CNC Rigid Router
The mission: design and build a CNC machine capable of high precision, high rigidity, AND large cutting envelope of 4’x5’x1′ (1220x1530x300 mm). This project combined many skill sets, from welding to electronics and has become a true labor of love. I plan to build a dedicated web site describing the entire process from CAD and procurement to inventing new ways to solve design problems.
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Kitchen Remodel
Total transformation of a cramped builder-grade kitchen into an elegant and functional space for family and food.
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Bowtie Piano Bench
I created a special router jig (Bowtie Jig) to cut slots for dovetail splines in beautiful reclaimed maple boards. The inlays are made of Purpleheart wood for a rich contrast and high-strength joint.
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Bamboo Hut (Japan)
This Bamboo Hut was an incredible journey stretching one year of weekends and evenings atop a mountain in rural Hiroshima. I learned so much about how to build (and not build) with bamboo – an amazing and diverse material.
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Concrete Dining Table
I absolutely love this table – it looks like a thick slab of Walnut, but in fact is a wood veneer covering a 400 lb (180 kg) concrete slab. It is extremely solid and rigid.
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Thermoformer
I built this to enable other projects like molds for concrete casting and teeth-whitening trays. Turned out to be a lot of fun, and I learned that a shop vacuum works best for pulling down the melted sheet.
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LED Fog Lights for Mini Cooper
Fun project using 3D-printed housing and thick glass. These lights were super bright and effective. Inside the car, I wired two switches in series: a toggle and intermittent switch (normally on) for quick flickering to improve visibility to other drivers.
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Small Bathroom Remodel
Tile on floor and walls. Reclaimed wood ceiling from old fence. I built a custom hanging cabinet from solid wood.
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Wheelbarrow Restoration
I found a broken old wheelbarrow for free and restored it using branches from a tree in my neighborhood. After stripping off the bark, I sealed it with boiled linseed oil. I sanded off the rust and gave it a fresh coat of black paint. I also added a stabilizer plate on the legs to reduce lateral sway.
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Porch Gates
To help keep our dog from running away, I built these swinging gates for the front porch.
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OLYMPUS DIGITAL CAMERA
Bowtie Chest of Drawers
My first big piece of furniture. I used a “dovetail spline” jig to reinforce the drawer boxes. Baltic Birch plywood for most of it.
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Bandsaw Restoration
This Tomlee Tool bandsaw was originally manufactured in about 1941. I break it down, clean, paint, and restore it to service and beauty again.
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Kite Aerial Photography Rig
Super-fun project: designed and built a remote-controlled rig to take aerial photos with the help of a kite. I repurposed an RC remote control system and servos to spin and turn up & down as well as snap photos. This was during the days when film cameras were more practical and much cheaper than digital cameras. I built this while living in Japan, so I got some really nice images over Hiroshima City and Shobara areas.
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Piano Restoration
I found this old Kimball piano for $80 and refinished the exterior. I also remade the brass hardware.
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