible. There is the 80/20 rule as well. You can document the dimensions and cut lists for repeat builds. Even though every step in a woodworking project is pretty much irreversible, the number of “Oops” moments can be drastically reduced over a period of time, with a decent experience.

But see, a real life product differs from a software in a very critical part of the build process – the safety inspection. Even the worst software bug can’t come close to the damage caused by a physical injury from a nasty oversight. When the foldable table-cum-cabinet I was building got almost finished, I suddenly discovered a potential finger-smashing pinch hazard from what I imagined as a cool design. The table part on the right side is foldable, so that also means nearly 29 inches of leg folds back and it is hinged close to the right end of the table, right where a person might keep the right fingers when unfolding the plank. Now if the legs have no retention mechanism, they will just open with a smash as soon as the clearance is available in the unfolding process. So I need to do two things:

1. Prevention of the hazard: I added a small retention clip so that the legs will be in its place until the user is ready to unhook it.
2. Protection in case #1 above is forgotten: Added a barrier next to the hinge at the underside near the right end of the table top. This will ensure the fingers stay out of the way of the pinch zone.

Without photos, none of my words make any sense, so here they are: http://therider.posterous.com/sewing-machine-cabinet

I still have to explain the mechanisms to my friend when I hand it over to her. I will possibly make a printout to ensure anyone using it follows right procedures.

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Tetra Society of North America

As if it was destined to happen, a coworker today showed me the website of Tetra Society of North America. It is a nonprofit organization that recruits skilled volunteers to create customized assistive devices for the physically disabled.

Why did it get me so excited ? Not only do I understand the plight of the disabled, I am currently running out of ideas of what to build next in my home workshop. If I get to make some kind of assistive device, whether out of wood or metal, it will not only make practical use of whatever skills I have, it will also justify owning whatever tools I desire.

Thank you so much, Ted. I just applied for a technical volunteer position and will look forward to making some contributions in near future.

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A few old sketches

My sister on her wedding day (1998)Juhi Chawla from a magazine

Yesterday I was discussing website development with a friend when we both had a good laugh recalling how our first pages looked like in geocities. And that reminded me, I put up scans of some pencil sketches in 1999 on my geocities site. I still fondly remember those nights in my second year of college. Room B-219, RP Hall, IIT Kharagpur. Each sketch took about 7-8 hours of continuous effort, and ofcourse that meant night-outs.

I wanted to see them again. Badly. Now.

My careful backup strategies paid off with a small caveat. I located those precious scans quickly, but they are only in a web-sized version. I don’t know where the original sketches or the full size scans are, or whether the originals are in good enough condition for a re-scan, but it sure felt nice to get them back.

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New place, new woodshop

My workshop - Jan 10

We moved to a rented house in the beginning of 2010. One of my two roomies moved out of the old place, and the rent looked pretty steep, so we found a 3br house for a little less. Besides the fact that all of us craved for some open space, the 2-car garage was a pretty good motivation to move my lazy ass.

It took us no less than a week to move and set up, but now I can say that it was totally worth the labor and pain. No more stair climbing nonsense, and my garage woodshop next to the kitchen is a total bliss.

Among my tools, I have only added a wood lathe and a bandsaw. As luck would have it, the lathe was my own over a year back and the current owner would not sell it but trust me enough to let me use it on rent. Could not find a good deal on craigslist so I rented it for 6 months. Who knows if my bowl turning passion will still be active or not. The bandsaw was a great find, and it makes me feel like I got a pair of scissors to cut wood in arbitrary shapes. Pretty darn fun.

Amazing how a little more space can fire up so much energy. I have taken up a little bit of acrylic painting as well, and anxious to see where it takes me. Painted my first 16×20 canvas last week and right now making a 24×24 hardwood canvas for another painting I have in mind.

Hope the creative energy stays on for a while. More later…

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Woodwork project: Desk-side shelf

Shelf upgrade equivalent to 10GB from 1GB ! Recessed notches to prevent slip outs

I am not a neat-freak but chaos beyond a certain point seems to hurt my productivity and mental peace. My first serious woodwork project was an utility shelf, barely 6″ deep, 2 ft wide and 6 ft tall, but it served me very well for the last three years.

Recently, easy access to everyday things has been an issue, since Priti loves to do origami and by now we have a lot of them lying around. So I decided it was time to upgrade. Nice excuse to play with the tools for a few hours.

I came up with a 6 ft tall, 2.5 ft wide and about a foot deep storage with 3 fixed shelves and 4 adjustable ones. About 5 hours of back breaking labor but the feeling of extra space is so nice that it makes me compare to an upgrade of 1gb to 10gb of RAM !

