Gilmore Red Lion Build
03-21-2015, 11:37 AM
#252
Very impressive indeed Kevin! I wish I could post photos and videos of the machine we are building, but I think my employer and the company we are building it for wouldn't be too appreciative. We've been working on it now for over a year! A normal size project only last two or three months.
03-24-2015, 09:19 AM
#254
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Mike
I think I will have just one more table update so as to get this thread back on track with the Red Lion.
At the end of that update I will include the 78 ft elegant table just for you, a true table oficianoto
Kevin
I think I will have just one more table update so as to get this thread back on track with the Red Lion.
At the end of that update I will include the 78 ft elegant table just for you, a true table oficianoto
Kevin
03-30-2015, 03:30 PM
#256
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Well, this will be the final post on the tea cup Board Table. With one caveat. You won't be able to see this table in all its glory cause the top is glass and that won't go on until the table is sitting in its new home. So the caveat is if I can get a picture of the table in its new home looking pert, I will post that. 
Here the 3/4 mdf sub tops are on and awaiting wood edges. The infield top edge is 8 1/2 inches wide 2 1/2 inches thick. The out field edge is 4 inches wide and 2 1/2 inches thick. Keep in mind each top section is 9 ft. long.
As you can see from the above picture the infield top is only 3 inches wide. This is the top that gets the 2 1/2 by 8 1/2 log glued to it.
This top was originally intended to be loose for shipment along with the trough and the outfield top. The problem with this is, large pieces of molding when a lot of material is removed to cut the profile the molding can twist and bow. This skinning Minnie top could not by itself hold a bowed log straight. So It was redesigned. The trough became permanently mounted to the base. The skinning Minnie top was then glued to the trough. This was done to beef up the little 3 inch wide top and make this musshie edge of the trough a true radius. Further beefing up of this little 3 " top was required.
Since the wood edge hangs out 8 1/2 inches there would be a lot of leverage to tear it off the trough. So fat butt blocks were glued between the top and the base to give the top a sound wrench free footing.
In the next picture you will see the fat butt blocks cut smaller than the space. Then glue smeared shims were slide in from both sides to make a perfect fit. This was done every 2 feet or so.
This is Alex working up the outfield edge while I do the infield edge. Alex is a great craftsman with a keen mind and a desire to be the best he can be.
He also has a helpful spirit and only has to be told or shown once. Looking over his shoulder is not necessary. If he is unsure he will ask. This is his first time on a project like this and has been a joy to work with. Indecently he is one year older than my oldest daughter.
After all the top edges were glued on and cleaned up it was time to focus our attention on the glass templates.
As you look at the following pictures you will see 1/4 inch mdf glass templates on the top. In your minds eye picture 1/4 inch glass with the underside white washed. The whit coating that will go on the underside of the glass is solid, non translucent, a complete white out. The lumber edges also get painted white. The inside of the data troughs will get painted to match the stainless steel.
For purposes of holding the doors somewhat level to fit the glass templates 1/8 inch cabinet bumpers were used. For the final assembly a finer tuned method was required. Glass throws a perfect reflection so the doors have to sit true with the infield glass ring and the outfield glass ring. And adjustable door stop was needed. Nothing could be found to fit this application so we made some. 3 weeks ago while Alex was building the troughs he also fabricated some adjustable door stops. There are 30 doors so 60 stops were needed.
A couple of finer details you won't see cause the table will be in a state of disassembly when they are fabricated are the 1/2 by 3/4 Stainless Steel bar the wraps the circumference of the table behind the doors. And each of the four returns gets a stainless steel accent applied to it.
I am hopeful to get a picture of the completed table in it's new home.
If not, this concludes the Tea Cup Board Table.
I hope you have enjoyed the updates.
Kevin
Here the 3/4 mdf sub tops are on and awaiting wood edges. The infield top edge is 8 1/2 inches wide 2 1/2 inches thick. The out field edge is 4 inches wide and 2 1/2 inches thick. Keep in mind each top section is 9 ft. long.
As you can see from the above picture the infield top is only 3 inches wide. This is the top that gets the 2 1/2 by 8 1/2 log glued to it.
This top was originally intended to be loose for shipment along with the trough and the outfield top. The problem with this is, large pieces of molding when a lot of material is removed to cut the profile the molding can twist and bow. This skinning Minnie top could not by itself hold a bowed log straight. So It was redesigned. The trough became permanently mounted to the base. The skinning Minnie top was then glued to the trough. This was done to beef up the little 3 inch wide top and make this musshie edge of the trough a true radius. Further beefing up of this little 3 " top was required.
Since the wood edge hangs out 8 1/2 inches there would be a lot of leverage to tear it off the trough. So fat butt blocks were glued between the top and the base to give the top a sound wrench free footing.
