Author Archives: diy

Mini Projects

Cheap Storage Shelves – Installing low cost shelving the easy way

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I’ve installed shelving using two different bracing methods, each having their pros and cons. The first method uses factory-made metal utility shelf brackets, the other, homemade wood shelf brackets.

The advantage to the metal utility shelf brackets is that they consume less space (if you use the cheaper ones) and they’re typically more aesthetically pleasing.

Homemade wood brackets consume more space, but are typically stronger than their factory-made metal counterparts (unless you use the more expensive metal brackets with an angled support bar).

wood bracketWood Shelf Brackets

To create wooden brackets, purchase an appropriately sized two-by piece of lumber from your home improvement store. If you’re putting up 14″ shelving , purchase a 2×12. The amount of lumber you need will depend on the number of brackets you need. Using a 2×12 for an example, if you need 10 brackets, you’ll need about 5ft. of lumber. Since you’ll be cutting triangles, a single ft. of board will create two brackets.

Use a miter saw to make alternating 45 degree and straight cuts until you have enough brackets. If you don’t have a miter saw, grab an angle finder for about $10.

To hang your homemade wooden brackets properly though, you’ll need to pick up some metal joist hangers. These essentially “cup” the wood bracket and provide tabs on the side which you can drill into.

Hanging Brackets

metal shelf bracketIn either case, metal or wood brackets, you’ll have to find a stud to screw into to support the weight of the shelf contents. Once you start driving your first screw, it may hit you that a stud is only 1-1/2″ wide and the screws on the metal brackets are about 1-1/4″ apart. The holes on the joist hangers are even further apart.

There are a number of tricks to dealing with this, but the one I like is simple, drive your screws at an angle towards the stud. You can get away with using a standard 1-5/8″ drywall screw for the metal brackets. But, for wood brackets that require joist hangers, I’d suggest using at least a 2-1/2″ screw to cover the greater distance and ensure a strong hold. Just be very wary of any wiring that might be behind the walls when using longer screws. The reason drywall screws are 1-5/8″ is because that’s typically a length that won’t poke into a wire that runs through the middle of a joist.

Once you have the brackets attached to the wall, you’ll need to drive screws up through the bracket, into the bottom of the shelf. You’ll need to go through bottom of the shelf to ensure that the screw head has good contact with the bracket. If you only have drywall screws available, and they end up sticking through the top of the shelf, you can knock the tips off with a hammer, the screw will snap fairly easily after a couple light blows with the hammer.

Shelf Material

For utility shelves, I use MDF board. It’s cheap and has a nice smooth surface that’s easy to paint. It also doesn’t expose an unsightly rim of individual plies around the perimeter of the shelf piece. Though, If you’ve ever need to wear a dust mask while cutting, this is the material to use it! MDF creates an enormous amount of dust when cut.

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Exterior and Landscape

Vinyl Lattice – Install and forget

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How many times have you wanted to spruce up your home or garden but didn’t want to deal with the maintenance that comes with it? Vinyl lattice is an excellent product that can be maintenance free if installed properly.

Before I detail how I prepped and installed my vinyl lattice, let me just point out a couple things:

  • It seems that most manufacturers recommend installation with staples. I used very long finishing nails, which supporting the lattice just fine.
  • It is also recommended that you “protect” any unfinished vinyl edges (where you have made cuts) by attaching a strip of wood. I did not do this, but instead opted to support the vinyl in a small dirt trench.

Cutting the Lattice

So you have this 32 sq. ft. sheet of wobbly vinyl, how on earth are you going to cut this in a controlled manner?!

When I originally starting researching this, I came across a few posts that suggested adding strips of wood to the lattice, then sending them through the table saw. What a hassle!

photo 1The easiest method of cutting vinyl lattice is to grab your circular saw, reverse the blade, and cut away! The reversed blade prevents the teeth from “chopping” through the vinyl, instead allowing the smoother surface of the blade to somewhat “melt” through it.

vinyl lattice supportThat’s simple enough, right. The next trick was figuring out how to position the lattice so I can run the circular saw blade across it. I decided to support the vinyl lattice on three 2x4s, evenly spaced on the ground. This would provide enough clearance for the circular saw blade.

