Hello to all!  Just thought you might like to hear my progress.  I did
get some great messages from you all with my last entry and I really
appreciate them all.  In one of the messages I had someone refer to
a wind chest and problems getting the dividers to come out square, so
I thought I'd share this with you.  If it sounds too confusing, sorry.

My Wind Chest

I have the parts cut out for the Melody Violins, but have put them by
the side for a while; I'm getting so many pipes that I need somewhere
to put them.  Instead of just buying some storage tubs, I decided to
build the wind chest and mounts.  This way I can have something to look
at while I work!

I read over the plans(?) again and tried the method described by the
drawings.  A notched front and back edge with the dividers inserted
into the notches.  I planed the material down to the required thick-
ness.  Then pondered the way to cut the notches.  I tried to get
exactly the 1/4-inch thickness of the dividers with my dado blade,
but had no luck in matching.  So, instead I cut one notch into the
front edge exactly 1/4-inch deep.  Then took some scrap maple and
planed it down to match the thickness of the saw cut.  I then cut this
to 1/4-inch high so that it just matched the depth of the saw cut.

From the drawings that I had to redo to get correct (I'm not going
into that now), I measured from the left side of the first notch to the
left side of the next notch and marked then cut the next notch one saw
blade thick.  I then stuck the piece of maple into the first notch.
Then I set the second notch onto the saw blade and ran my miter push
up to the front material.

I clamped the front edge material to the miter and slid it back
till it was well back from the blade.  I then used some cyanoacrilate
glue ("ZAP", I use it in my model airplanes) and stuck the small piece
of maple to the saw table (I have a cast iron table on the saw).
I proceeded to cut the next notch by simply moving the previous notch
onto the little maple piece.

I continued until all the notches were finished.  These notches are
only 1/8 inch thick.  I returned to the first notch marked it and
widened it with the saw to 1/4 inch wide.  I then inserted a piece
of 1/4" X 1/4" maple into the slot and glued it to the table saw table
in what I thought was the right spot.  I recut the rest of the slots
stepping over onto the 1/4" maple piece until they were all done.  Oh,
I did do the process to the front and back pieces at the same time.

I then laid them onto each other expecting to see two pieces that
were mirror images of each other.  Wrong! -- It didn't work!  Well,
there went several hours of work.  I sat down and pondered the
situation, and then I remembered the method I use to space wing ribs
on some of my models.  Yep, I'm gonna go on. :)  Now, here's how I did
it an got it to work and even come out square!

I planed two pieces of maple to 1/4 inch thick, cut them to 1-5/16"
wide and 36-7/8" long.  At the same time I planed enough material
for the dividers and about 4 foot of extra material.  Using a square,
I marked the wind chest top with a reference line square to the front.
I then glued an end piece to it cut to the proper length.  Then I glued
on the front and back being sure they were straight and square to the
end piece (I also drew a reference line for the back piece).  Using the
other end piece I checked the space in between the front and back in
several places to be sure nothing was too tight for the dividers to fit
into.

While this was drying, I cut about 100 little spacers from the extra
maple I had planed.  These were cut to match the width between the
dividers.  After the front, back and one end piece were set up, I began
inserting the dividers and spacers, using very slow drying epoxy.
When all spacers and dividers were installed, I put two pipe clamps
running from the end that was already glued in place to the loose or
uninstalled one.  I then cranked down the clamps adjusting them to
keep the dividers square to the front and also compressing the spacers
to eliminate any gaps or excess epoxy.

There, I have it -- A very nice, square wind chest top with dividers!
I know I probably haven't explained this so anyone else can understand
it, so if you would like clarification on anything just drop me a note.

Randy Charles
http://club.in-touch.net/home/rcharles