Construction Begins!

Well the time has come to build the cabinets! I have been staining all the pieces, though a few need another coat or two. It is amazing when everything starts to come together. I think I'm going to let the following pictures do the talking...

The cabinet was constructed with screws and not glue. This will make it easy to take apart for transport...for the time being. The grills and molding will all be glued on. So, after than, there's no plan on taking the cabinet apart.

As much as you can really see the finish line at this point, what will really bring this entire project together is the molding. As stated in the past, crown molding will be at the top, thus covering that 2-plus inches at the top of the grill. I will have molding around the bottom as well. I can't really describe it, bit it has a lip on the molding, which will make it really easy to install. While buying all this molding, I started thinking about two more visible parts of the cabinet that might need a special touch - the left and right sides.

I'll admit...I forgot to tape those edges when staining the wood black. So, naturally, there is some black stain throughout the side. Not much, but enough where the mahogany stain will not cover it up. Plus, which I didn't really think of this at first, the wood screws can be clearly seen! We can't have that now, can we!

SO, while picking up the top and bottom molding, I found a small strip of molding - the same width as the pine boards - that can run down the length of the side, thus hiding my mistakes and the screws. To modify an old saying..."[Molding] can hide a multitude of sins!

Just with this post, the next should be another big step to the completion of Opus IV. I'm in the process of starting the individual pipe design projects. More on that in a later post.

Now that I have the cabinets back at my place, I can't help but think I found a spot for both of them. Still not opposed to setting it in the corner of my apartment. However, this arrangement might grow on me.

Until next time...

Grill Master

The next step is to create the two grills, four total, for the cabinet. I created a template that fits the size of the wood and traced the design on each piece. However, a 45º chamfer needed to be cut into one side of the piece so that the two may come together when assembled. The old Dremel table saw, which I used extensively with Opus' I thru III, created this edge. No surprise, the blade was not the sharpest and didn't come out 100% clean. It's going to have to do. The most time consuming part is the design. Two weeks ago, I traced the pattern and added started holes for the scroll saw blade to fit through. I borrowed the scroll saw from my dad and set up a little work station on my patio.

After I roughed the shape, I used a hand held Dremel rotary tool with various sized milling bits and barrel sanders. The combination worked very well. The outside shape was done the same day when prepped the piece with starter holes.

Two Grills with Pattern and Starter Holes

Slowly, the grill started coming together. If you remember from previous posts, I tried to incorporate the Fleur-de-lis in the design. Now, If I used a CNC machine to route these pieces out, it would have been more uniform. However, since they have been done my hand, there are certainly dievations. But, I guess that's what gives it character.

Almost Done

Two of Four Complete!

I hope to finish the other two grills next weekend. After this, I can continue staining a few more pieces and start assembling the cabinet!! Opus IV is nearing completion. I'm hoping the finish date will be by the end of April / beginning of May.

Until next time!

Opus IV

Yes, the corner facade project will now be referred to as Opus IV. As a young fan of my blog reminded me, it is another project, so it should have an Opus number. So, how is Opus IV moving along? Glad you asked!

Since my last post, All ten (10) pipes for both facades have been restored. I'm very happy with how they came out. Now it's time to really put the pedal to the metal and finish the cabinet.

All the wood has been cut for the cabinet. This includes any holes that need to be drilled and the countersunk holes at the base plate for the pipes. As far as the the colours are concerned, I choose walnut for the case, oak for the grills and the interior will  be black.

I started with what I'm seeing now as a mistake. I started staining the main back panels the walnut colour. However, I soon realized I didn't quite know who to apply these oil based stains. First mistake was trying to wash the brushes with water. Thanks to this mistake, I had to rush to Walmart and buy some mineral spirits to clean not only the brushes, but my hand which was becoming sticker by the minute.

Right now, though not definitive, I might get new pine and re-cut these pieces and start over. The saving grace is that this walnut color on these pieces will not be seen when displayed as it will be up against the wall. However, I'd rather now do anything half-a**. I power sanded one of them down but I'm still not happy with it.