This ended up producing very clean cuts, not to mention giving a little attention to the unused edge on my circular saw blade!

Fastening the Vinyl Lattice

Manufacturers suggest using staples, but that seems like overkill. You be the judge though, if your lattice will be vulnerable to strong weather conditions or other forces, staples will beat nails any day of the week.

I went with finish nails for two reasons: I had them already and their really easy to use!

finish-nail-lattice

How much lattice do I need?

You can do the math, or just use our lattice calculator to figure out how much lattice, how many finish nails and even how many cuts, time required and cost!

That’s it!

I might point out though that the lattice isn’t meant to cover imperfections. You might think that the tight diamond pattern would draw attention away from any marks or imperfections in the surface behind the lattice. It doesn’t. Spend a little time cleaning up the surface that you’ll be apply the lattice to beforehand.

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Refinishing

Stripping paint

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I set out to strip the 30 year old paint on my front porch today thinking that, with the help of a chemical stripper, it would be as easy as erasing a chalkboard. Well, it’s not!

The Paint Stripper

Spray Stripper

I started out with a spray stripper. This product came in a 1/2 gallon can, along with a small plastic spray bottle. When I saw it at home depot, I thought it was way too good to be true. Turns out I was right.

  • It was not as strong as the much thicker, gel-style stripper, which can’t be sprayed
  • Because it was so thinned down, it often ricocheted off of the wood surface and back on to me (not a huge issue with the protective clothing, but it’s still worth noting.)

Gel-style Stripper

 While this may not be the most common name for this type of stripper, I use it because it reminds me of the difference between regular wood stain and gel stain. It’s much thicker, and needs to be applied with a brush.

  • Takes more time to apply, but works faster and stronger than spray stripper. At the end of the day, the job went faster with gel stripper. Typically, I let the gel stripper sit on the wood for about 15 minutes before attempting to scrape the paint off.
  • It does “eat” your paint brush. Be sure not to use your favorite horse hair paintbrush to apply stripper. It will make the bristles very soft and unusable for painting. Purchase a dollar paint brush from your hardware store.
  • Wear gloves. Even when I was being extremely careful, I found it difficult to avoid getting small amounts of stripper on my hands and arms.

The Scraper

Once the stripper had enough time to work on the old paint, it was time for the muscle work, scraping the paint.

Putty Knife

I had started scraping the paint with a putty knife. That didn’t last long. My arms tired quickly and I found myself having to reapply stripper simply because the putty knife wasn’t sharp enough to get under the paint.

Plastic Scraper

The plastic paint scraper was only $2 and worked surprisingly well. It also has a small “ledge” to help catch stripped paint as it falls off of the wood surface, making it easier to collect it in a waste container.

Metal Paint Scraper

It was a close match, but I think the metal paint scraper outperformed the plastic one by a bit. You might wonder why. The metal paint scraper actually “gummed up” after just a couple strokes. For some reason the paint, once removed, would adhere to the blade area of the scraper. So, after every two or three strokes, I’d have to remove the paint from the blade.

My suggestion is that you purchase a plastic and a metal scraper, as there certain areas that worked better with one or the other.

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Platform / Storage Bed

Bed Frame Electrical – Adding Outlets

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I knew adding outlets to the bed frame would give “power naps” a whole new meaning, so I couldn’t resist!

Before we dig in, let’s start with a disclaimer:

I am not a licensed electrician. I'm familiar with the National Electric 
Code (NEC), but do not by any means know or understand all of the codes within. 
Some codes are specific to your town or state. I don't make any claims to the 
safety of the my installation methods, nor that they fully comply with the NEC.
This post is meant as an inspirational guide only and should not be acted on 
without consulting the NEC or a qualified and licensed electrician.

The NEC’s primary concern is safety, so I’ll attempt to offer safe installation methods. I do, however, encourage comments from professional electricians where something could or should be done differently. Give me your worst!

