Workshop extractor

Intake side. Made from aluminium.
knoba - Workshop extractor

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Exhaust side. Enclosure made from 304 stainless steel, plywood & galv weldmesh.
knoba - Workshop extractor

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240v Torin Sifan extractor, centrifugal fan. Fabricated wall interface.
knoba - Workshop extractor

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3 developments. Mallet formed. Pop riveted & silicon seams. Cad file below.
knoba - Workshop extractor

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Removable grill made from plywood & weldmesh.
knoba - Workshop extractor

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Hardwood former (1st) used for hammer forming intake cowling
knoba - Workshop extractor

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Hardwood former (2nd) used for hammer forming intake cowling
knoba - Workshop extractor

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Hardwood former (3rd) used for hammer forming intake cowling
knoba - Workshop extractor

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First phase complete. To do: trim edges & fold over returns…
knoba - Workshop extractor

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Softwood former (4th) used for hammer forming edges of intake cowling
knoba - Workshop extractor

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Needed to make a tucking fork for this operation
knoba - Workshop extractor

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Front side.
knoba - Workshop extractor

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Back side.
knoba - Workshop extractor

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Power. Extractor is quiet & very powerful.
knoba - Workshop extractor

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Materials:
(FAN)
1 x Extractor fan
1 x Wall interface plate (1.5mm galvanised sheet)
1/8" pop rivets
Rawlplugs
6 x 12x2" stainless steel self tapers
6 x m8 stainless steel washers

(ENCLOSURE)
1 x 4'x4'x1.0mm 304 stainless steel sheet
1/8" pop rivets
Silicone sealant
1/2" closed cell foam sound insulation
High temp spray glue
10mm mild steel bar
2 x m6 stainless steel button cap bolts
2 x m6 stainless steel washers
Plywood
Weldmesh

(INTAKE)
2.0mm 6 series aluminium sheet
Grab adhesive

(ELECTRICAL)
240v metal clad switched outlet with light (5Amp fuse)
Metal clad surface mount backbox
22mm (7/8") through hole rubber grommets
1.0mm twin & earth cable
Rawl plugs
Screws
Earth sleeving
Trunking
Cable ties

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Torin-sifan – Ddn200-180a Extractor

Sassda – Stainless Steel

Rivetwise – Pop (blind) rivets

MK Electric – Commercial / domestic

Thor – Hammers & mallets

knoba – workshop extractor – 2017.dxf

knoba – Metalwork mallets

•••

http://www.homemadetools.net

Metalwork mallets

large diameter heads & long reach heads in double wedge, round & flat
knoba - metalwork mallets

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Heads are home grown & seasoned holly, wedges are mahogany & handles are beech.
knoba - metalwork mallets

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Handles turned from old table legs, spoke shaved ovoid, danish oiled and burnished smooth with 00 wire wool.
knoba - metalwork mallets

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Added extra weight with heated and shrunk rings
knoba - metalwork mallets

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3 smaller mallets, beech dowel handles, holly heads.
knoba - metalwork mallets

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All heads danish oil soaked in poly bag, finish left on heads
knoba - metalwork mallets

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knoba - metalwork mallets

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knoba - metalwork mallets

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Materials:
Large heads: 2 x 125x50 mm o/d (5"x2" o/d) holly
Long reach heads: 2 x 180x40 mm o/d (7"x1 1/2" o/d) holly
Small heads: 3 x 100x32 mm o/d (4"x1 1/4" o/d) holly
Large head handles: 2 x 280x40 mm o/d (11"x1 1/2" o/d) beech
Long reach head handles: 2 x 325x40 mm o/d (12 1/4"x1 1/2" o/d) beech
Small head handles: 3 x 330x15 mm o/d (13"x19/32" o/d) beech
Danish oil
00 Wire wool

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Wood-database.com – holly & beech

Colron – refined danish oil

Liberon – steel wool

•••

Jessops tripod camera mount

Machined from hardwood scrap (not the wired thumbscrew).
knoba - jessops tripod camera mount