Today, I stained those parts that will be black and I'm much happier with how I applied the stain and how it came out. Some are done, some need one more coat. At the same time, the opposite side of most of these parts will need the walnut stain

Side Door Panels

Other Side Door Components with Finished Top/Bottom Pieces

Still much to do with this Opus, but it's moving along. At the same time, and not to get ahead of myself, I announce two upcoming projects. The next one will not get an opus for the basic reason as it's taking a few of the center pipes from this set and "decorating" them for friends and family. I will design each pipe unique to the person I will be giving it to. Yes, it's safe to assume that I will make one for myself. Yes, it's also safe to assume I will be using the very center and largest pipe of this set. The other three will be for my sister, my father and for my close friend, the same friend who received "Opus C." Since they are gifts, the design for the latter three will not be revealed until they are finished and presented to the respective person. However, I'll certainly document the process of mine here. For kicks, these pipes and all sorts of materials and other goodies comprise my patio closet.

The second upcoming project, which will be Opus V, uses the remaining four pipes from the set I used for Opus IV. They will be "stenciled," or painted different colors/patterns. I've been meaning to use Red Aromatic Cedar for some project and this one seems to fit the description. So, the case will be made out of this material and the pipes will reside in it. There will be a grill, also made from the same cedar boards. This Opus will not only be another aesthetic piece of art in my apartment, but it will make the place smell great. I always loved the smell of that wood! The below rendering only gives a slight glimpse of what it will look like. SolidWorks can only do so much with what I have in my head.

Opus V

I think that sums it up! I cannot guarantee a weekly update, but will certainly update this blog when I can. Until next time...

Big Flashy New Year

HAPPY NEW YEAR!! What will 2015 bring? Well, one things for sure....this project! Now...for the flashy part. I'm talking about GOLD!

Since my last post, I had finished the pipes and they are now ready for the gilding phase. This is a first for me. I've never done any gold-leafing before. So, I bought some gold sheets and appropriate materials and had a go at it.

First came the task of taping around the mouth, only leaving the area I want gilded. After this, I bought a can of size, or special adhesive, to spray in the area where the gold is to be placed.

Things were looking good. One by one, I sprayed the size and placed a sheet of gold on the mouth.

There's still a good amount of gold on the sheet after I covered the area. So as not to waste the gold, I used two half-sheets of gold for the second pipe. This did not go well. From the start, you could see that there are two sheet as there was a clear line no matter how I tried to overlap it. Being me, I went into panic mode but decided just to start again. I sprayed size over the gold, let it sit and then applied a new full sheet over the mouth. So far....crisis averted...

"Crisis Pipe"  Second from Left

When it came time to remove the tape, most of the lines were crisp. However, some are a little flaky. This is most noticeable with the one I screwed up on. Looking back, I think I should have left it to dry a little longer. However, I'm going to buy some liquid size, as compared to the spray, try to carefully re-guild those areas that are torn or otherwise need a touchup.

Certainly a step forward, an exciting one at that. But, a few corrections need to be made. Afterward, I will paint the inside mouth black, then shellac the entire pipe thus bringing it together, then insert the restored ears. I have already sanded down the next five pipes. Those pipes will need a little more TLC than these five as there are a more nicks and gashes that need to be taken care off. Most of those marks were filled in with these five. However, a few are still noticeable. I'm fine with this....makes me remember how old they actually are!

A Gentle Rain

In all honesty, I try to be witty about the title of these posts. However, there's a nice gentle and somewhat relaxing rain outside my place right now. So...I guess it's somewhat appropriate. Now...for the update.

Before I get into the main project, the side project of the two mangers are now complete. The only thing they need now is hay. However, the Christ child is not yet here...we still have a few more days of Advent left before Christmas.

My Manger

My Friends Manger

The Reason for the Season

Now...as far as the main project, some progress has been made. I bought material for the cabinet itself. However, I soon realized I didn't buy enough. So, the rest of the cutting will have to be left for another day. If it has not been said, pine has been chosen for the case.

As for the pipes, I drilled holes in the top for the positioning dowel. Silly me, I figured propping up the pipe to the drill press would be the solution...badda bing badda boom! Goes to show I've got much to learn. With my dad's wisdom and guidance, a quick fixture was made to keep the pipe secure while I hand drill the hole at the top.