Rough Electrical

The first step was to determine which electrical box would be suitable for this project. I unfortunately could not locate a plastic box that was shallow enough to prevent the mattress from resting against it. I did find a 4×4 metal box though, but we are required to ground it.

electrical box openingAfter determining that the 4×4 metal box was the way to go, I used a jigsaw to cut a 4″ x 4″ opening in each frame side. You’ll want this opening to be flush to the 2×3 stud in the rear, so you have something substantial to mount the box to.

From my understanding of the NEC, since you are putting the box inside a wooden opening, it needs to be perfectly flush with the surface of the frame. If putting a box in drywall, you are afforded more flexibility.

I used wood screws to secure the box to the frame, being unable to site a specific code that disallows wood screws (it may exist, I just couldn’t find it).

Securing the wire

In this step we’ll secure the wire going into the box and also ground the box. For the power feed to the box, I choose replacement power cords from Amazon. They are 14/3 cords, so they’ll work with a 15 Amp electrical outlet.

I am not certain that this type of sheathing complies with the NEC for use in a furniture project, so you may wish to double check that.

wire cable clampUsing a replacement cord allows us to “plug” our bed outlets directly into a home outlet. The first step is to punch out one of the knock out holes on the back of the metal electrical box, then insert a cable clamp in it’s place. The exact part you’re looking for is a 3/8″ saddle connector.

Once you’ve done that, insert the unsheathed end (which has the 3 wires hanging out) through the clamp and into the box. When you screw the clamp down on the wire, be sure that it is completely clamping onto the sheathed part of the wire. In other words, the black outer sheathing should completely pass through the clamp.

wire stapleThen, be sure to secure the wire along the bed frame with staples. The NEC does have guidelines on this. Last time I checked, you had to staple within 8″ of the box itself, then every 4 feet. I stapled every 12 inches since it’s such a small run. This is extremely important, not only for code, but to ensure that the drawers don’t hit the wire as they slide in and out.

You don’t need to crush the wire with the staple, just enough to keep it somewhat snug against the frame.

Depending on the length of your replacement cords, you may choose to install the power strip first, so you can make sure it’s in a location that’ll be accessible to both replacement cords. You could, optionally plug both replacement cords directly into a wall outlet, but I chose to install a power strip directly on the bed frame, then plug that into a single wall outlet.

Finish wiring

Now for the tricky part. Here’s another reminder that I’m not an electrician and am not fully aware of the most recent revision of the National Electric Code. Proceed at your own risk and consult the NEC whenever possible.

electrical box adapterI decided to add one switch and one outlet to each side of the bed, hence the 4″ square electrical box. The switch will control the lower of the two outlets.

Before you get started, we’ll need to add an adapter to our metal box, which allows us to attach the receptacle and switch. The adapter plate shown to the right just screws directly to the box.

After that, make sure you have a green grounding screw attached the box (if using a metal box). If you’re looking at the box and notice a “bump” in the back of it, that’s where the grounding screw goes. You can purchase grounding screws at your hardware store. I did not have one handy, so I just grabbed one from a spare electrical outlet.

separate outlet remove tabIf you’ve ever looked at a receptacle, you may be wondering how you can have a switch control only one of the outlets. Most outlets have a “tab” that we can grab with a pair of needle nose pliers and remove, which essentially separates the outlets electrically. We only want to remove the HOT tab. The neutral (white wire) tab needs to stay intact (otherwise we’ll need to run two neutral wires to the outlet).

Once we do this, we’ll have to supply power (black wire) to each outlet. One black (hot) wire will come directly from the power source (replacement cord). The other black wire (hot) will come from the switch. This guide may help:

 

From Replacement Cord:
Ground Wire (unsheathed copper):  Goes to metal box itself, switch and receptacle (green screws).
Hot Wire (black): Goes to upper outlet and switch.
Neutral Wire (white): Goes to receptacle (just one outlet, since we did not remove the tab).

From Switch:
Second Hot Wire: Goes to lower outlet.

You’ll need wire nuts to connect the wires together. My advice would be NOT to use the ones with “wings” that assist in turning the nut. These take up a lot of room in the box. Go with the “wingless” wire nuts.

