Sound in a box

Our Church meets in a  local school hall. it is really a lovely venue. the building is fairly new and the facility is well looked after.

the school has some sound equipment that they use for assemblies and events that was sitting on he edge of the stage and really was a bit messy. the problem is that if equipment is left open with lots of hands and fingers around, then it does not last. the the pastor asked me if i can build a box to house all the goodies that was sitting on the side of the stage. something that they could lock to keep the little sound desk and the wireless microphones and other paraphernalia that they had there safe and neat. 

great project. i took a couple of basic measurements to make sure that everything that needs to go in will fit and then designed a little box with a lid and two doors that could lock with just one lock. 

i decided to make it a recycling project (you might have guessed this by now). so everything that was used (except for the fasteners) was recycled from something else. 

at work i once made a jig once for a colleague,we tried to make some dune boards (in lunch times of-course), used the jig once and then it sat, for years. so i cut it up and made some hinges that would allow the door to open up a full 270 degrees. in other words it would be able to fold right back against the side of the cabinet.

here are the hinges and other locking hardware right after i painted it. 

i still had some of old crates left. remember the drawers and the speaker shelves? same material: 16mm plywood. 

i cut it up and shaped it and then assembled the box. here is a pic of the assembled box.

i watched a video on YouTube once where a guy made his own wood stain using vinegar a steel-wool. this seemed to fit right in with the wholes recycling idea and i made some. you basically pour some vinegar into a container drop some steel wool in there and let it sit for a couple of days. it all ferments nicely and TADA!!! a chemical wood stain. works pretty well. here is a comparison with the box coated and the lid of the box still un-coated.

the school is celebrating their centenary year this year and i thought (since it was a gift) that we could celebrate it with them. i hand cut some lettering from the left over material used for the sign that i put up in my garage. these where spray painted (with paint left over from other projects). i then fitted them to the side of the box. i also made a little "recycle" emblem to remind everyone that the entire unit is proof of the worth of recycling. 

after varnish (i used some that i had from the restoration that i'm doing on my doors and windows at home) i fitted the box at the school. i mounted it to the side of the stage where they used to keep it and moved everything into its new home. 

i had made provision for the cables to be routed through the side of the box that was out of general sight. this worked well and there was enough slack in the cables to comfortably reach the new destination. admittedly i lucked out a bit in that last detail...

the locking mechanism was simple pieces of metal shaped to the desire shape that lined up in the front to accept a padlock. the lid fits in behind the doors and at the back, a piece of angle iron was inlaid into the plywood (keeping the back flat so the box would still mount flush to the stage). so the lid slips in under the angle iron and behind the doors. when a padlock is fitted everything is locked together and the bax cannot be opened. 

total time spent on this box from design to final mounting was about 60 hours... 

Play house

A couple of months ago I got given a pile of crates that required a better end than the scrap heap. so i stripped them all into sheets and designed a little playhouse for my 2 year old girl. I bought some 38x38mm batons that were treated for insects and cut slots in them. i then slid the sheets into the slots and made a basic box with holes for windows and a door.

Needless to say this Impressed Emily to no end! she was running screaming with her hands above her head lie the woman that get stuff on the Oprah's favourite things show.

I lined the door and window holes with more slotted batons. making the structure stiffer and stiffer as I went.

No house is complete without a roof, so up went some trusses and i made a little patio outside the front door. i had paint left from  painting my house and covered the entire structure with a couple of coats to seal and cover the wood.



With it being easier to paint a room where you can stand up straight, i decided to get most of the painting done before the roof went on. All the trusses got a coat of Plascons "Carrot Muffin", and i painted the inside of the house the same colour as Emily's bedroom.

Had to putt a tarp over the top since it started raining and the roof was not up yet...

I took some more of the sheets and cut them into strips fr the roof. A friend let me use his nail gun to get the sheets onto the roof. After being very sceptical of the nail gun idea i must say that after having used one, the sincere need to have one in my tool kit settled on me in earnest. Now I just need to convince my wife. the entire roof got coated in a water based bitumen type product and then painted with roof paint.

Things got a bit busy and the house stayed like this for a couple of months. Until last week when my wife reminded me that the house still needs a door. I remembered an old folding desk that we converted into a shelf by removing the desk top. I thought that a solid pine stable door would do the trick and proceeded and cutting up the old desk top. I routed a lip so the doors could hook into each other and made a heart shaped peep hole in the upper door. these then got hung with some cabinet hinges, and it looked pretty cool.

Everything then got taken off, sanded down and varnished. In anticipation of this door i had turned some door handles on my little lathe and made something up so that there would be some way to grip the door.

The handles got mounted on the door with some sliding bolts on the inside to connect the upper and lover door and to "lock" the door into the door frame. I added a little piece of off cut wood to the lower end of the door frame to ensure that the door could not be pushed past closed by an over enthusiastic little one.

Inside of the house needed some touch ups so i repainted the ceilings and the touched up the trusses. the skirtings also got painted. no little cottage under a fig tree is complete without some terracotta tiles so next i taped some masking tape on the floor and painted the floor. .

The end result was pretty pleasing, Emily loves it and all her dolls have had a meal in her "new" house.

Covered in clay

So my mom in law turned 60 a couple of weekends ago and we signed up for a visit to celebrate. The visit turned into an early Christmas because we will not be seeing that part of the family over the actual Christmas time. 

This year moms house was full and we got to stay with my wife's dad on the farm just outside the village. He lives in a house that he literally built with his own hands. 

Cob, a mixture of clay and dry grass, is rolled into balls, slapped in place and shaped with your hands making the wall. This is done in a circular fashion, working your way around the wall until you get back to where you started, by which time the cob should be dry enough to start the next layer.

This process is followed until the desired height s reached. After all this you need to seal the clay from the rain, else it will just become a neatly washed pile of mud. To seal it, it gets plastered with a mix of clay and lime. Then you roof it, floor it, furnish it and move in (in short that is).

What a lovely place. Because of the thick natural walls the temperature is beautifully regulated inside, summer and winter. None of the walls are perfectly straight, giving the house a lovely natural feel.

At night everything settles due to temperature differences, making the house feel alive as it moves at night. A huge porch gives a lovely farmhouse feel and give a great vantage point to enjoy a stunning view over the farm and of the surrounding mountains.

The only thing missing is a line up of motorcycles and some sort of a test track... LOL!! I don't think that dad will bite though... :)