Sunday, December 18, 2005

Nothing Ever Goes Smoothly

In life--or in carpentry--nothing goes smoothly, all the time, anyway. After fixing my glue problem on the checkerboard, I was ready to cut the strips the other direction today. It sounded simple--just cut each strip 1.5 inches wide. I checked and double-checked my measurements. I was proud that I even remembered to add in the width of the table saw blade! And I also remembered to put the pieces on the saw with the unpainted side down, so as to ensure a smooth cut on the finished side.

Yet, despite my care, the first strip splintered at the very end of the cut. I thought perhaps I had pushed it too hard. So I was even more careful on the second strip. Second verse, same as the first. I flipped the piece with the finished side down, thinking that perhaps I had mixed up the rule in my head and reversed it. This time, not only did the end splinter but the painted finish chipped in several places. (Obviously, I had the rule right the first time.)

My next thought was to put masking tape on the cut line to minimize the splintering. After all, I read that you're supposed to do that when cutting plywood to ensure a smooth cut. Alas, that didn't help my problem one bit. So I finally accepted the fact that I was going to have to do some fancy sanding and touchup once I finished the board.

My husband suggested later that perhaps my table saw blade was just too coarse for a finer cut. Most of the time, we use it for ripping plywood. This was a nice grade of poplar. It didn't splinter on the miter saw, so maybe he's right. But it didn't do me any good tonight, since I didn't have a spare blade handy.

I was pleased, though, to see how nicely the pieces fit together to form the checkerboard. Just like the instructions said, you flip every other one, and it makes the pattern. Once I do the repairs and make the frame, I think it will look pretty good--at least for this novice.

Only one week 'til Christmas, and I have to finish the board and cut and paint the checkers. The dowels are primed, and the cutting should be easy on the miter saw. (With no splintering!) The painting, though, will take some time. I'll have to spray paint the pieces, and I'm sure it won't be easy to paint the little sides of each disc.

Somewhere during the week, I also have to sew Kate's pillow. And I never have started on my husband's gift. It looks like I may have to re-evaluate my project for him and do a different one. I'm off work this Friday--and he's not--so perhaps I can finish up his gift then. Once I do that, and polyurethane my mother's address plaque, I'll be done. With crafting presents, at least!

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