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knoba - jessops tripod camera mount

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Fits the unusually shaped jessops tripod
knoba - jessops tripod camera mount

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All; Freecycled, recycled.
knoba - jessops tripod camera mount

•••

Wood seasoning rack

North facing, sheltered from; light, heat, rain & infestation.
knoba - wood seasoning rack

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Rack is made from recycled; forklift pallet, aluminium chairs, twin wall polycarbonate. 316 stainless wire (new). Ground below good for spalting.
knoba - wood seasoning rack

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I make my own log sealer from old water based interior emulsion & PVA glue.
knoba - wood seasoning rack

•••

Van cab steps

Left; Hammer-formed finals (4mm thick, ground, beaten & polished).
Centre: Hardwood bucks routered from decking off-cuts.
Right: Original plastic steps (loading caused rust in underlying structure).
knoba - van cab steps

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No annealing required. Machined nylon66 interfaces stuck with PU sealant.
knoba - van cab steps

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Fixings are M8 stainless countersunk bolts & M8 square weldnuts.
knoba - van cab steps

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themetalstore.co.uk – aluminium 5 bar checker plate

duckduckgo.com – square weld nuts

wikipedia.org – Nylon 66

Sikaflex – EBT+ polyurethane adhesive

•••

Wooden cornices

Turned in the round, quartered, back relieved & carved.
knoba - sunglass modding

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Home seasoned apple, linseed oiled & beeswaxed
knoba - sunglass modding

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Wood database.com – Apple

•••

Carved Tudor Rose

Butt jointed (no tongues or biscuits) well seasoned knotty pine
knoba - Carved Tudor Rose

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Marking out guide for Rose design
knoba - Carved Tudor Rose

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Starting in, must have tea…
knoba - Carved Tudor Rose

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Fleshed out.
knoba - Carved Tudor Rose

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Did not have the right carving gouges for this size work
knoba - Carved Tudor Rose

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Stopped project to make some better size gouges…
knoba - Carved Tudor Rose

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3 sepals left to go
knoba - Carved Tudor Rose

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36″ o/d x 1.75″ thick. 120+ hours.
knoba - Carved Tudor Rose

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Enjoyed those little sepals
knoba - Carved Tudor Rose

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Boss in centre is for a light pattress (it’s a ceiling rose)
knoba - Carved Tudor Rose

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knoba - Carved Tudor Rose

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Danish oiled then wire wool and waxed
knoba - Carved Tudor Rose

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Turned magnetic Beech fixing covers
knoba - Carved Tudor Rose

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On my ceiling, sub rosa
knoba - Carved Tudor Rose

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Colron – Danish Oil, Wire wool & Finishing wax

Pfeil – Carving tools

knoba – Carved picture frame

knoba – Carving gouges

knoba – Gym mirror

•••

Tool tang drill bit

Almost any steel will do. 7mm o/d, 2 straight flutes, 1/4″ increment depth marks
knoba - Tool tang drill bit

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Used in lathe, with new handles. Enlarge to fit individuals tangs…
knoba - Tool tang drill bit

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4° included taper (as per machine taper)
knoba - Tool tang drill bit

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Can easily remove shank for re-tempering. Link to CAD file below
knoba - Tool tang drill bit

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Wiki – Machine taper

knoba – Tool Tang Drill Bit – 2017.dxf

•••

Chop saw mitre framing jig

Easy to make (ply & baton) checks accuracy of chopsaw 90° cut
knoba - Chop saw mitre framing jig

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1 joint 1 cut, or, 2 joints 1 cut…
knoba - Chop saw mitre framing jig

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Perfect.
knoba - Chop saw mitre framing jig

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Link to CAD file below
knoba - Chop saw mitre framing jig

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knoba – Chop Saw Mitre Framing Jig – 2017.dxf

•••

Carved picture frame

Inner panel was gifted to me, so made this frame for it…
knoba - Carved picture frame

