Wooden Step (No Welding)

[Don52]

Thanks.



The top is just the glued together planking that you an purchase from Home Depot or Lowes.
It is actually 5/8" thick. I just ripped one inch wood , which is actually 3/4" thick, for the sides and the extension.

-Don...

[Don52]

I do prefer working with metal as opposed to wood.

-Don...

[Don52]

11. Biscuit installed


12. Side extensions glued and clamped


13. Front and back extensions installed and glued


14. New 9-inch-tall step
...

[Don52]

6. Dato blade


7. Wobble blade


8. Biscuit cutting machine


9. Biscuit cutter

10. Biscuit cut detail
...

[Don52]

I built a wooden step to help my wife get into bed. After she tried it out, she decided that it needed to be higher so I added a 2” addition to the step. In addition to the extension, I also added an outrigger to stabilize it if you stepped on the edge of the step. I used biscuits to attach the extension...

[Don52]

Ryan,

My customer did send me the stock that I will eventually use to fabricate the brackets that will support the drawer brackets.
He didn't send me the drawings and CAD files yet, because he still needs to check some dimensions on the boat itself.
The long bars are 36"...

[Don52]

You could be right.
It's 19°F and windy and I am still riding my bicycle outside.
The boat is now in its heated winter storage.
This picture was taken Jan 22 while the bottom of the boat was being painted.

34. Winter storage
-Don...

[Don52]

I think that I figured out where the hatch in question is located.
It is located in the lower right of the following picture.

32. Wide angle view
...

[Don52]

The brackets will support a 1” shaft that will hold two bushings that will support a drawer that will be used on a boat. The two cross drilled holes are for screws that will actually retain the 1” shaft to the brackets. The shelf and 1” shaft must be removed to access to the engine compartment...

[Don52]

Thanks,
-Don...

[Don52]

I used my Kurt vice to support the part to enable me to drill the 1/4” cross hole in the 2 inch diameter. I used my 3-D indicator to find the center of the shaft.

26. 3D Indicator


The last step was Drilling the 1/4” cross hole.

27. Drilling .25 inch cross...

[Don52]

I used a Center Drill (not shown) and a 1/4” drill to create the four mounting holes.

21. Drilling .25 inch hole


I ran into trouble when I attempted to 90° counter sink the four holes because the drill chuck interfered with the 2 inch diameter.

22. Albrecht...

[Don52]

I ran into trouble when I tried to cut the 1/8 inch radius on the corner of the flange. The tool holder interfered with the largest step of the jaw of the chuck. To solve the problem, I used a set of soft jaws, which were previously machined to a 4 inch diameter. This jaw allowed the tool holder to...

[Don52]

At this point I faced the end of the 2 inch diameter the correct distance from the flange.

11. Facing 2 inch diameter to length


The next four pictures show the steps to create the 1” hole in the center of the part.

12. Center drilling 1 Inch hole
...

[Don52]

And here is a picture of the flange at the correct diameter.

6. Flange complete


For this picture I turned the part around and grabbed the flange of the part in the three jaws of the chuck.

7. Part flipped


The following two pictures show...

[Don52]

I know that this is a Welding Forum and it is heresy to talk a customer into machining a part from solid instead of making it a weldment, but that is exactly what I did. The first two pictures are the solid model that my customer gave me of the weldment that he desired. The flange is 4" in diameter...