After you’re done with the finishing wiring, screw on your outlet wall plate and test your finished work!

This completes the platform bed post. Carry your bed components to your bedroom, screw them together, and enjoy!

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Platform / Storage Bed

Installing the Bed Frame Drawer Components

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The magic behind drawers is their ability to slide in and out of their frame. Did I just blow your mind? The idea seems simple, but it’s one of the more difficult aspects of a cabinet or furniture project to pull off. The drawer can be difficult to open and close if the drawer box isn’t cut to the proper size, the shims aren’t of the proper thickness or the drawer isn’t level.

At a high level, putting drawer slides on a drawer is a two step process:

  1. Attach one half of the drawer slide to the drawer itself.
  2. Attach the other half to the frame (the opening that the drawer will sit inside of).

Before I do anything, I typically place the drawer inside the frame and just get an idea for approximately where I’d like the components to be attached.


For my projects, I almost always go with a 22″ Accuride Full Extension Slide Self-Close Slide. Accuride has been recommended by more than a few professional cabinet makers, so I trust them for just about all of my projects. The price is a touch steep, at about $15/pair, but I think you’ll find it to be a bargain when you compare them against the lower end “wheel guided” slides.

drawer-glide-releaseBefore beginning either of the two steps above, you’ll need to separate the two halves of the glide. There’s a lever that you’ll pull, which allows the two halves to come apart, as shown to the right.

On the Accuride, this level is labelled “release”. Simply pull down in the direction of the arrow, then pull the two sections apart with just a little force.

Step 1: Attaching the Drawer Slide to the Drawer

We’ll start with the first step above, attaching the one half to the drawer itself. The piece with the “release” label is the one that we’ll be attaching directly to the drawer side. Once you’ve decided where you want to place it on the drawer, make a note of that measurement, as you’ll want to reproduce it on all drawers to ensure they are at the same finished height.

I typically drive three 3/4″ wood screws through the drawer glide and into the side of the drawer. Most recently, I was lacking 3/4″ wood screws, so I simply grabbed my bolt cutter and lopped the end off of some 1 5/8″ drywall screws, to get them down to 3/4″.

installing drawer glide

You’ll want to make sure that the end with a 90 degree angled piece is flush against the back of the drawer panel, otherwise, the drawer will not completely close.

I usually perform this step on all of my drawers before proceeding to the next step, to ensure that I keep consistent distance from the bottom of the drawer.

Step 2: Attaching the drawer slide to the frame

This is the step that takes time to master. In your first attempts, you’ll be able to get the drawer slides to function, but perhaps not as smoothly as they should. The 2×3 nature of the bed frame project will make it even more difficult as it take a lot more effort to make 2×3 frames square than traditional cabinet stock (3/4″ hardwood or plywood). Don’t be discouraged, and certainly don’t count the project as a failure if your drawers don’t slide in and out like a factory-made piece of furniture.

The first step is the attach the outer half of the drawer slide to the frame, as shown below. I typically use 3/4″ wood screws, but since the weight rating on these slides is only 100 lbs, I’ve also felt comfortable using 1 5/8″ standard drywall screws (they’re pretty “skinny”). The front of the slide should be inline with the finished surface of the frame, so the drawer closes snugly.

attaching drawer slides

Repeat this for all of the drawer slides, making sure they’re all level and at the same elevation as each other (to ensure that the drawer fronts line up vertically).

Remember that your drawer opening should be 1 1/16″ wider than the drawer itself. If it is wider than it should be, you can insert a shim to fill the gap. Plywood of varying thickness makes great shimming material.

drawer shim

Once you have all the slides in place, push the drawers into the slides you’ve just attached. You may need to give a little force on the initial entry, but afterwards, it should slide relatively smoothly within the tracks.

finished drawer glides

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Installing the Bed Frame Drawer ComponentsBonus Tips & Tricks

This post has a Tips & Tricks section to supplement the main article above.
Like, Tweet or Google+ this page to see these tips.