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Frame is 13×12″, Sycamore maple, walnut oil & beeswax finish
knoba - Carved picture frame

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4mm Rosewood dowels in mitres. Carved in a celtic style.
knoba - Carved picture frame

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Wood-database.com – Sycamore Maple

•••

Plywood picture frame

1″ thick x 19″ o/d, “Far Eastern Plywood”, waxed.
knoba - plywood picture frame

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Picture & 4mm glass is about 300mm square.
knoba - plywood picture frame

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knoba - plywood picture frame

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Wenban Smith – Far Eastern Plywood

•••

Electric Guitar

20 year old incomplete project, found on freecycle.
knoba - electric guitar - 01

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It finally has a voice and a lovely, unique, sound range.
knoba - electric guitar - 02

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Fodic neck.
knoba - electric guitar - 03

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I’ve done a lot to this guitar to get it up; hand beaten stainless steel jack port…
knoba - electric guitar - 04

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Custom electrics; 3 x dpdt phase reversal switches, hi & lo tone controls.
knoba - electric guitar - 05

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Non-magmetic 3 series stainless steel, all inlayed.
knoba - electric guitar - 06

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New house guitar. Have some wood inlay to do & more wood carving.
knoba - electric guitar - 07

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A first for me. Wood inlays (white oak)
knoba - electric guitar

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Switches are 3 position DPDT (down = out of phase, centre = off, up = on)
knoba - electric guitar

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304 stainless made from sheet
knoba - electric guitar

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Body is dark red meranti.
knoba - electric guitar

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Depth spotted with drill and chiselled flat, hide glued.
knoba - electric guitar

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Closing trim
knoba - electric guitar

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knoba - electric guitar

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EMG – musical instrument pickups

knoba – Electric Guitar – 2017.dxf

•••

Hand graver

Hand graver for engraving metal.

Iroko handle, cast & machined brass body, 1/8″ hss lathe tool, m4 grub screws.
knoba - hand graver - 01

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Handle is flat on one side to allow the tool a low attack angle.
knoba - hand graver - 02

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knoba – Hand graver – 2016.dxf (CAD file link below)
knoba - hand graver - 02

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knoba – Hand graver – 2016.dxf

•••

Nogging master for arched wood roofs

Component parts overview…
knoba - Nogging master - 01

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2″ by 2″ softwood, M8 coachbolts.
knoba - Nogging master - 02

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Assembled.
knoba - Nogging master - 03

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Folds up.
knoba - Nogging master - 04

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Machined a nice thumb nut for it from aluminium.
knoba - Nogging master - 05

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Nogging master measuring dwang geometry…
knoba - Nogging master - 06

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Place on timber (3″ x 2″ here), mark & cut!
knoba - Nogging master - 07

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knoba - Nogging master - 08

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Notes.
• Perlins can be continuous or split form.
• Saves time.
• Eliminates waste, cost & mistakes.
• Inexpensive & easy to make.

~§~

*** Mk2 incorporates the “Plate Pilot” for accurate ‘birds mouths’ on the wall plate / 1st perlins nogging.

•••

Leather strap cutter

For cutting stiff leathers into parallel strips (belts, straps,etc.)…
knoba - Leather strap cutter

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Mostly made from Iroko & stainless steel.
knoba - Leather strap cutter

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knoba - Leather strap cutter

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knoba - Leather strap cutter

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knoba - Leather strap cutter

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knoba - Leather strap cutter

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knoba – Leather strap cutter – 2015.dxf (link below)
knoba - Leather strap cutter

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knoba – Leather strap cutter – 2015.dxf

knoba – Adjustable Dowel Jig

Wood Database – Iroko

•••

Single bevel edge fishtail carving skew

Someone gave me this today (it’s a Marples & Sons 1/2″ bevel edge chisel)…
knoba - single bevel edge fishtail carving skew

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It’s in pretty poor shape…
knoba - single bevel edge fishtail carving skew

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The sole of the blade…
knoba - single bevel edge fishtail carving skew

