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277753 Paul Gardner <yoyopg@g...> 2023‑09‑18 Re: Moulding
Nicely done, Dan!  Thanks for the "after" photos with the after action
report putting a nice bow on the project.  This reminds me of a recent
interaction with a neighbor.  A nice, youngish couple bought a flat down
the street and I see the husband periodically with the garage door open
working on projects in his shop space.  A few weekends back, I'm down in my
shop and my wife came home saying she just stopped to chat with the
neighbor (and his father) who were busy trying to fabricate a section of
moulding to match the non-standard profile in their 1925 home.  She was
very perplexed by what she was seeing and urged me to go down and see if I
could be of any assistance.  I rolled up to find them routing the profile
of a cross section of moulding into a 3/4" board with one of those fancy
Shaper Origin handheld CNC routers.  They had done a number of test pieces
but the shape still wasn't dialed in right.  Now it was my turn to be
confused.  What's the plan, here?

Well, turns out if you make 240 of these cross sectional pieces and then
glue them end to end, you'll get a section of molding the size they need
for the job.  Holding a piece of cross section in my hand, I asked them if
they were committed going down the road they had already embarked upon.
When they answered "no", I told them how I would go about the job with a
few hollow and round planes.  After explaining what those were, they still
seemed a little dubious.  So I asked them if I could take the  cross
section back to my shop and I'd be back in 30 minutes with something for
them to look at as proof of concept.  I had a 4' piece of scrap poplar in a
suitable width and was further delighted when I realized that underneath
the heap of debris on top of my table saw, a 3/8" stacked dado assembly was
still mounted on the arbor from a project last year!  This would save me
some time towards the already over promised turn-around-time.   But I had
most of the shape accurately roughed out in under 20 minutes and then took
the project to the bench.  It took two hollow sizes, two rounds, and a
shoulder plane to get the rest of the profile dialed in.  By the time I was
done with the sanding profiles, I was only 15 minutes over my promised
delivery time - and my shirt was soaked in sweat.

I found them where I'd left them and handed them the newly minted section.
They took it upstairs and it fit in seamlessly.   I'll admit that I did
register some delight telling them how it was done and how he could
actually do most of the work in his shop with tools they had.  All they
needed was to do the H&R work on my bench and I'd be glad to show them how
and let them have at it.  They were soon to be leaving on a trip and would
be gone through Labor Day (May 1st, Jeff).  I haven't heard back from them
yet.  We'll see what becomes of it.

Paul, in SF.

Recent Bios FAQ