Amass Workshop - Progress Update 3

Since the last update on the workshop a lot of time and effort has gone into the joinery for the door and the gable end doors. I set out to not use the router for any of the halving joints for both the main door and the gable doors. Every halving joint had to be manually marked out and chiseled out. The only time I used the power tools was to create a square cut for the shoulder of each halve.

End Halve joint

Mid Halve joint

So as you can see in this illustrations, the main door and gable windows used two main types of halving joints. Either end halving joints or mid halving joints. But the tricky part is doing the top angular end halving joints. I used a bevel angle which allows the user to lock in an angle and scribe it onto the material just like a ruler. Also measuring long to short and the lengths of the halving and depth was critical to the fit.

Each component separate from its partner

Glue up of the gable windows, using a board to stop any twists

Used a scribe and marked depth and length of halving

Routered a rebate for the glass to sit in.

Next is the window jams. These were also quite complicated. As the jam needed to be rebated and each top end of each vertical component cut at the exact angle of the rafter. Essentially a opening was produced with some structural Pine in the end of the truss work. The window jam acts as the outer frame for the gable window to swing in and out of. Both the window jam and gable windows were made from Design Pine (treated and primed) as they will be exposed to the elements.

Components for Window jam

Both window jams, with rebated edge and primed

The window jam is fixed in place

Just to point out the window jam is always made before the actual window itself. Or in any case whether its a door or window. Once the jam is fixed in place. Measurements are taken for the window or door, allowing for tolerances such as movement in a out of jam.


The gable windows were added to the workshop to allow the hot air to flow out. As we all know hot air rises, this was a double strike as the windows were also there to allow for timber and what not to be stored on the bottom of the truss work. The gable windows had a coat of paint, glass and hinges attached before being hung in the window jam. They really look the part!

Gable windows will have window arms to stop the wind catching them

Windows glass, Glazing Silicone and Tasmanian Oak beading.

Next is the door, the door was easier to make. As there weren't any angular halving joints. I wanted the door to be wider than the standard door to allow for machinery and furniture going in and out. The standard for a door is usually 2040mm (Height) x 820mm (Width). I kept the standard height but made this door wider.

Glue up of the half joints

Laying out the Pine lining boards, tongue and groove, 12mm

Pine lining boards were attached and then cut flush with the frame

Door ready to be hung!

A workshop isn't one without a decent set of stairs. Got some treated Pine that suited the stairs at 245mm x 45mm. Drew a template on some scrap particle board, laying out the height and positioning of tread and string (strings are the sides pictured below)

Pocket is routered out for tread

Treads were cut to length and screwed to strings

Threaded rod is added with nuts and washers for strength

The next update should include, hopefully the last things on the to do list. Such as storm water pipes, weatherboards painted, doorway from workshop to garage, workshop bench. And then the most exciting part - machinery!

Stephanie Ng - Halo Light

The Halo Light by Stephanie Ng is a modular lighting system that can be hung in many different arrangements. These arrangements can be linear or circular, complimenting the specific interior environment that its in. 

Stephanie's sketches

Initially Stephanie's design was implementing the process of Silicone moulding. After some time in Solidworks a 3D form was finalized ready for the next stage. Next the 3D form had to be printed out via a 3D printer and then was sanded and sealed. This pattern was made to act as the form to create the outer negative Silicone form. Which then would form the Polyurethane resin final.

Silicone Moulding process

The next phase of the design process directed the design down a new path with another process that could achieve the same form desired at lower costs. Metal spinning uses a blank sheet of Aluminium in this case, and then formed over the pattern with spinning rollers that gradually mould the spinning Aluminium sheet over the pattern.  The final spun Aluminium form was powder coated with a dry powder that can be either a thermo plastic or thermoset plastic which is applied electrostatically and then cured to form a durable tough protective layer.

Final Aluminium spun housing

Another key design hurdle was that when each light was hung from the ceiling in a module formation, the cut outs on the housing didn't meet up exactly. To eliminate this problem magnets were used as locating mechanisms which helped hold the over all form of the modular lighting system together.



The design is versatile with each individual light having a cut out to allow the next light housing to slip into place. 

Linear formation - Each light nests next to each other

Circular formation

And to top it off, Stephanie's Halo Light won best Concept Award in the Edge segment at the 2013 Australian International Furniture Fair.









Stephanie is currently refining the design for manufacture and going into production in the near future. If you have any queries about the Halo light please follow this link to Stephanie's Website.

http://www.stephaniengdesign.com/

Ashley Allen - Dollop Light

Dollop Light

Ashley Allen

 


















Ashley's Dollop light won the Commercial Award at the Edge, Australian International Furniture Fair in Sydney, 6th of February, 2013. Congratulations Ash!




The process of this light is the most interesting part of this light. Not just the final product that is pictured above. 

Ashley outlined his process from start to finish on this particular project. There are a lot of different types of techniques throughout the design and manufacture that combine to make this light. First off the design as any design blossomed on a piece of paper and then eventually transverse to Autocad where a 3D model was constructed to ensure a centre of gravity in the lights curvacious form.  Next the final 3D form was rapid prototyped in 2 halves by www.shapeways.com which was glued together and then primed and sanded. 