Let's be honest, I'm still quite an armature. After drilling the holes, I realize they are not all at a depth of one inch as I designed in the computer model. Most importantly, the are not 100% straight into the wood. However, there is always a solution to these matters. When it comes time to secure the pipes in place, and the dowel is jutting out way under 90º from the base of the pipe, I can always decrease the dowel diameter and add a shim. This will most likely be the case. However, as of now, I'm happy the holes have been drilled.

Throughout the week, I prepped a test piece for how I am to paint and finish the pipes. I was very please with the results and learned a few things in the process. Most importantly, I know the steps I will take once I start painting the pipes. This includes the step with the gold leaf, or gilding the mouth of the pipe. I outlined a diamond on the test piece. In reality, the gilding will cover the egg shape around the pipe mouth

Yes, the picture is rotated the wrong way....but you get the idea, right?!

This now leads up to what I have been doing for the past few hours in the dark clouds and gentle rain...sanding and cleaning the pipes! (I know...so exciting!) After I sanded the first one, I looked at the metal ears of the pipe mouth, which were quite dirty as well. I used a brillo-type attachment for my Dremel sander. The results were very pleasing! However, after two pipes, there was no more brillo on the attachment. Still, since I'm so pleased with cleaning up the metal, I plan to find a few more attachments I can do that with and NOT paint those ears. Remember - and this sort of blows my mind - these pipes were made wither IN THE 1920's OR 1930's!!! Yes, I have the honor (one might say) to bring these very old wooden pipes back to life!

Compare and Contrast the Ears of the Center Pipe with the other Ears. Nice, huh?

All Sanded

After sanding all the pipes, I went ahead and placed some wood filler in some of the nicks and gashes of these pipes. This was followed by some more sanding and will be followed by a little more sanding next week before I start the painting process.

Well, I'm going to go enjoy the rest of the evening, listening to the gentle rain. Oh, I have to give a shout out to the Ibis (or what I think is an Ibis) who stopped by to say HI when I was working.

Until next time...

Advent

Though the secular world already considers it Christmas, we are still in the Advent season. We, as Christians, await for the coming of the Christ child. Advent is an awaiting, the preparation for an important person, place or thing. There is a reason I stress a more "liturgical" theme for this post because I have a little tangent project.

I have a life sized baby Jesus statues that has been passed down through my family. When I first received the statues, the manger that belonged to it was in complete shambles. So, I didn't take the original manger. This was about a year ago. Now, as Christmas approaches and I bring out that beautiful statue, I deem it fitting I throw together a manger.

I am making two, the other is for a close friend who also finds his baby Jesus without a manger. The difference, which I didn't realize in the design phase, was that mine is much bigger than his. Therefore, my manger will be a little longer than my friends. I went ahead and cut all the pieces and am still currently gluing everything together.

I'm sure by next week...the last Sunday of Advent, the manger will be ready, filled with hay, awaiting the birth of the Savior, Christ the Lord.

Now, returning to the project at hand. This weekend, I went to look at material options as well as cut the pipes down to size. I noticed that I modeled the thickness of the frame pieces at 1/2 inch. In reality, there is not wood choices that have a thickness of 1/2 in, rather 3/4 in seems to be the standards throughout all options I'm considering. So, I went back to the drawing board and made the corrections to get the new dimensions of the project. So, the only material I purchased was for the grill, which is 1/4 in hard Birch. I will eventually purchase Pine for the frame.

First, the pipes. They are solid wood. So, very simply, I measured the desired length of each pipe and hacked off part of the pipe. Here are some pictures of this process and the result:

Original Pipes

Tops Hacked Off

Final Result

So, it looks like things are moving right along nicely with this project. Next step will now be to clean the pipes and get them ready to be painted the usual silver color like all the other pipes I've done. At the same time, material for the frame needs to be purchased and cut to size.

Until next time...

Grill Design

Well...after piecing various patterns into Photoshop, I finally came up with a good one for this project. It follows my usual "flower" patter as seen on my previous opus models. However, this one displays three fleur de lis symbols.