For those who want to make one, here is a cut list:
1. 12″ wide white melamine panel with pre-drilled holes for shelving: 6ft x2 (I bought two 8 ft long panels since there was no 12 ft)
2. 12″ wide solid white melamine panel: 30″ x3 (bought one 8 ft panel)
3. 12″ wide pine panel: 30″ x4 (bought two 6 ft panels)
4. 1/8″ thick handypanel for backing board: 3 pieces of 24″x48″, then cut each to 24″x31.5″

I used pocket joinery and glue to fix the 3 melamine shelves first. The structure at this point is not very rigid, it can shear, leading to joint failure since melamine is not very dense. For the extra rigidity, the backing boards are glued and nailed behind. The adjustable shelves got notches cut where it sits on the metal spoons, to prevent an accidental slip out, by an earthquake or otherwise.

Oh and the total cost of wood from home depot: $80. Satisfaction of building a quality storage shelf for our daily use: priceless.

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Woodwork project: Toy riding airplane

Wooden toy airplane

One of the major reasons I love woodworking is to build things of emotional value, in this age of rampant consumerism. Handmade heirloom wooden toys are something no made-in-china plastic electronic gadget can beat in terms of value and the sheer amount of fun a kid can have.

I wanted to build classic toys since I took up this hobby in 2006. I had to wait till my friends started having kids, but in the meantime I made a bunch of furnitures and gizmos to justify my addiction for tools. I did learn enough to design according to my time at hand, and turn it into a product. The hardest part is figuring out the exact sequence of operations. It is not uncommon to do everything well and then glue on the wrong side right before the final assembly !

I got this idea from John Michael Linck’s riding airplane model. I only needed to know the exterior dimensions and I designed the parts according to my own plan. I just hope my friend’s kid finds it comfortable when she starts walking in a few months.

Building a wooden toy airplane Building a wooden toy airplane

For the curious, the wood is softwood pine. The top wing span is 24″ and the fuselage is about 28″. For the wheels I used omnidirectional casters from home depot. A jigsaw was needed to cut the curved fuselage. The round profile of the wood is done in a router after corner rounding on the drill press with a sanding drum. Joinery is mostly glue since I wanted to minimize screws on a toy. I hope it will hold.

Can’t wait to see this toy in action early next year. Maybe I will see a pilot’s logbook with imaginary flight plans very soon.

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Woodwork project: flexible platform on tripod

Homemade flexible platform on tripod

My desk at office is raised high because I often like to work standing up. The ergo folks are good and I feel quite comfortable in that setup.

It bites when working from home. My only desk being occupied by my personal laptop, the office macbookpro goes on the bed and I am in a pretty bad ergo position when sitting on my chair. I could make a wooden table specifically for work, but it would take up valuable space, and won’t still be adjustable. There gotta be a simple solution but I kept procrastinating doing anything about it. Till yesterday.

I got a light box for my color slides and got the urge to bring out my projector and enjoy viewing them on the wall. Again I faced the table issue, ‘coz the projector needs to be adjusted at the right height to enjoy a good quality show.

And then it hit me – a wooden plank on top of a sturdy tripod can work as a super flexible platform.

Quickly implemented my design at the woodshop around midnight and after the epoxy dried, it looks like it is working absolutely fine. A small piece of velcro can ensure the laptop does not slip. A bungee cord can secure the projector.

Attaching bogen quick release on a foot square board

The most important construction part here is obviously the attachment of the quick release (QR) plate to the board. Some fairly heavy and expensive gadgets are gonna be on top so I had to design this part carefully. A standard 1/4″ nut is equivalent to a standard tripod socket, and it is pretty small, so it must be installed at the center of a foot square plank very rigidly. I drilled out a 1/4″ hole and then using a forstner bit, drilled a flat bottomed hole just big enough to fit the 1/4″ nut, till just a millimeter from boring through the other side. As a result the nut could sit a mm away from the QR plate, separated by the wood. It is now secured from the bottom and sides and I poured two-part epoxy on top of it to completely lock it in place.

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Oil is beautiful

Sierras - oil

My first serious attempt in oil painting on canva-paper turned out a pleasant surprise. What an amazing medium and workability. Love the fact that I can paint right out of the tube and one color can go over another easier than in watercolor. Painting in watercolor, in comparison, seems like a minimalist approach, and quite a lot different than oil, with its own charm. I guess I will keep working on both mediums.

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New Lathe

I find myself very much hooked to woodturning by now, so I decided to have a better lathe. Thanks to craigslist I sold off my earlier central machinery lathe within 24 hours of posting an ad.

I was deciding between the Jet and Rikon mini lathes and visited the San Carlos Woodcraft today morning with Bhaskar. The shop guy recommended the Rikon for its better feature set over the Jet, and a $50 discount on the Rikon made them both equally priced. They didn’t have the Rikon in stock, but booked one for me at the Dublin Woodcraft. We drove for 40 min to go there and found it to be a bigger store. There was also a free demo of sharpening woodturning chisels by a local artisan, and it was a perfect tutorial for both of us at that moment.

Here is the Rikon model I got.

Came home with a lighter wallet but lots of anticipation to turn bunches of spindles and possibly bowls in the coming weekends. Keep checking my woodturning gallery often.

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Chessboard

Chessboard

Woodwork projects with Bhaskar are without doubt getting ever more interesting. The proof is now at hand. With a couple scrap maple and a single piece of walnut from a wood shop made this project possible in a weekend.

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