Platform / Storage Bed

Finish coating the platform storage bed

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You may call it lacquer, shellac or varnish. I refer to it as polyurethane. Why I choose the most difficult word to spell or pronounce, I’m really not sure! Either way, polyurethane is a varnish,  a resin dissolved in a liquid and applied to wood (or other materials). It’s pretty amazing stuff. It goes on easy, is relatively cheap and protects for years to come.

So, why do we finish coat our wood projects? I’ll answer that question with both fact and example. The example comes from our own home, many years ago. At the time, we not only had no experience in refinishing hardwood floors, but also no money. We rented the sander, re-stained the floors and put on a coat of polyurethane. That’s right, a single coat. Never, ever apply only a single coat of polyurethane to anything! This is what happens after only 2 years of regular foot traffic on our floors:

Single polyurethane coat

So, other than preventing physical wear on your wood components, why else is polyurethane a wonder-product?

  1. Reduces long-term UV damage (helpful if your finished product will be exposed to natural light – such as by a window, etc.)
  2. Resistance to water.
  3. Easier cleanup.
  4. Resistance to oils.
  5. Easy to apply and inexpensive.
  6. In most cases, it’s food safe once fully cured (unless it comes in contact with products that would dissolve it, such as alcohol).

Applying Polyurethane

There are numerous methods to apply polyurethane to wood. I have experience only with lambswool applicators and foam brushes. A lambswool applicator is ideal for finishing large surface areas, such as a flooring installation. It is larger than a traditional foam brush and can be attached to a pole to make it a little easier on your back.

I find using lambswool applicators a bit difficult on smaller projects, not to mention expensive if you can’t finish the job in one day. That being said, I usually opt for cheap foam brushes.

Unless you’re experienced, it’s a good idea to make sure your work piece is parallel to the floor when your applying the polyurethane. Even the thinnest of coats can run if left at the mercy of gravity. Apply a uniform thin coat using the foam brush, then let it dry for a few hours. I usually give it a whole day to dry between coats, but if you are in a hurry, you should be okay to sand after 4-6 hours.

What’s that? I need to sand after the first coat?

Yes. That’s the short answer. It seems counter-productive to run sandpaper over that perfect coat of polyurethane you just applied, but believe me, it’s worth it.

Some people will tell you that it’s not worth the time to sand between coats, as there’s no way to evenly create scratches for the polyurethane to sit by sanding. But, we’re not just doing it improve the bond (which it definitely does do). We’re also doing to sand down any imperfections or dust particles that made their way into the previous coat.

sanding sponge

On hardwood floors, I usually go with a 220 grit as a finer grade won’t make much of a dent on such a large scale. For smaller projects, I use 320 or 400 grit, to ensure that I don’t remove too much of the previous coat.

After you’ve sanded, let the dust settle for a couple hours, than run a tack cloth across the entire surface.

tack cloth

That’s it, you’re ready for the next coat!

How many coats?

This is subjective of course, but there’s a big rule of thumb. The more wear and tear you expect, the more coats you should apply. On walkable surfaces such as hardwood floors, do not go any less than two coats. We make it common practice to apply a minimum of four coats.

For projects in which light wear is expected, two coats may very well suffice and last you the rest of your life.

But, never, ever call your project complete with just one coat. I’ve done it before and have never learned a more cosmetically disastrous lesson!

polyurethane platform bed

polyurethane drawers

 

Polyurethane Tips

  1. When you empty your pockets to buy that $40 gallon of polyurethane, take steps to keep it free of contamination by pouring a small amount into a disposable container for use. This is important especially if you’re using a foam brush, as pieces of foam tend to make their way off of the brush and into your polyurethane container (not to mention dust and larger wood particles).
  2. If you were going for a flat finish, don’t be alarmed when it looks bright and shiny right after application, that’ll go away!
  3. Don’t forget those “invisible” areas. If a portion of your project will be unseen, it still may make sense to apply polyurethane, especially if stain has made it’s way onto that unseen area.
    Stain can be absorbed into any surface it comes into direct contact with, especially carpeting. So, be sure to cover it with polyurethane, if it is isn’t visible.
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Plumbing

Dishwasher water supply line installation

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I’ve seen it done a few ways – “hard” plumbing with copper all the way up into the dishwasher water supply fitting, PEX tubing, and flexible tubing installations. I personally have run copper all the way up to the dishwasher in the past, simply because I didn’t have flexible tubing on hand. When a dishwasher component broke a couple years later, I had to cut the copper to get the dishwasher out. PEX tubing really isn’t any better, it’s still rigid enough to require, at a minimum, disconnecting it from the dishwasher to pull the appliance out.

