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By Dalboy
Something new for me I am embarking on making a model Monmouthshire waggon. I will be making the wheels using felloes and not just turning the rim from a solid each of the spokes will have a round tenon. I will also be attempting some small through mortice and tenon joints which could be fun. There also will be some metal work on it as well probably brass which will be painted.

Mind you it could all end in tears

So far I have prepared the wood for most of the wheels and rough turned the naves ready to be reversed and fitted into a chuck

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All the wood for the four wheels thicknessed ready for cutting

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I took the time to make a story stick and a small drawing

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By Dalboy
Spent today cutting this lump of Oak up into rough thickness for parts needed for the wagon

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I made out a quick cutting guide marking off as I prepared each piece

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The rough cut strips of wood which meant many trips from bandsaw to surface planer to give a flat surface which to run along the fence to cut each strip. The very small piece was taken from a piece that I already had at the correct thickness for it before running the rest through to make it even thinner

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All the pieces except for the wagon flooring and side panels which I will do when the time comes, All these pieces are now at the correct thickness ready to be cut into components for the wagon. I have added the wheel parts to this to give an idea of how much is needed and to think that some of these will have up to 4 pieces cut from each of them.

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I took the time to put some masking tape on the ends and mark the thickness on it for easy identification when I start cutting out the parts

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By Dalboy
Thanks, guys. it will be a bit slow for a few days as I need to get something done this weekend so bear with me. The wheels are going to be fun as not made any like this before but with a bit of patience I am sure I will get there.
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By Dalboy
CHJ wrote:Meticulous as ever Derek, on such foundations are works of art raised.

Not that meticulous did you notice not all the wood had the tape with sizes on them someone ran out of masking tape :oops: :oops: :oops:
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By Dalboy
After a weekend break from the workshop I am back onto the wheels of the waggon. Set up the mitre saw and double checked the angles as the front wheels have 5 feloes on each wheel and the rear have 6.

I have put a 6" ruler in one photo to give an idea of size

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By Dalboy
A little more done spent the first part of the time marking out the Felloes ready for drilling holes for the staves.

Then it was onto the naves which needed turning. Even though the front and rear wheels are a different diameter the naves for front and back are the same size.
They were so easy to sand, as where normally you need to be careful sanding them to keep detail. With these it does not matter if the edges between the various diameters get rounded over.

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By Dalboy
In the morning I enjoy watching a couple of programs on the TV so I took the opportunity to sit and make some templates whilst watching these.
When I did get out to the shed I transferred these to the prepared wood and mark out for various components,
If that is not enough some parts need to have mortice and tenons cut into them, remember that some pieces are only 5/16" thick.

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I proceeded to rough cut these out and also cut some of the square pieces. I nearly have a kit of parts still plenty of sanding to bring some of these to the correct shape before marking them again to cut chamfers to the edges as well as drill holes.

From this

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To this.

Note that I have labeled different components so as not to confuse me later in the build

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By Dalboy
Spent a couple of days sanding the parts and getting the shapes correct, This involved many trips back and forth from the sanding to the plan and checking they match. I have included the first photo from my last post to help show the difference between the unsanded parts

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I have now separated the parts into smaller groups to assemble them as small sub-assemblies. These will need marking out drilling holes and cutting mortices and tenons.

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By Dalboy
Been busy today first on the list was set up a dust extractor for the bandsaw which arrived first thing this morning.

Then it was time for more work on the waggon followed by digging three rows in the veg patch, just can't do more than that.

Anyway back to the waggon all I seemed to do was drill some holes in one of the bed cross members as well as cut 4 through mortices. Most of the time was working out the best way to cut these, I went for a 1/16" drill bit held in the chuck of the drill press with only 1/2" sticking out.
I drilled the holes first then small rows of drill holes for the mortices as you would for a full sized ones with a bit of care and keep operating the handle on the drill press I was able to get a mortice with round ends and as they did square ones when the waggon was built I used a needle file to square the ends.
I still have a load more to do on the waggon, the plans suggest that if you do not want to go to all of that trouble just glue the pieces butt joint fashion but where is the fun in that.

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I've learnt on here that if you see a post by Dalboy then it's (more than) "worth a look".

Once again, work of the very highest quality Sir!

=D> =D> =D>