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The top of the blade (the bevel edges can just be made out)…
knoba - single bevel edge fishtail carving skew

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Here it is again after a couple of hours reworking…
knoba - single bevel edge fishtail carving skew

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The blade has been: extracted, reforged, re-shaped, ground, hardened, tempered, lapped, polished & stropped.
knoba - single bevel edge fishtail carving skew

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The handle has been: re-turned, sanded, waxed & polished.
knoba - single bevel edge fishtail carving skew

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A sweet tool…
knoba - single bevel edge fishtail carving skew

•••

Leather Edge Bevellers

Made from medium carbon steel, brass & spalted cherry.
knoba - leather edge bevellers

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knoba - leather edge bevellers

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knoba - leather edge bevellers

•••

Head knives

Head knives for cutting & skiving leatherwork.
knoba - head knives

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Made from spalted silver birch, brass & medium carbon steel alloy, mirror polished with beeswax finish.
knoba - head knives

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Donor steel from old saw blade (old non tct blade). Took 2 teeth off to see if the metal could be hardened.
knoba - head knives

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Heated both teeth to cherry for 3 min, quenched one & left other to cool.
knoba - head knives

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My quenching bucket. Spark tests (grinding) on the 2 teeth gave good results.
knoba - head knives

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Cleaned up both sides with abrasives (flap wheels, silicon carbide discs, etc.).
knoba - head knives

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Stuck my templates to the blade…
knoba - head knives

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Cut them out with angle grinder.
knoba - head knives

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Centre marked a sharpening pivot point…
knoba - head knives

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Drilled that mark…
knoba - head knives

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Took off paper & made a sharpening jig for the belt sander.
knoba - head knives

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That’s how this is going to go…
knoba - head knives

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Sharpened & polished.
knoba - head knives

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Heated to cherry for 3 mins (12mm = 30mins soak time). Had to keep the torch moving to keep the blade hot over its entire surface.
knoba - head knives

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After quenching the blade but not the tang.
knoba - head knives

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Re-polished.
knoba - head knives

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Seasoned birch from my garden…
knoba - head knives

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Turned some handles for my blades…
knoba - head knives

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With thanks to Cap’n Eddie Castelin for his superb wood turning videos (link below).
knoba - head knives

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knoba - head knives

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knoba - head knives

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Machined up some brass ferrules and epoxied on.
knoba - head knives

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Tangs were tapered (4° included angle) to common machine taper specs (see link below)
knoba - head knives

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Very pleased with results, they feel great, strop well and hold a good wire!
knoba - head knives

~§~

knoba – Leather Head Knives – xcf files – 2015.zip (link below)
knoba - head knives

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knoba – Leather Head Knives – xcf files – 2015.zip (link below)
knoba - head knives

~§~

You tube – Cap’n Eddie Castelin

knoba – Leather Head Knives – xcf files – 2015.zip

Wiki – Machine taper

Wood Database – Silver birch

Colron – Refined Finishing Wax

•••

Leather pouch for modded bevel edge chisels

Tool roll made from the softest full-grain Italian hide.
knoba - leather wallet for chisels

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Fastened with Velcro.
knoba - leather wallet for chisels

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Knocked back (stepped) soles for accurate lapping.
knoba - leather wallet for chisels

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Wasted shanks for better reach.
knoba - leather wallet for chisels

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Bahco – 424P Bevel edge chisels

Forum – Homemadetools.net

•••

Small wood plane

Luthiers wood plane.
knoba - luthiers wood plane

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Body & wedge made from English oak, pin from Rosewood, blade from high carbon steel.
knoba - luthiers wood plane

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knoba - luthiers wood plane

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knoba - luthiers wood plane

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Wood Database – English Oak

Wood Database – East Indian Rosewood

•••

Sausage handle Router jig

Designed in CAD & transposed, with the datum lines, to 3/4″ plywood template.
knoba - sausage handle router jig

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Makes repeatable side hand-holds…
knoba - sausage handle router jig

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LibreCAD – Open Source 2D-CAD

Dewalt – DW331K Heavy Duty Top Handle Jigsaw

Freud – 1/2″ (dia.) bearing flush trim bit

Freud – 3/8″ Radius rounding over bit

•••

Woodwork clamping blocks

4″ x 4″ x 2″ softwood. Non-marking, large surface area with 1/8″ edge over-round.
knoba - clamping glue blocks

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Waxed for an easy glueing release agent.
knoba - clamping glue blocks
Better to be made before one needs them!