The best solution, in my opinion is a flexible line. Vinyl is a good material for this, and you can find vinyl tubing in 10 foot sections at just about any hardware store. I went with the braided vinyl tubing for extra strength, though that’s probably overkill.

If this is your first shot at a plumbing job, you may be wondering how we’re going to connect vinyl tubing to our existing copper water lines. And, whether or not it’s going to involve sweating a fitting on the copper with torch and solder. We’re going to do this without solder, for about $20, including the vinyl tubing.

Parts needed:

  1. Barbed male adapter for the dishwasher female fitting – 3/8″ to 1/2″. Check your dishwasher, mine required a 3/8″ male fitting, yours may be different. My home depot did not carry these in brass, so I went with a plastic one.
  2. SharkBite 1/2″ female adapter
  3. Barbed male fitting – 1/2″ to 1/2″.
  4. Two stainless steel clamps (to fit the vinyl tubing).
  5. 10ft. vinyl tubing

Tools required

  1. Screwdriver
  2. Hacksaw or copper pipe cutter

The job is a lot simpler than it sounds. If you have a pipe cutter handy, great, just cut the copper supply pipe as close as you can to the dishwasher. Otherwise, break out that hacksaw and try to make a straight cut. Luckily, SharkBites are a little more forgiving than solder, so do the best you can. A plumber will tell you to sand the end of the pipe after you cut it, but to be perfectly honest, I have skipped this step before and haven’t had any problem. If you are sweat fitting the adapter onto the copper – sand it down, with out a doubt. They sell little round wire brushes that fit right over 1/2″ pipe to make easy work of this.

Beyond that, just have a look at the image below for guidance.

dishwasher supply line

Your next step will be to connect to you dishwashers water inlet. As I stated above, my model sported a 3/8″ inlet, so be sure to get a barbed fitting that will step down to 3/8″.

dishwasher-water-supply

Tips

  1. You may think you can get away without the stainless steel clamps, and you can, for about 10 minutes! It may not be the first or second time you run your dishwasher, but sooner or later when the water kicks on, the un-clamped vinyl will slip right off the barbed fitting, leaking water at full throttle in all directions.
  2. Leave about three extra feet of vinyl tubing coiled up underneath your dishwasher, in your cabinet, or in your basement. This will come in handy when you need to pull out your dishwasher for maintenance. Maintenance happens, especially with modern dishwashers and all their fancy components. We’ve had our dryer vent break recently, a component not available on older dishwashers.
  3. Be sure to cut the vinyl tubing straight to prevent leaks. You can do it with a utility knife, but using tree branch clippers works even better and cleaner.
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Platform / Storage Bed

Wood staining your finished project

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If you’re an intermediate woodworker, skip this post. Why? Because I have nothing to offer those who already have some experience staining wood. My staining skills are intermediate at best and, if I had the budget, I’d pay someone else to stain and top coat my projects.

Nevertheless, I have learned a few things over the years as I struggle to become a decent wood finisher. While this post is in the context of the platform bed project we’re working on, it applies to any solid wood or plywood project.

can of paintThe platform bed has a significant amount of visible plywood face (none of the plies or sides are visible), so I had to make sure I used a plywood with a decent grain. The other option, of course, is to paint. I prefer paint as it’s much more forgiving of your level of wood craftsmanship. In my case though, the rest of the furniture in the room is stained, so we wanted a consistent look.

