Wood from old Wine Crates

A good source of free wood is old wine crates.  

If you need thin fine-grained slats for small projects, an old wine crate is a very good choice. 


The problem is taking it apart.

You need a rubber mallet and a slat of wood. Put the slat in the corner that is nailed together to distribute the force of the mallet. 
Have patience.  It is often more difficult to take something apart than it is to put it together. 

Hold up the crate and tap on the slat. 

But not too hard. 

Try not to splinter the wood.


Some old wine crates are made of bad wood, and they will shatter.  But many other crates are made of good strong pieces
.

This one came apart easily.

(Careful with those nails!)

A candle can be used to wax the nail shafts.

Then tap the point of the nail to push it out. If you wax the shaft, this part is easy.






If you want to remove a lot of nails,  here is a useful tool you can make for yourself. It is a claw to hold the nail head, made from common brackets:

It is like the claw of a hammer.  But this claw will not damage your piece of wood.


See how it works:

Clamp the claw tool to the workbench. Fit the nail head into the claw. A few taps of the rubber mallet and the nail comes out with ease.

Voila!  Free wood!  No nails, no cracks and ready to use!

These fine pieces I will trim and use to build a spice rack or maybe a bird house. 

Thanks for visiting, & come back soon. I will be discuss how to find free wood in future posts.  

    -- Tim

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SHUTTERS TO SHUT OUT THE NOISE

On a visit to Paris   I couldn't help but admire the French windows featured in the older city apartments. Look them up on Google images. You will see that they open inwards, towards the inside of the room. They are very pretty, often with window glass that comes very close to the floor. Lots of light, and a control of ventilation that typical American-style windows lack. But also, French windows are excellent at controlling noise while still allowing air into the apartment.

This is because of the reverse-megaphone effect, whereby noise is lessened by the V angle of the two shutters.

I decided this was the answer to the noise problems in my own apartment: I would build interior shutters (or volets as the French would say) to shut out the noise.

Let me share this as a visual woodworking plan. As you can see, my shutters are in 3 tiers. The lowest houses my air-conditioner. The second tier is the large shutter doors to let in the most light and air. The top tier is to vent from overhead.

Shelves separate each tier to further isolate the noise.

On the top shutters I added translucent plexiglass windows.  I would have included more windows, but cost was a big concern.

I would go into detail about how to build and mount the shutters, but every window is different. Also, there are many choices in shutters. 

 Here is the enclosure for the air conditioner.  The heavy door keeps out noise while it is not in use.


As you can see in the photo (right), I made a cutaway to allow the power line (and my DSL & phone cables) to feed out.




Perhaps my project will inspire you to design your own solution.

Here is the full set of shutters.  Like I said, this post is about the benefit of interior shutters. To sound proof a room with windows is not an option, but sound reduction is possible with shutters. Full length shutters instead of three sets will provide sound reduction even more efficiently. I chose to construct three isolated tiers simply to give myself more ventilation options.

If you have problems with noise and dirt,  interior shutters like this are worth considering. Nothing can shut out all of the noise, but these shutters have made the warmer months much quieter in this noisy city where I live.


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DIY- How to Build a Mini Workbench

I decided one day that I needed a small and very sturdy  compact workbench which could be easily moved from room to room. It features a 24 x 18 inch top with corner cutaways for fine detail work. And all it took was time and basic woodworking tools.


The top is half-inch plywood; (go for a sturdy ply that has thick, solid layers, not a delicate decorative ply.) This thin ply keeps it lightweight, and makes C-clamping of wood a whole lot easier.

Boy do I hate spending money.
All the wood you see used in this project I found in the trash. Yes, you heard that right. I live in a big city, and there are plenty of people who toss out leftover wood and cuttings. I will talk more of working with "reclaimed" wood later on in this blog.

I gathered up the following:

2x3" stud; -- 2x3"clear; -- 1x4" common; --l 1&1/8" square baluster; -- 1x12" common; --  and a piece of 1/2 inch plywood.