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Colron – Refined Finishing Wax

Freud – 1/8″ Radius rounding over bit

•••

playstation game rack

knoba - ps2 game disc holder

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knoba - ps2 game disc holder

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Half blind sliding dovetails make the rack ‘flat-packable’ without using any fasteners or tools.
knoba - ps2 game disc holder

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knoba – Game holder – 2007.dxf (link below)
knoba - ps2 game disc holder

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knoba – Game holder – 2007.dxf

Wood-database.com – Iroko

Colron – Refined Finishing Wax

•••

Leather wallets for rasps

knoba - leather wallets for rasps

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knoba - leather wallets for rasps

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Cromwell – Bastard rasp

Cromwell – Saftey wooden file handle

Ebay – 15mm snap fastener

Pfaff – select 3.0 sewing machine

•••

Planer / thicknesser blade honing jig

Planer thicknesser blade honing jig

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Planer thicknesser blade honing jig

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Planer thicknesser blade honing jig

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Oak.

Planer thicknesser blade honing jig

•••

Garden table

Garden table from cable drum (freegle).

Garden table

~§~

Garden table

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ilovefreegle.org

Ronseal – Decking oil

•••

Trammel set with micro adjustment

Trammel set

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knoba – Angle grinder pigtail for polishing

knoba – Metal casting furnace

Toolstation – 61139 Stainless Steel Threaded Bar M5 x 1m

•••

Human plant pot stand

Template
Template

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Slots together

~§~

no fasteners or fixings

~§~

knoba – Metal horse

Wenban-Smith – Timber Merchants

Ronseal – Diamond hard floor varnish

Starrett – Jigsaw blades

Dewalt – DW331K Jigsaw

Dewalt – DW433 Electronic Belt Sander

Dewalt – DW626 1/2″ Router

Dewalt – DW621K 1/4″ Plunge Router

Triton – SJA 200 SuperJaws

•••

Gym mirror

Ionic order Greek styled columns with carved volutes
(Definition of NOSCE TE IPSUM – know thyself)
Gym mirror

~§~

This homemade lathe setup gracefully accommodates the tapering of the original column shafts
Gym mirror

~§~

Saddle on lower beam allows a router to do the fluting.
Gym mirror

~§~

Gym mirror

~§~

Gym mirror

~§~

Triton – SJA 200 SuperJaws

Emir – Quality hand tools

Dewalt – DW729K Radial Arm Saw

Dewalt – DWS780 Mitre Saw

Bahco – Premium hand tools

Colron – Refined Finishing Wax

•••

DJ Desk for Hotel

DJ Desk for Hotel
DJ Desk for Hotel

~§~

DJ Desk for Hotel

~§~

1st mock-up for clients brief “DJ desk” done in Blender.

~§~

Knoba – Dj Desk – 2013.blend

•••

Electro etch pen

Electro etch pen for id marking hardened steels & alloys
Electro etch pen

~§~

knoba – Spur drive

Vintageprojects.com – Etching pen plans

Rapid Electronics – Electronic Components

•••

Dewalt DW 320 radial arm saw table

Radial arm saw table

~§~

Radial arm saw table

~§~

Radial arm saw table

~§~

Radial arm saw table

~§~

Radial arm saw table

~§~

Radial arm saw table

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Radial arm saw table

~§~

Hammerite – Direct to Rust Metal Paint

Parkersteel – Carbon Steels Square Hollow Section

Castors-Online – 75mm Swivel Castor with Single bolt fixing

knoba – Radial Arm Saw Stand – 2011.dxf

•••

Garage / workshop doors with Stainless steel hardware

Garage / workshop doors with 304 Stainless steel hardware
Garage / workshop doors with Stainless steel hardware

