My own organization is crucial to the success of a class, especially with an advanced project class. If I have not examined each operation we need to do, in what order we will do it in and, most importantly, how many operations we can do simultaneously, then we will get very little done and the project will not even be close to finished in the time allotted.
My hands-down favorite thing to do is develop the process for manufacturing a new product. This involves figuring out how to design a product so that it’s not only durable and functional, but also economical to build. Then all the jigs, fixtures and CNC programs have to be created and tested until the whole process is running smoothly. Up to now, the most challenging project has been our line of wooden sunglasses which were developed for a specific client. We spent hundreds of hours just figuring out how to build the first pair then hundreds more hours refining the process until they became profitable.
oh yeah, and buying a bunch of cap nuts is not so easy unless you order ahead of time. i went to two hardware stores (one family owned and one big box) and they kind of laughed at me when i said i needed 32. so i got regular nuts, tightened them so they were flush with the all thread on the front side, hammered it against the board and tightened the back side while holding the front one in place with a wrench. so, some of them have a little bit of overhang on the back side, but i don't have to worry about gouging skin while walking past it. for my next set, i'll order the cap nuts in bulk from ebay ahead of time...
But what if you want to make a box? The revered (and overly-mystified) dovetail joint is a very strong way to join corners of boards. Of all features that non-woodworkers admire today, the dovetail joint is the one that creates the most awe. It is composed of one side cut into wedge-shaped “tails” that mate into corresponding “pins.” When fitted together, the wedge shape prevents the boards from sliding apart in one direction. This joint has been very standard construction since the 1700s. Never meant to impress, it was usually intentionally hidden behind veneer, molding, or paint so that no one would have to look at that “ugly” joinery. It wasn’t until the arts and crafts movement that visible joinery was considered an aesthetic asset. Today, making dovetail joints has become a litmus test for serious woodworkers, but don’t let this scare you away from trying it. Check out a few of the four million “How to Cut Dovetails” videos online and then get into the shop. It’s much more straightforward than people think: Cut tails. Trace the tails on the other board. Then cut out the waste you traced. That’s pretty much it. All the fine tuning is just practice.
Another fine example of remodelling furniture and re-using what already exists in the house. The bookcase involves using your old kitchen cabinets, and building new shelves on top of them. The final product can also be used as an entertainment unit, housing a television, books and things of your interest along with ample storage to keep other utility objects.