Tacking on the few things I learned in the bed project, here’s my cumulative (albeit limited) knowledge on the art of staining:

  1. Stain is thin. It drips, flicks, flies, sprays and splatters. If you’re using a foam brush, move it slowly from the stain can to the work piece. Foam brushes don’t absorb the stain as well as a rag does, so it will make its way off of the brush easily.
  2. Start at the top and work down. Stain, being thin, drips very easily. By starting at the top, you can do cleanup as you stain the lower pieces.
  3. Gel stains are one way around the “drippy” nature of stain. I have not had great success with them though.
  4. If possible, put your work piece parallel to the ground. Working on a flat surface almost eliminates runs (on reason why spraying cars is so difficult).
  5. If using a brush, use as broad a stroke as possible to even the distribution of the stain.
  6. When staining wood floors, old t-shirts work great to spread the stain, and you’ll be surprised at how easy it is.
  7. You don’t need a new foam brush each time you stain. If your staining efforts will span many days, wrap the brush in a plastic bag when you’re done. I’ve had brushes stay flexible for almost two days when wrapped tightly.
  8. Foam brushes are cheap, they don’t last forever. After a few uses you’ll find that the handle will dislodge from the brush. Never start a staining project without a spare brush handy. If you don’t have a spare and your brush breaks, it can be glued back together temporarily with wood glue (believe it or not).
  9. Before you stain, it’s good to vacuum off your project, but even better to run a tack cloth across all surfaces to pick up any residual dust.
  10. If you don’t have a tack cloth, I’ve heard of folks that apply heavily diluted varnish or turpentine to a rag to create a poor man’s tack rag.
  11. If stained using two different methods – wiping and no wiping. With the wiping method, I’ll let the stain sit on the wood for a few minutes (to let the thinner evaporate), then wipe it off. With the no wipe method, I keep running the brush along the surface until the stain is evenly distributed, then I leave it. Both have worked well in the past.
  12. If you absolutely have to leave a dry edge, make it jagged, feather it out, or gradient it down. If you stop and leave a solid line, it will be very noticeable.
  13. Use a respirator. They are cheap, and it’s not worth the headaches you’ll have without one (not to mention other more serious problems). I personally use an organic vapor respirator.
  14. Stain goes a long way – I’ve never need more than one quart for any given project. Don’t buy two cans unless you have a very large project.
  15. Do not over sand if you are staining, Sanding creates nice “grooves” for the stain. If you sand any finer than 180 grit, you start eliminating the grooves necessary to hold stain.
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Workshop / Tools

Extension cords from above

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Until today, my basement workshop was an obstacle course. Woodworking requires a good amount of power tools, many of them handheld and powered by extension cord. So naturally, I had a few extensions cords running across the floor. As if that wasn’t enough hazard, I noticed that one of them had been sliced through halfway, most likely by a tool that I had laid on top of it.

Beyond the hazards, it’s just plain inconvenient to work with extension cords lying across the floor, as the wrap around objects and get caught on just about everything.

I was at home depot today getting supplies and just happened to come across the retractable extension cords. I had seen these before but never really wanted to spend the money. Well, I was in the right mood today. For just $25, I now have a retractable cord hanging from my workshop ceiling that sports 3 outlets.

While I was at the store, I had to make an assumption though, one that I verified once I returned home. That assumption was that all of my hand tools were under the maximum load that the retractable cord could handle. I had purchased a 16 gauge cord, which is even smaller than the lowest household circuit, typically now only used for lighting – the 14 gauge.

It’s important to verify this, as the 16 gauge cord was only capable of support tools that require less than 1600 watts. Any more than that and two things can happen:

  1. The tool sustains damage over the long term as it can’t grab the power it needs.
  2. The cord overheats.

Naturally, you save a good deal of money when opting for the 16 gauge retractable extension cord. Even moving up to a 14 gauge put me in the $65+ range.

When I got home to install, I also realized that I had lent out my wood boring bit, so I could not run the extension cord that leads from the retractable cord to the wall outlet through my floor joists. I decided to temporarily run it across the bottom of the joists as shown below.

Arguably, this is against code, or at least would be with household wiring. The National Electric Code is concerned with safety above all, and does not allow for smaller gauge wires to be run across the bottom of floor joists unless protected. Perhaps that are concerned with people bumping them, or worse, hanging something on them!

