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> My chest freezer collar for keggerator, The latest idiocy from Stout_fan Labs
stout_fan
post Nov 24 2006, 08:12 PM
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I've, been inspired by the rest of you guys, over here so now it's my turn.
"About bloody time" some of my friends are saying.
So here's to seven more brews on tap. (IMG:style_emoticons/brewboard/biggrin.gif)
And ten more pounds on my midsection. (IMG:style_emoticons/brewboard/blush.gif)
I actually did an iso drawing of the thing, but I still haven't found time to get my scanner working.
Initially I was just going to throw the taps on the center like every one else does. Hey, it works!
I was inspired by this concept-
(IMG:http://photos.eibner.dk/2005/03-27/.cache/640x480-IMG_8062.JPG)

Plus I use the top of the freezer as my rifle cleaning station. Banging a handle and turning a faucet on while yanking the cleaning rod through the bore is a real possibility. So the end station looks like a good idea.

I purchased a bunch of Red oak from the local sawmill. Today I cut most to length, and ripped a few to finished dimension.

I also built a 2 1/2" thick plywood grid to keep my planer sled from curving. A curved sled will give you a horrible snipe. So here's the final output of today's work:
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/Collar_cut_wood.jpg)

"Great" I hear you say. "A bunch of lumber sitting on a table saw. Woopie!"

OK, I'm sorry it doesn't look like much now. Hopefully when I get it fully assembled, it may look a bit better. (IMG:style_emoticons/brewboard/wink.gif)
I'll try and persuade Bitjock at work to scan my hand drawn ISO for me. That way you can see where I'm going with this.
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gnef
post Nov 24 2006, 08:42 PM
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nice. definitely keep us updated with pictures!
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stout_fan
post Nov 25 2006, 09:46 PM
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Thanks gnef,
Well I thought I'd just try photographing the dang plan sheet. Ya know, those digital cameras are pretty good!
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/01-plans.jpg)

I did the concept two ways. The right side is fancy blind dovtails holding the thing together. The left side is plain jane with Kreg pocket holes. I like the dovetail concept, but there are two considerations against using them.
1. Time. I'd like to finish the woodworking this week, not next month.
2. When the freezer blows and the replacement isn't the same size, and I dump the collar, those dovetails are going to look pretty silly.

But I kept the dovetails in the collar to hold the upper and lower sections on. I just had to do SOME joinery!

Anyway, you can see the back plate that protects the handles from "accidental activation" (IMG:style_emoticons/brewboard/wink.gif)

The lower section houses the drip tray. I have another sheet with dimension calculations on it, but it isn't pretty.

So the first job was to cut the female dovetails in the collar. Here's the seet-up with a stop limiting the dovetail depth to 5"
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/05-dovetail_stop.jpg)

And here I am cutting the female dovetails in the collar.
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/04-f-dovetails.jpg)

And then you cut the males taking 1/16" at a time to prevent tear out-
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/03-m_dovetails.jpg)

Behind my finger is the backer board to support the cross grain cut. Otherwise the bit takes a major chunk out of the end of the board.

And the finished pair-
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/06-dovetails.jpg)

I cut the vertical sides ( I really ought to number the pieces in the drawing to reduce confusion) out of one piece. I cut that piece equal to the combined height of the top and bottom section, plus 2" extra for allowance for screwing up the dovetails. Yes I did need some of that extra length for a "do over"

So here's a concept of how the final cut went-
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/08-pieces.jpg)

The great part about the Incra stop is that you can adjust it to clear part of the dovetail for setting cutting length-
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/07-cut_to_length.jpg)

And then you just flip the piece around, the stop maintaining the distance for a perfect cut. Remember the female dovetails were cut to 5" long? Well, this next shot shows cutting off a section of the dovetail so it isn't to long for the collar.
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/09-dt_length.jpg)


Yep, ya gotta love Red Oak.
And not a speck of Pine (IMG:style_emoticons/brewboard/biggrin.gif)
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stangbat
post Nov 25 2006, 09:52 PM
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I like the protection for the handles. Plus it gives an area to put the info of the beers on tap. The build in drip tray is a great idea too.
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gnef
post Nov 25 2006, 09:59 PM
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that looks excellent. i wish i had that woodworking skill. i just drilled shank holes through the door of my top/bottom fridge to make it into a kegerator. haha. very nicely done though!
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frankw
post Nov 25 2006, 10:03 PM
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That's going to look great! Keep the pictures coming.

Frank
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cavman
post Nov 25 2006, 10:08 PM
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Nice fence on the TS, like the homemade featherboard as well it looks a twin to one of mine. Great router table, must be a lift.
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wermerj
post Nov 25 2006, 10:25 PM
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The pics are great. I wish i wasn't living in a 1 bdrm apt or id' figure out a kegerator. alas, its bottles for me.
Is woodworking a hobby or a profession? from the pics it looks like you know what you're doing.
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Beer4Life
post Nov 25 2006, 11:17 PM
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Wow, I think that the guy who built out cabinents could learn a thing or ten from you. Keep on keepin on
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stout_fan
post Nov 26 2006, 09:12 AM
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QUOTE(cavman @ Nov 25 2006, 10:08 PM) *
Nice fence on the TS, like the homemade featherboard as well it looks a twin to one of mine. Great router table, must be a lift.
Thanks, the fence is an Inca micro adjust. And you guesed right that is a router lift, and sweet it is -
(IMG:http://www.woodpeck.com/media/mainprl.jpg)
I went with the 32 pitch threads, but I think the 16 pitch would be better. It takes forever to adjust the height, and you really don't need .001" vertical increments. .002" would work just as good.

