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A remix of the knife block

https://www.instructables.com/id/Knife-Block/

by Christian Kneull of Estlcam.com

I was going to enter this in the Remix contest but due to my wife being in hospital time got away from me.

I loved his original and this is a little more "rough and ready" but constructed without megabucks CNC mills etc, I have used tools that the home handyman is more likely to have access to, however, if anyone wants to buy me a CNC lathe/mill/laser cutter I won't say no!!

All the Ply I used was rescued from skips at work (it is old packing cases for pumps/motors etc) hence the marks and scuffs

TOOLS

I used various as I was experimenting, to find the easiest way to do each stage

But among them were

Band Saw

Dremel (various attachments)

Oscillating Saw (also known as a renovator)

Drill and various bits

Hand Fretsaw

Files

Sander

CONSUMABLES

Waterproof PVA adhesive

sandpaper/glasspape

Rare Earth Magnet

Since completing this I have bought a Scroll saw and may have a go at another one with this

Step 1: Decide on Your Pattern

Now I thought the original pattern was awesome, simple, minimal and stylish. Unfortunately my computer wouldn't let me download Christians attachment so I drew my interpretation freehand, then photocopied it a few times so I could play with it. Once happy with it I stuck it on my Ply with watered down PVA adhesive. The Ply was taped together with parcel tape (this is for the 2 outer pieces --see next step)

Step 2: Cut Them Out

Now the original plan was to cut around the heads/ plume and the pegs on the feet and shield arm first, then glue the three pieces of Ply together and cut the rest so they were all exactly the same.

Needless to say, the best laid plans etc..................

I was using 18mm ply, thus 3 layers is 54mm, unfortunately my Bandsaw will only open to 45mm so MOD1

cut the centre piece with plume, and tape the remaining 2 pieces together and cut out, then assemble.

When cutting out I would recommend drilling holes at all the tight turn areas if using a bandsaw, I didn't and got stuck a couple of times-- like I say this is all about experimentation!

Step 3: Assemble the Pieces

So eventually all 3 pieces were cut out and I glued them together.

Once dry I filed and sanded them down until they were nice and even. it took ages and I got a blister on my thumb!!! (Cue Money for Nothing by Dire Straits)

I found that the little cylindrical sanding attachments on the Dremel were pretty good for this

Step 4: Make the Base

I didn't take many pics at this stage, however I cut 2 pieces of Ply and measured out where the 2 foot pegs were going to be on one piece.

I then drilled the 4 corners and cut out the rectangles for the foot pegs with a hand Fret saw (so basically ended up with 2 rectangular holes with "bunny ear" corners on the top piece) , checked fit and filed as required.

Once Happy with the fit I laminated the 2 pieces together and gave a damn good sanding.

Although I haven't photographed it I did the same process with the shield.

Step 5: Assemble

So all sanded and glued (lots of sanding!!) I started with 100 grit, gave it a coat of polyeurathane varnish and then sanded down to 400 grit and a couple more coats.

Step 6: Fit the Magnet

Drilled a small (8mm) hole in the plume and located the Rare earth magnet, this was glued in place.

I got the magnets off TradeMe (8 for about $6)

Step 7: Cutting the Slots in the Shield

Unfortunately I didn't take any pictures of this step (tbh I was borderline going to chuck the whole thing in the bin it was so frustrating!!!)

However, I tried several different methods with various sucess

METHOD 1

Using my smallest router bit, I routed a slot, found that very difficult to control and get a decent cut, threw shield away

METHOD 2

Drill Hole and cut out with Hand Fretsaw,, result difficult to get two nice parallel cuts and need a largish drill hole to get the pinned blade in, threw shield away!

METHOD 3

Drill 3mm hole either end of slot and use Oscillating Saw to cut out, clean up edges/widen as required using Dremel grinding attachment, this worked pretty well (until the Oscillating saw blade broke), kept this one.

I then fitted the knives into the slots and "fettled" as required to get a good fit

Methods I may try if I make another one

1. Using the Scroll Saw now I have one

2. Using a Biscuit Jointer (on the 2 mating faces prior to laminating)

Step 8: And Finish

So it was then just a matter of a bit more assembly and varnish and there it is.

I learnt a fair bit, especially about tool limitations etc, however, although not as professional as Christians one, a pleasing result, just took a lot, lot longer to make than I expected.

PLEASE BUY ME A CAD/CNC MACHINE!!!!

Hey just a thought, if I can do this with a Bandsaw and some files, what could I achieve if I had a

Form 1+ 3D Printer and Formlabs Materials resin suite

VOTE FOR ME PLEASE!!!!!!

Thank you for your instruct able
very cool Eddie
<p>Thank you for presenting this without a need for laser cutters and CNC machines or 3-D printers. I once made a comment in which I mentioned I did not have access to a 3-D printer. I was not complaining, but got told I could somehow find a TechShop, none of which are within hundreds of miles from me, or I could buy one, since they are coming down in price. I was not even complaining, just mentioning that not all of us have access to the fanciest stuff. I am very thankful to have a welder now. I did not have one for my first 52 years. Even at that, I have mixed emotions about presenting projects that require welding. If I had not already made a knife block of a different design for my wife, I would be making this.</p>
<p>You should make a CNC machine Phil. It is a fun hobby. I'm making a pretty cheap one over here that should be fairly capable once I've tuned it up a bit. I went too cheap on my linear slides, so I'm in the process of upgrading them. At first I tried running skate bearings on pine wall studs. It kind of, sort of worked:</p><p><a href="http://i.imgur.com/ATX29wd.jpg" rel="nofollow">http://i.imgur.com/ATX29wd.jpg</a></p><p>(I put a pencil where the tool will go and ran a test file)</p><p>But I want it a bit more accurate than that so I just bought some steel angle to put over the wall studs. Soon the bearings will ride on steel. The bearings were digging into the wood. Hey, I tried the really super cheap method, what can I say?</p><p>Initially I wanted my whole machine to cost about $200, but now it is looking more like $400 will cover it. I think it is going to be pretty amazing when I'm done with it though. The first run was already pretty impressive to me. Enough so I had no problems going out and spending a bit more to make it better.</p>
While I have an impressive collection of power tools now, including several drills, saws of various shapes and sizes etc. I am always amused by isles that start with &quot;first take your 5 gigawatt photon torpedo laser array&quot; etc
<p>at the risk of shameless self-promotion, here is a center finder I did. As you can see in the text I was providing an alternative to one someone else did using a laser cutter. https://www.instructables.com/id/Another-Center-Finder/ It worked very well and used a little high school geometry rather than a laser cutter.</p>
<p>Thanks for your comment, I would love some of the cool toys that some of the guys have, but out here in rural NZ sometimes we are just grateful to have electricity :-)</p>
I expect rural New Zealand has many similarities to rural Iowa in the United States where I grew up. My father had a few basic handtools and a workbench with a vise. He did have an electric drill and an electric bench grinder. I had to learn to &quot;make do&quot; with materials from a scrap pile and his few tools. Doing more with less keeps a person humble and makes him appreciative later when he may get his hands on something that once was only a dream.
Very Clever. I like it.
<p>Great job! I love this project! I'm sorry you missed out on the remix contest but I'm glad you still posted it :)</p>
<p>Thanks,have posted in the formlabs comp so will see how that goes</p>
<p>Awesome remix! It's good to know these things can be done without a CNC machine! Thanks for sharing!</p>
<p>Thankyou</p>

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Bio: I am a Marine Engineer in the RNZN (39 years done in various navies) and am looking forward to retirement!!! so I can do more ... More »
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