So, at least temporarily, I’ve replaced one hazard for another. If you are going to do this, do it right and drill holes through your floor joists for the extension cord. Or, better yet, put an outlet in next to the retractable cord.

retractable-extension-cord

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Platform / Storage Bed

Sanding the Bed Frame Components

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People have written books on sanding & finishing, so I can’t even scratch the surface (pun intended) in this post. If you’ve never sanded wood before, I hope this will be enough to get your started. I suggest you continue your reading on the topic from other sources though.

In the previous steps of our bed frame project, we’ve put together the face frames and drawer front, then attached them to our plywood backers or drawer boxes. Unless you’re a machine, you’ll find that this process lead you with slightly “uneven” joints. If you’ve clamped properly before attaching the components, you can reduce this. In my case, however, I had purchased stock from two different suppliers. One supplier had planed the boards down to 7/8″, the other 3/4″.

power hand planerIf I were smarter, I would have planed the 7/8″ board down to 3/4″ with my thickness planer. I missed this detail though, and am left with a couple face frames with very uneven joints.

If you have this issue, or have ever had to sand down a considerable thickness of wood, you know how painstaking it is! We’ve introduced the thickness planer but clearly we can’t pass our entire face frame through it. My suggestion, before your first round of sanding is to purchase a cheap, powered Hand Planer, and run it along your stiles that don’t line up.

If you do end up using a hand planer, don’t be frightened by the rough finish it leaves on your wood. The next step is to sand down your components with a heavier grit sandpaper, I usually start with 60 grit. Sandpaper is expensive, especially if you purchase it in 5 packs at your local big box store. Try getting a bulk 25-pack online. I usually buy my sandpaper from hardware world. Their shipping prices have gone up a little bit lately but if you buy 2 or 3 packs, you’re still way ahead.

I like to sand my face frame stiles first, to the point that they are flush with the rails they are perpendicular to. Then, I continue to sand the rails. I use this approach because you usually end up leaving “cross-grain” scratches on the rails after sanding the stiles to bring them flush. This brings us to one of the most important techniques in sanding – sanding with the grain of the wood.

If you have a wood floor at home, think about how it might look if you dragged a metal object across it and created a huge gouge, perpendicular to the direction of the wood, and across many boards. That would be pretty noticeable, right! Now, consider that the gouge runs with the direction of the wood, far less noticeable.

sand with wood grain

The same principal applies in sanding with the grain of the wood. Sanding makes miniature scratches, and you want the scratches to go in the same direction as the grain to minimize their appearance.

sand hardwood edgesBefore we switch to a finer grit sandpaper, take that 60 grit and run it along any edges that might come in contact with human hands. It’s sounds funny, but wood is sharp, especially hardwood. If you’ve gone with a shaker-style look as I have, the edges will be sharp as a knife. I’ve actually cut myself on my cabinet drawer fronts, trying to open them before they had handles.

For this reason alone, I like give one or two passes with the 60 grit along the edges of my drawer fronts. In the case of this bed project, consider doing the same for the headboard and footboard face frames. This will not affect the appearance that much and can save you and/or your children from a painful hardwood attack!

To finish your sanding job, you may want to run another finer grit paper along your surfaces. Heavier grits tend to leave visible tracks in the wood, so are more ideal for “rough sanding”. However, don’t go too smooth; the smoother the wood, the less apt it is to retain stain. You want scratches, they hold stain, but just enough so they aren’t visible. I typically finish my wood projects with 120 grit sandpaper – hand sanded. Do you need to hand sand the final pass? I don’t know, it just seems like a nicer approach, one that ensures every movement of that sandpaper goes in the direction of the grain.

But wait, what about all that sanding dust? Sanding dust is one of the reasons I moved my workshop to the basement – it covers everything like a winter snowfall. What’s worse, is it takes hours for that dust to settle, so it has quite a bit of time to travel.

You can make a pretty rough door out of 4×8 sheet of plywood, put it on hinges and throw a latch on it. That’s both too much work and too permanent for me. I opted for a shower curtain, which goes up and comes down easily. See my post on using a shower curtain to contain workshop dust.

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