In the next picture you will see the fat butt blocks cut smaller than the space. Then glue smeared shims were slide in from both sides to make a perfect fit. This was done every 2 feet or so.
This is Alex working up the outfield edge while I do the infield edge. Alex is a great craftsman with a keen mind and a desire to be the best he can be.
He also has a helpful spirit and only has to be told or shown once. Looking over his shoulder is not necessary. If he is unsure he will ask. This is his first time on a project like this and has been a joy to work with. Indecently he is one year older than my oldest daughter.
After all the top edges were glued on and cleaned up it was time to focus our attention on the glass templates.
As you look at the following pictures you will see 1/4 inch mdf glass templates on the top. In your minds eye picture 1/4 inch glass with the underside white washed. The whit coating that will go on the underside of the glass is solid, non translucent, a complete white out. The lumber edges also get painted white. The inside of the data troughs will get painted to match the stainless steel.
For purposes of holding the doors somewhat level to fit the glass templates 1/8 inch cabinet bumpers were used. For the final assembly a finer tuned method was required. Glass throws a perfect reflection so the doors have to sit true with the infield glass ring and the outfield glass ring. And adjustable door stop was needed. Nothing could be found to fit this application so we made some. 3 weeks ago while Alex was building the troughs he also fabricated some adjustable door stops. There are 30 doors so 60 stops were needed.
A couple of finer details you won't see cause the table will be in a state of disassembly when they are fabricated are the 1/2 by 3/4 Stainless Steel bar the wraps the circumference of the table behind the doors. And each of the four returns gets a stainless steel accent applied to it.
I am hopeful to get a picture of the completed table in it's new home.
If not, this concludes the Tea Cup Board Table.
I hope you have enjoyed the updates.
Kevin
Last edited by Melchizedek; 03-30-2015 at 04:01 PM.
03-30-2015, 04:48 PM
#258
Wow! Fantastic work Kevin! I'll trade you jobs if you want. We are in the middle of our inspection with the customer and my section of the machine went to hell in a hand-basket! I swear it ran perfect before they arrived. Hopefully both you and I will be reaching the end of our projects and can get back to the important work, OUR PLANES! 
03-30-2015, 05:08 PM
#259
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Mike,
This post is especially for you. The official furniture connoisseur.
This table is dear to my heart. The table above is cool indeed but this table is Elegant with a capitol E.
Elegant trumps cool in my book every time. Cool can grow tiresome. But Elegance never grows old.
The table above was a joy and a privilege. But, and this is a big but. Everything about the table above became a struggle.
There was no doubt in my mind how to proceed but every step became the hard way. For a number of reasons. No explaining it, it just was.
The trouble with the table above was, There was 90 feet of each and ever procedure and many of those procedures became the hard way.
Life just goes like that some times.
On the other hand the table below flowed like warm butter. It was fabricated under very similar circumstances. An insane deadline and insanely long hours. But it went together smoothly and gave energy along the way. TeaCup sucked energy away.
Anyway, this table was completed in Nov 2011.
I won't comment till the end and just let the pictures tell the story. I
Without further ado ...................
This last image is grainy. It is a scanned image out of a trade publication. I wish it were sharper.
There was so much left out on the presentation of the Elegant Lady. It was hard to choose what to post.
I count this project as the greatest honor I have ever had the privilege to be a part of. Warm feelings even now.
For all those who have been saying to yourself. " Where the hell is the Red Lion ?"
Well It will resume just as soon as I get over my fatigue from teacup.
Kevin
This post is especially for you. The official furniture connoisseur.
This table is dear to my heart. The table above is cool indeed but this table is Elegant with a capitol E.
Elegant trumps cool in my book every time. Cool can grow tiresome. But Elegance never grows old.
The table above was a joy and a privilege. But, and this is a big but. Everything about the table above became a struggle.
There was no doubt in my mind how to proceed but every step became the hard way. For a number of reasons. No explaining it, it just was.
The trouble with the table above was, There was 90 feet of each and ever procedure and many of those procedures became the hard way.
Life just goes like that some times.
On the other hand the table below flowed like warm butter. It was fabricated under very similar circumstances. An insane deadline and insanely long hours. But it went together smoothly and gave energy along the way. TeaCup sucked energy away.
Anyway, this table was completed in Nov 2011.
I won't comment till the end and just let the pictures tell the story. I
Without further ado ...................
This last image is grainy. It is a scanned image out of a trade publication. I wish it were sharper.
There was so much left out on the presentation of the Elegant Lady. It was hard to choose what to post.
I count this project as the greatest honor I have ever had the privilege to be a part of. Warm feelings even now.
