Kyserike Kraftsman

Well I didn’t get the rest of the trim added to the carcase this weekend as I had planned. I had a small problem trying to glue and clamp the vertical corner trim pieces because I didn’t have the correct clamps available, but after some trial and error I decided to glue the corner trim pieces together first as a unit, let them dry thoroughly and then attach them to the carcase corners. Yesterday I glued up the individual corner assemblies and tonight I attached the four assemblies to the carcase corners. It’s drying now (sorry no photo).

This weekend I also received some of the hardware that I will be using. I ordered a solid brass hasp and a solid brass piano hinge from Lee Valley and a pair of spring loaded chest handles from Rockler.

Here is the link to the chest handles that I choose for the tack trunk in case you are interested in using them yourself.

Heavy Duty Trunk Handles
Solidly built to handle hefty loads. Choose from Brass plated or Chrome plated finish. 5” wide x 3-11/16” high. 1/2” thick backplate. 13/16” thick spring loaded . Sold individually. Heavy Duty Trunk Handles

It’s been a busy week, but I wanted to at least make an update so you can see how I’m progressing with the tack trunk build.

After the carcase glue-up I decided to strengthen it even more by adding screws to all the joints. This will be covered by the oak trim so they wont show in the final product.

Bottom oak trim and gussets added

I added the bottom oak trim next, extending it down past the bottom of the carcase enough to cover the gussets in each corner that will be used to mount the casters (or feet). I decided to use biscuits to join the oak trim to the carcase to strengthen the bond and also help with the alignment. The glue-up of the bottom oak trim wasn’t the easiest glue-up ever since I was using mitered joints and wanted to get them nice and tight but I got through it. The biscuits certainly helped during the glue-up. I’ll be securing the bottom oak trim with a few screws through the inside of the trunk also since I’m sure this part of the trunk will be taking a beating .

After adding the bottom trim I glued gussets into each corner as shown in the photo. These added strength to the corner and also more material for mounting the casters.

Next step is to add the rest of the trim to the carcase. I’ll try and get this done by the end of the weekend (but I make no promises !). Stay tuned ….

After completing all the dados on the tablesaw yesterday I did a dry fit and clamp of the carcase. Everything looked good, but I decided it was too late to start the glue-up so that would have to wait for the next day.

Tonight I did the finally check for square, dismantled the dry fit and started the glue-up. This took longer than I had expected, but I kept moving at a good pace hoping I would complete it before the glue started to set-up.

I used a waterproof glue (Titebond III) but the setup time is quick so you need to work fast with this many panels to assembly in one shot. The divider also had to be positioned and glued at this point since this wouldn’t be possible after the carcase was assembled. The shelf and sliding tray rails I’ll add later.

Assembled Carcase Drying

Of course I felt that I could use about 10 more clamps to get the joints nice and tight but I made do with what I had. I did purchase a new band clamp and pipe clamp for this job. I could probably use about 2 more band clamps for this assembly.

The glue-up is complete and drying. Next I’ll add the oak trim to the bottom, but before I do that I need to build a miter sled for the table saw so I can cut some perfect 45 degree miters. Stay tuned ……

Enough of the designing and tinkering in Sketch-Up it’s time to get building the tack trunk if I’m going to have it done by sometime around Chelsea’s birthday!

Tack Trunk Carcase

Yesterday I started the actual construction of the plywood carcase.  The carcase is made from 3/4″ oak plywood. I had a real hard time trying to find some good quality plywood to use. The stuff you can get at the local home goods stores is really cheap with voids and very thin veneer. I even went and talked to one of the local cabinet shops in the area to see where they purchase cabinet grade plywood around here and the answer is they don’t.  They end up ordering it from a supplier and even then the quality isn’t what it used to be. I did find some oak plywood at a local Home Depot that was fairly good, but I ended up digging through a pile of 15 sheets (by myself)  before finding two that were acceptable to me.

By the end of my time in the workshop yesterday I had rough cut the pieces for the carcase from one of the 4×8 sheets of plywood into managable sizes and ripped them to the correct width.  Today after work I cut the individual pieces of the carcase to thier correct dimensions, and using the tablesaw cut the rabbits in the bottom, front, and back pieces. I also cut the dado for the sliding tray support.

Inside of the tack trunk carcase

I still have the stopped dado to cut in the front and back pieces for the shelf support and also the stopped dado for the dividing panel in the carcase then it will be ready for glue up.

Did I mention that I am also creating a set of plans for the tack trunk?  I will have them available for a nominal fee after I complete the build. If you want to order yours now, just send an email to TheKraftsman@kyserikekraftsman.com.

Update 07/25/2010: The plans are now available in the download store.

Main Divider - Click to enlarge

A few recent additions to the tack trunk design:

• A main divider in the middle of the trunk.
• A removable shelf to split the left compartment into an upper and lower.
• A sliding/removable tray.
• Trim added to the upper part of the trunk.

I added a divider to split the trunk into two sides. The right hand side will be the largest compartment in the trunk.

In the left hand compartment I added a removable shelf that extends to the length and width of the compartment. Items that are not needed often can be stored in the lower compartment. The shelf also acts as a base for the grooming tote.

Left Hand Shelf - Click to enlarge

The sliding tray is about 5 inches deep and can either be moved to the left hand side of the trunk or removed to gain access to the area under the tray.  The grooming tote may need to also be removed in order to slide the tray completely to the left hand side.

The trim was added to the top portion of the trunk because I needed to be able to mount the piano hinge securely for the lid. I think this trim will also be used to secure the locking hasp.

Next I’ll add the hasp, handles, and casters to the sketchup model. Then I think it will be time to start building !

I think I’ll also find a way to increase the width of the bandage/wrap holder. Chelsea was a little concerned that the 3 inch width would be too narrow.

Don’t forget to check back for updates !

The tack trunk with the sliding tray added - Click to enlarge

Trunk with tray, tote and wrap holder - click to enlarge