Actually I bought the featherboard from Peachtree for $5 at a wood show.



QUOTE(wermerj @ Nov 25 2006, 10:25 PM) *
... Is woodworking a hobby or a profession? from the pics it looks like you know what you're doing.

Thanks, but it's just a hobby. Presently I'm designing TV transmitters for a living.

This post has been edited by stout_fan: Nov 26 2006, 09:15 AM
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cavman
post Nov 26 2006, 01:29 PM
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QUOTE(stout_fan @ Nov 26 2006, 09:12 AM) *
Thanks, the fence is an Inca micro adjust. And you guesed right that is a router lift, and sweet it is -
(IMG:http://www.woodpeck.com/media/mainprl.jpg)
I went with the 32 pitch threads, but I think the 16 pitch would be better. It takes forever to adjust the height, and you really don't need .001" vertical increments. .002" would work just as good.

Actually I bought the featherboard from Peachtree for $5 at a wood show.
Thanks, but it's just a hobby. Presently I'm designing TV transmitters for a living.

That sure is a sweet lift, my feahterboards are free just use some scraps and in a couple minutes you can have any size you desire.
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stout_fan
post Dec 1 2006, 06:20 PM
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Back again,
I had time to glue up the lower back of the tap box. The piece is marked as K.
It is 14 1/2" high. It also had to be planed down to 5/8" thick. I decided to put a glue joint on the two boards, and join them to look as best as possible.

Here's the router bit and its next victim. It was jointed face down.
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/11-glue_joint.jpg)

Adjusting the height slightly, and turning the second board face up, You run that one through the same bit.
It is a good idea to have a piece of scrap to run through to be sure you have it adjusted to the correct height.

So here are the finished pair.
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/12-glue_joint_mate.jpg)

I had to jog the second cut up and down .006" to get the tongue a bit thinner to fit into the slot in the first piece.

More to come...
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automobiliben
post Dec 4 2006, 10:45 PM
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Grr, I am jealous of your wood working tools. The old lady says that I can't get any till we move out of the townhouse and into a place with a basement. Keep the updates coming, that looks great!
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stout_fan
post Dec 4 2006, 11:30 PM
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QUOTE(automobiliben @ Dec 4 2006, 10:45 PM) *
Grr, I am jealous of your wood working tools. The old lady says that I can't get any till we move out of the townhouse and into a place with a basement. Keep the updates coming, that looks great!

Thanks, without a basement or a garage, it's a bit hard to do this in the living room and keep SWMBO sane.

The embarassing truth is I still haven't given much thought on how to hang the regulators yet. (IMG:style_emoticons/brewboard/blush.gif)
To quote Harrison Ford- "I'm making this up as I go." (IMG:style_emoticons/brewboard/omg.gif)

So I left off with a glue joint, the only real joinery in this project other than the dovetails.
Anyway, today is a lesson in how to not do things. And hopefully a skillfull covery from a disaster.

If that doesn't glue y'all to the edge of your seats, I'll resign my superglue concession. (IMG:style_emoticons/brewboard/tongue.gif)

Here's the basic concept, we start off with a template cut in masonite to guide a router to make that curvy thing at the top of the side pieces (parts E & F). After rough ( and I do mean rough) cutting on a bandsaw sanding the template smooth on a spindle sander.
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/13-sanding_template.jpg)

So I use double stick tape on the backside of the template-
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/18-tape_up.jpg)

And stick it to the next victim-
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/14-whaat_not_to_do.jpg)

Piece of cake eh?
Easy as pie. Just use the template following bit in the router table to remove all that is not template (please excuse the DaVinci reference, I'm not anywhere close to being in his league (IMG:style_emoticons/brewboard/smile.gif) )

Only one problem: The experts say to cut it down so only 1/8" of stock remains beyond the template.
Template, Shemplate, I've got 3 1/2 horses of router that can remove anything INCLUDING body parts!
What's the problem? Well in 2 words: Climb cutting.

OUCH! (IMG:style_emoticons/brewboard/sad.gif)

Grabbed the work and made short work out of dileaneating the grain structure of the wood-
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/15-and_why.jpg)


Above the ragged edge, you will see my NEW curve profile.
I did it for art's sake. That's my story and I'm sticking to it!

So here's how much I had to "reprofile" for "asthetic" reasons.
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/16-new_line.jpg)

And cutting out the piece roughly allowing 1/8" of stock removal, LIKE YOU ARE SUPPOSED TO DO!
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/17-right_line.jpg)

And guess what? It worked like it was supposed to-
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/19-proper_routing.jpg)

The problem is that after the wonderful "success" of the first attempt I was a little gun shy and was slow on the feed rate-
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/20-results.jpg)

Yep, I burned the wood. (IMG:style_emoticons/brewboard/blush.gif)
So I got it right on the second attempt.
here they are-
(IMG:http://img.photobucket.com/albums/v225/stout_fan/chest_freezer_keggerator/21-finished_tops.jpg)


And as far as the burn?

That's what they make sandpaper for! (IMG:style_emoticons/brewboard/tongue.gif)

edit- corrected plans pic to have updated piece identifiers.

This post has been edited by stout_fan: Dec 4 2006, 11:43 PM
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Japhmi
post Dec 5 2006, 01:46 PM
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QUOTE(automobiliben @ Dec 4 2006, 10:45 PM) *
Grr, I am jealous of your wood working tools. The old lady says that I can't get any till we move out of the townhouse and into a place with a basement. Keep the updates coming, that looks great!

My wife's dream for Christmas a present this year would be a router to go with the table saw I got her for her birthday.

Wifes who love power tools (IMG:style_emoticons/brewboard/inlove.gif) . There's nothing better.
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