For all those who have been saying to yourself. " Where the hell is the Red Lion ?"
Well It will resume just as soon as I get over my fatigue from teacup.
Kevin
03-30-2015, 06:49 PM
#261
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Thank you Robet, and yes it is a good feeling.
Thank you David,
I am really looking forward to that Pepsi scheme you got picked out.
Hope you get a long stretch of regular hours so you can get back at it.
Sorry to hear Murphy paid you a visit.
He lurks around every corner, There is an Eagles song "get over it" with a line that applies to Murphy.
" find his inner child and kick it's little ars" Didn't really care for the song but found that line humorous.
Soon, Steve. Soon
Kevin
Thank you David,
I am really looking forward to that Pepsi scheme you got picked out.
Hope you get a long stretch of regular hours so you can get back at it.
Sorry to hear Murphy paid you a visit.
He lurks around every corner, There is an Eagles song "get over it" with a line that applies to Murphy.
" find his inner child and kick it's little ars" Didn't really care for the song but found that line humorous.
Soon, Steve. Soon
Kevin
04-03-2015, 12:41 PM
#265
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Thanks Mike,
I knew you would appreciate the Elegant Lady.
Pete, thank you.
Different personalities is a nice perspective. Hadn't thought of it that way.
Thank you Vincent
I hope the face lift on your new place is going well.
Kevin
I knew you would appreciate the Elegant Lady.
Pete, thank you.
Different personalities is a nice perspective. Hadn't thought of it that way.
Thank you Vincent
I hope the face lift on your new place is going well.
Kevin
04-03-2015, 06:00 PM
#267
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But not much will happen this weekend cause of Easter. Much of this weekend is spoken for already.
I tend to be a weekend only most of the time builder. At the end of a work day I am usually spent.
But once in a while there is some left over for the hobby. It's kinda funny.
While I am at work I will be thinking what I will do on the Lion when I get home.
During my 35 minute commute the desire ebs away. I think it escapes out the vents
But yes, Work on the Lion will resume.
Kevin
04-03-2015, 07:34 PM
#268
Ya know Kevin, it's kind of interesting how we're both coming to the end of our big projects at the same time. Like wise I'll be getting back to my Stinson soon, that is after all the other repairs I must do to the other planes. It feels good when the long hours are finally over doesn't it?
04-09-2015, 10:10 AM
#272
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The building phase of Tea Cup was completed yesterday. It is now in the hands of the finishers.
It has been a long grueling 8 weeks. So I took today and tomorrow off.
So this morning I worked on the cowl plug.
This first pic is where I left off some weeks ago.
That top layer was then sanded to the plane of the sides.
Then an opening disc was cut and on outer donut was cut.
The disc was used to center the donut then the donut was spot glued down.
Then the center disc was removed and the cowl opening was cut into the foam.
Then the center disc glued down to make a floor for the opening.
I then made a sanding block the profile of the cowl. I had planned on shaping the outer profile and the inner lip all at once.
This was a mistake. The inner lip part of the sanding form gouged the inner lip part of the foam. When I realized no matter how carful I was this wasn't going to work,my inner lip was toast.
This pic of the sanding form is slightly altered. It originally had a more defined lip. I ground it off, to little to late.
The little foot near the lip did its job. It was to stop the sanding. It would rest on the disc once profile was cut.
A coat of epoxy was applied to the bullnose. Once that sets up I will build up the decimated lip with some filler and sand in the profile.
Also you will notice the foam is a little over sanded at the middle plate. It will be filled and re shaped.
It's good to be back on the Red Lion.
Kevin
It has been a long grueling 8 weeks. So I took today and tomorrow off.
So this morning I worked on the cowl plug.
This first pic is where I left off some weeks ago.
That top layer was then sanded to the plane of the sides.
Then an opening disc was cut and on outer donut was cut.
The disc was used to center the donut then the donut was spot glued down.
Then the center disc was removed and the cowl opening was cut into the foam.
Then the center disc glued down to make a floor for the opening.
I then made a sanding block the profile of the cowl. I had planned on shaping the outer profile and the inner lip all at once.
This was a mistake. The inner lip part of the sanding form gouged the inner lip part of the foam. When I realized no matter how carful I was this wasn't going to work,my inner lip was toast.
This pic of the sanding form is slightly altered. It originally had a more defined lip. I ground it off, to little to late.
The little foot near the lip did its job. It was to stop the sanding. It would rest on the disc once profile was cut.
A coat of epoxy was applied to the bullnose. Once that sets up I will build up the decimated lip with some filler and sand in the profile.
Also you will notice the foam is a little over sanded at the middle plate. It will be filled and re shaped.
It's good to be back on the Red Lion.
Kevin
