This weekend, while sick unfortunately with a nasty cold, I did get out into the shop to continue working on the kitchen reno, batching out drawer box parts (11 drawers (55 parts) for the kitchen, and eight drawers (40 parts) for the pantry, not including drawer faces and face frames). My rough strategy to batch out drawer box parts in as few set ups as possible, at least as I wrote out on a scrap chunk of 2x6, has been:
- Rough cut parts to length leaving 2-3 inches extra to account for snipe or tear-out.
- Rough cut part to width (for the few boards that are wider than my jointer).
- Joint one face and one edge flat/square
- Resaw the bulk of the unplaned face away, taking each part down to approximately 3/4" thick.
- Drum sand to final thickness
- Cut parts to final width and length at the table saw/miter saw
- Rabbet long-side ends (likely on the shaper, but I have admittedly not decided which tool to use yet)
- Dado all parts for drawer bottoms (again my preference would be the shaper, but I have not come that far just yet)
- Dryfit/Check for Square
- Glue-up
- Paint *(Wife's choice, I would have preferred clear coat on maple, and painting only the fronts and face frames myself)
- pre-drill for slides and install
Unfortunately, I'm not sticking to one process at a time, exactly, but taking each 12' board through parts 1-4 in a round, and then stacking them next to the drum sander (which still needs a new dust shroud built). So much for efficiency...
I took care earlier this week to do a proper set up of the bandsaw (Rikon 10-326, purchased summer 2023) via the Snodgrass method, because i figured it would be easier on the ears and on the back to run the parts through the bandsaw as opposed to taking 3/8" or so off each board in 6-8 passes through the planer. Hopefully less of a racket as well for the neighbours to deal with by running the bandsaw and the drum sander, both of which are considerably quieter than the jointer and planer. (An additional task assigned to justify the newly purchased (used) drum sander was only half in the brain as well. If my wife asks, I
need to run them through the drum sander, there's no other way!)
The bandsaw worked ok as set up, but not good enough to run this number of parts through. I have previously resawed (resawn?) oak on this saw with much nicer results while set up stock with very little tuning, but for some reason I was getting an awful lot of chatter and a rough finish out of this poplar. After some reading, I decided it was worth it to try the higher blade speed setting on the saw, so I took a few minutes to swap the belt onto the back set of pulleys. From what I read, the higher speed might be a benefit in harder woods; While I know, poplar isn't the hardest of the hardwoods, it felt like a worthy endeavor to try and run the higher blade speed.
Well the speed increase is noticeable, sounding initially like a freaking jet engine taking off. The saw levelled out but then developed an intermittent squealing sound almost immediately. I reset all of the guide bearings away from the blade, spun the wheels both by hand, played with the drive belt tension both up and down and I cannot reproduce the sound with the saw off, but it's certainly there when it's running, albeit as I said, intermittently. Against my better judgement relating to the ugly sounds the saw made under no load, I set all my guide bearings again and decided to grit my teeth through a test cut on one of the pieces of poplar... The finish quality was noticeably much nicer at the higher speed, but the sound was still ugly.
I determined that I would drop back down to the slower blade speed and see if that solved my sound issues. Alas, it did not, but that brought me to lunch, so I decided it was time to take a break. I have yet to get back out there, but I am under a deadline to get at least the first set of drawers finished here soon. I will have to spend some hours out there this week to pull the saw out into a more open area to start diagnosing, and then see where to go next with the project, because I need to have that dishwasher installed before my surgery in T-minus-6 weeks.