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Garage / workshop doors with Stainless steel hardware

~§~

Garage / workshop doors with Stainless steel hardware

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Garage / workshop doors with Stainless steel hardware

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Garage / workshop doors with Stainless steel hardware

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Garage / workshop doors with Stainless steel hardware

~§~

Garage / workshop doors with Stainless steel hardware

~§~

Garage / workshop doors with Stainless steel hardware

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Garage / workshop doors with Stainless steel hardware

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Garage / workshop doors with Stainless steel hardware

~§~

knoba – Sliding Dead Bolt – 2009.dxf

Cibo – Finit-Easy

Cibo – Finimaster Pro

Parker steel – Stainless Steel Metric Flats

Wenban-smith – Hardwoods

Wenban-smith – Softwoods

•••

Wood turning fixture & rests

Lathe wood turning fixture & polished 304 stainless steel rests
Wood turning fixture & rests

~§~

Wood turning fixture & rests

~§~

Wood turning fixture & rests

~§~

Wood turning fixture & rests

~§~

Extended rest.
Wood turning fixture & rests

~§~

Wood turning fixture & rests

~§~

knoba – Radius keepers

knoba – Spur drive

Homemadetools.net

•••

Sycamore & stainless steel mirror

Sycamore maple, american white oak & 304 stainless steel mirror
Sycamore & stainless steel mirror

~§~

Sycamore & stainless steel mirror

~§~

Wood-database.com – Sycamore Maple

Wood-database.com – White Oak

Azom.com – Stainless Steel Grade 304

Colron – Refined Finishing Wax

•••

Stainless steel TV Stand

Polished 304 Stainless steel & oak flatscreen TV Stand
Stainless steel & oak TV Stand

~§~

Stainless steel & oak TV Stand

~§~

Stainless steel & oak TV Stand

~§~

Stainless steel & oak TV Stand

~§~

Stainless steel & oak TV Stand

~§~

Stainless steel & oak TV Stand

~§~

Stainless steel & oak TV Stand

~§~

Stainless steel & oak TV Stand

~§~

Stainless steel & oak TV Stand

~§~

Stainless steel & oak TV Stand

~§~

Stainless steel & oak TV Stand

~§~

knoba – Tv Stand – 2008.dxf

Forum – mig-welding.co.uk

Colron – Refined Finishing Wax

Parker steel – Stainless Steel Metric Rounds

Cibo – Finit-Easy

Cibo – Finimaster Pro

Metalgeek.com – Tube Coping Calculator

•••

Wooden retro rocket plant pot stand

Wooden retro rocket plant pot stand

~§~

No fasteners or fixings – slots together
Wooden retro rocket plant pot stand

~§~

Wooden retro rocket plant pot stand

~§~

Wooden retro rocket plant pot stand

~§~

Colron – Refined Finishing Wax

•••

Wooden coffee table

Wooden coffee table

~§~

Slots together, no fixings, fasteners or tools required, flat-packs for easy transport/storage
Wooden coffee table

~§~

knoba - Wooden coffee table

•••

Wooden bed

Slots together, all wood, no fasteners or fixings, flat-packs.
Wooden bed

~§~

Wooden bed

•••

Wooden shelves

Slots together, no fasteners or fixings, all wood, flat packs.
Wooden shelves

~§~

Wooden shelves

~§~

Reversed, half-pin, half-blind, sliding dovetail hybrid.
knoba - Wooden shelves

~§~

Shelf side joint.
knoba - Wooden shelves

~§~

Mortise & tenon in foot joint.
knoba - Wooden shelves

•••

Wood work bench

4″ thick top with custom stainless steel fastners
Wood work bench

~§~

Wood work bench

~§~

Wood work bench

~§~

Wood work bench

•••