Do have to tell you that none of the wood I found looked very pretty? Did I care? -- No. A workbench is for work. Work ain't always pretty.

 Here you can see the shape of the top of the workbench: 
  
With my Black and Decker sabre saw, I trimmed the corners to a 45 degree angle, and cut notches to facilitate delicate work.

In the back I didn't cut the board, but left it straight in case I needed the edge to rip something. Then I gave the whole thing a cursory sanding.


In the bottom of the photo at right, I am filling the open ply edge with DAP Vinyl Spackling paste. Marvelous stuff. After it dries, give it a a sanding with a sanding bar. It's a very nice way to finish off that ugly plywood edge.

 Here I'm using a miter saw to cut and trim the 2x3" stud into the "feet." The trimmed corner makes the workbench much more "people-friendly."


This miter-saw you see here is a Swedish-made Nobex type 202. I've had it for years, and it is excellent. The thing is hand-powered, less noisy and not as messy as a power rotary miter. Not bad for picture framing too.

The braces:

I then trimmed the 1x4" pieces to 16" across, and added 1" baluster to form the bracing. Here, at right, you see I have pre-drilled and counter-sunk the holes and used 1&1/4" drywall screws to attach it to the baluster. These pieces of baluster will receive the screws which will secure it to the uprights. (Trust me, you'll see!)

By the way, all of this has been done using only drywall screws, (no glue.) 

You should sand it. Mine was done with my lovely Dewalt orbital sander. It's a good idea to smooth out rough wood to avoid splinters later on.


Here is the support structure. 

You can see how I have used a 16" piece of 1x12 as a base reinforcement, moved towards the center for core strength. It is also tied in with 1" baluster, just like the other brace (see above.)  As you can see, all braces are cut 16", they all mount on the interior, ergo the interior space measures 16".

A piece of 1x4," also cut at 16" ties together the "feet."

Along the top I have attached some pieces of 2x3" clear stock which the top will screw into. The perfect flatness of the clear 2x3" stock helps to make a firm, steady attachment, so necessary in keeping the unit strong, firm and vibration free.

If you look closely, you will see how I have pre-drilled and counter-sunk the holes for the drywall screws to tie into the braces and attach the "feet." The holes must be just slightly larger than the diameter of the screw shafts so that it connects with ease without hanging up the operation. 

I always scrape the screw threads along the edge of a wax candle before I drive them home. It makes driving screws a lot easier. If you are fussy, you can also pre-drill a finer hole to accept the drywall screws, but I only do that if I'm going into delicate stock.


Also, this is important: because reclaimed wood is rarely perfectly straight, I assembled the unit on a flat floor, tying the pieces firmly together in whatever way kept the thing most solid and firm. This may leave the finished unit with a small flaw or two, but the point here is stability, not perfection. You will be happier with this when you are tearing through tough stock with a sabre-saw and this little workbench holds its own and doesn't teeter around.

Here is the side view. Not bad, huh? I counter-sunk holes in the top to tie into the 2x3" clear pieces (shown here), and was careful to counter-sink all pre-drilled holes in general. This is not only a more attractive and tidier way of working, but the sunken heads keep the screws snug and tight.

For a paint finish, I chose Insl-X Aqua Lock, an acrylic water based sealer. I call it the "miracle paint," because it adheres to almost anything, seals out common stains, helps to waterproof your work and has such adhesion that it actually strengthens the surface of the wood. It has a fine eggshell finish and once dry doesn't look like an undercoat at all.

The finished mini-bench. 

I wiped the Insl-X Aqua Lock sealer into the grain of the wood on the top just to have a little fun beautifying the thing.




Well, from these photos you get the general idea of the design of this project, and maybe you can do your own DIY design to adapt it to your particular needs.

These small benches, BTW, are perfect for jewelry designers, and also make ideal work stands for sculpting in clay.


Later on I'll share a design for a larger, collapsible work-table I devised. Until then, have fun.

-- Tim