Box section for shelving

[Screwdriver]

How much of the optimisation is done in Sketchup and how much is done manually? Haven't touched Sketchup for a very long time. For stuff like this I tend to use the linear calculator here - http://workshop-buddy.com/cut-optimization-calculator.html

The optimisation is all mine but I set the guide lines to be the length of existing stock and model the required cuts. Then I just rearrange them until they fit with the least possible waste. In this example it should be obvious the most efficient cut must be in pairs. That helped quite a bit. I also ran back out to double check my measurements because I recall leaving them long (just in case).

The web calculator you linked to couldn't do it. Might be a Mac thing but it just says can't fit...

 

[Screwdriver]

So I have dragged myself out the workshop (forge) and crack on getting this done.

Chopped up all the bits including the mitres.

Thought I'd try out my new "welding squares" (thanks @hotponyshoes).

They work well. Nice and light, nice and square with useable holes. Just seems a bit of a shame to get them dirty!

Put the top and bottom rail on the sides first.

Tack

Weld.

Done.

Now I don't know if this is the "right" way to do it (some instruction would be helpful) but I cobbled up a square, set them flush etc. and single tack one side before tapping back to square!

Fully tacked all four supports to one side then place the second side on top and held in place as shown.

Incredibly it worked and the whole "frame" is reasonably square, perfectly acceptable for what it is. A log store.

Next do the other one, sadly I won't see any helpful comments until that's done. Gonna do that now...

 

[Screwdriver]

Found the nastiest rougest piece of angle iron in the garden to make a bracket (it was almost the right size).

Boiled in citric...

Lovely.

Because it's so damned cold, brought everything into the house for marking up etc.

Drilled

Sliced

Done

It fits this way up

 

[Screwdriver]

...and it goes on here

Except it really didn't want to. Not the first combo/drill/tap thing I've broken off (cheapo Chinese version). Came out ok.

Everything being cooked up in the kitchen...

It's the bracket for a companion set though this is my set, not the proposed set which I believe is bigger.

Made a dip tank out of a found basket and some plastic sheeting. Just kept turning it over and brushing on the antiquing fluid.

Took ages but got both done, then flushed with water in the bath and dried.

Really awkward process since they needed to be immaculately clean with acetone and wire wool, then dipped, flushed and dried. Each step has to be separated from the last and I need to preserve the finish prior to lacquer tomorrow.

Just relieved it's done tbh. I have all sorts of issues with this relatively rough, scaly box section. Tying to get a nice "gun blue" finish. Does look good and much nicer in real life.

 

[Screwdriver]

Forgot to show the bracket after chem blacking...

 

[Screwdriver]

They needed to be varnished and in this weather, that means bathroom spray booth.

All went ok except the floor is now even more sticky...

Happy with the result.

Finish looks better in the flesh. The chemical blacking gives it a peacock sheen that does not photograph well.