Fleur de lis is French for Lilly flower (Flower of Lilly). The symbol became closely synonymous in the early Middle Ages for the Blessed Virgin Mary. Their are various depictions of Mary holding a Lilly. As with the three leaf clover of St. Patrick, the three pedals of this symbol is also said to represent the Holy Trinity with the band at the bottom being Mary. The tradition says that without Mary you can not understand the Trinity since it was she who bore the Son. (Information gathered from Wikipedia...what a scholar!)

This pattern will be tough to produce and will take many hours just to produce one. I see myself using various tools, such as a scroll saw, jig saw, drill press and Dremel barrel sander. I will use 1/4" Red Oak for the material and most likely seal the wood instead of painting it. This is similar to the grills on Opus 3.

I may only be able to display one of these models in my apartment. However, I am going to build two. It seems only fitting that I make the project "symmetric" so as to one day place them one day in each corner of a room, similar to a divided facade use by organ builders due to the space and placement of a pipe organ in the specific room.

Well, I should really get to sleep. I plan on buying material and cutting them to size this weekend. Until next time...

And Now for Something Completely Different...

No, it's not Monty Python's Flying Circus. However, it is a new and completely different project than what was previously described as Opus 4. Let me explain...

Lots has happened since my last post. Most notably is that I have moved into my own apartment. After moving into a new space, and settling in, thoughts of decoration come to mind. Above my couch there is an empty canvas.

Couch

A friend of mine mentioned that he had 25 fake solid wood organ pipes that belong to a reed organ that he owns. They were meant to be a false facade for the reed organ, but he is not using them. So, my first thought...what if I used them in some arrangement above my couch?

Fake Organ Pipes from Reed Organ

I soon realized that the pipes are rather large, though still manageable, for the space. The center pipe just fits the length between the couch and the ceiling. So, after some more input and bouncing some more ideas around, Maybe there is another way to utilizing these pipes. Something more artistic maybe...

My previous opus' have been scaled models...obviously. However, now I'm working with 1:1 scale. The benefit is that these pipes are fake...solid wood. This means I can cut them down to size if I so choose. The problem with this is I cannot change the diameter. Since I cannot change the diameter, I can only decrease the length of each pipe so much that it doesn't look realistic anymore.

So, I have decided to use five pipes from the left hand group of the above photo and design a corner display. It will mimic one of those center displays in my previous models. However, the difference is that this is on a much larger proportion. It will be a corner display.

Corner Pipe Display

So, this may not solve the blank canvas above my couch...but there are 21 more pipes to have fun with. Be that as it may, this display stands three (3) feet tall. The pipes are decreased to an overall length (OAL) of 34 inches. The model, itself, is rough. The grill work will look a little more "ornate." I will need to sit down and make a more elegant, yet practical, template. Not exactly sure on the type of wood used, but the thickness will be 1/4 inch. Two (2) inch tall crown molding will be on the top and one (1) inch tall molding will be at the bottom. There will also be some sort of illumination inside.

Remaining Pipes from Original Set After Corner Model Completion

As far as the pipes are concerned, they are old. I will sand them down, prime and paint them a silver color unlike the wooden brown that they are now. I'm contemplating gold leaf or something for the mouth of the pipe. However, this is still up in the air.

Well, I think that's a good update...certainly well overdue. It might not be as adventurous as Opus 4, which I would still love come to fruition one day. However, this project is more feasible, both financial and practically, for me at the present moment. As with all my creations, my Opus', it will be a unique piece of art.

I now end with a performance on a reed organ. This is now the same model reed organ that these pipes have come from. Rather, it's a larger three manual organ. For those of you who do not know, or have not guessed, reed organs are not pipe organs. They utilize brass reeds to produce the note whereas a pipe organ uses air through a pipe to produce the note. That is why these pipes are fake. They are only there as a false facade. It's the same inspiration that prompted me for Opus 1...when someone sees an organ console, a PIPE organ, they expect to see pipes! Ergo, a false facade to appease the audience even thought the music is coming from the reeds inside the console! Enjoy!