Rapid prototyping - two halves to be glued and primed.

The finished rapid prototyped form now acts as the form for plaster. A two piece plaster pattern is made around the prototyped form. Earthenware slip is poured into the plaster pattern, producing a 4mm wall thickness and left to sit for 20min. The slip is then poured out and sits for 8hours allowing the material to cure and harden. 

Rapid prototype acts as a pattern for the plaster form.

Plaster form ready to go

Earthenware Slip poured to create 4mm wall

Leatherhard casting ready to be extracted from mould

Final form

The casting was then drilled at the top for the power cord, and sits for a furthermore 7days.The very fragile 'Greenware' casting is then transported to the kiln to be fired to ~1000 deg C (Bisque stage) at the Northcote Pottery Supplies. The inside was clear gloss glazed at ~1100 deg C. 



And to finish it off a 10W LED downlight is attached to 2core power lead. And a particular feature of this light is that the LED downlight can not be seen underneath as the form hides it from view.




Keep your eyes open for Ashley and his work. I have listed his website if you have any questions or queries on his work. He is based in Melbourne, Victoria, Australia!




                                                     http://www.ashallen.com.au/

Australian International Furniture Fair 2013

The 6th - 8th of February at the Sydney Exhibition centre, Darling harbour. The Furniture fair to kick start the year 2013 showed new ideas, designs and styles. 

The Edge design exhibit. Which is open to students and commercial sectors held a wide variety of young and established designers.


 The finalists for the exhibit were picked to showcase their work. Here they are listed!




Finalists for 2013


Adam Lynch & Dale Hardiman // Desk Light - Mr Dowel Jones
Commercial

Alessandro Frangelli // Lidcombe College of TAFE
Apto Table - Student

Alex Brown // RMIT
Puppet Light - Student

Alex O'Connell // RMIT
Quasi Stool - Student

Alisa Newey // Qld College of Art
Emerge Display Screen - Student

Andre Hnatojko // HNAK
Son - Concept

Ash Allen // RMIT
Lionheart Stool & Dollop Light - Commercial

Asher Abergel & Gal Benarav // Asher Abergel
Cork Connection - Concept

Ben Brayshaw // RMIT
Clam Chair - Student

Callum Campbell // Central Institute of Technology
Float Shelving & Holiday Table - Student

Calvin Su // Lidcombe College of TAFE
Span Bench Seat & Twist Table - Student

Camille Sahid // Lidcombe College of TAFE
The Paperclip Desk - Student

Carina Li-Lin Vincent // Central Institute of Technology
Loopy Boy Lamp - Student

Christelle Chane Tho Wor // Central Institute of Technology
Crinoline Light - Student

Christopher Macaluso // EggPicnic
Andes Lamp - Concept

Craig Birkholtz // Central Institute of Technology
Stick Lamp - Student

Dana Burns Watson // Lidcombe College of TAFE
Slumber House Bedside Light - Student

Deepa Rao // RMIT
Tri Book Shelf - Student

Demelza Nussio // UNISA
Burdhaus & Letahaus - Student

Edward Linacre // Edward Linacre Design
Cypress Pendant Lamp & Topaz Pendant Light - Concept

Faezeh Bassam // Lidcombe College of TAFE
Glissade Light - Student

Jack Flanagan // Central Institute of Technology
Squeeze Clock & Ditto Tables - Student

Jack Frost // Jack Frost Design
Sevente Desk Light - Student

James Lauman & Jordan Soriot // UTS
SOCIOlantern - Student

Jayney Smith // Central Institute of Technology
Wanderlust Lighting - Student

Jaz Wood // RMIT
Perch - Student

Joshua Bourke // RMIT
SBR 1419 Chair & Ottoman - Student

Lenny Hanniford // Lennylovesloulou
Lola Lamp - Commercial

Mart Hough // RMIT
Deer Stool & Syntax Timepiece - Student

Nicholas Sadowsky // UTS
E-ColourWave Magazine Rack & FP3 Stool - Student

Nico Evans // Lab De Stu
Czech Hedgehog - Commercial

Selene Hemala // Central Institute of Technology
The Slim Lamp for Shy Corners - Student

Sholto Hayes // Lidcombe College of TAFE
Tear Drop Table - Student

Stephanie Ng Hui Sien //
HALO Light - Concept

Toby Nowland //
Fold & Peg Stool - Student

Tom Askham // University of SA
Task Lamp - Student

Viktor Legin // Viktor Legin Design
TLS Desk Lamp & Droplet lamp - Concept

Vivien Rink // Vivien Rink
MIA Chair and Stool - Commercial

Yulia Holil // Central Institute of Technology
Stack O'Clock - Student



Edge Awards


So down to the real deal. Who won the top awards at this years Edge?

Commercial Award: Ashley Allen - Dollop Light

Student Award: Ben Brayshaw - Clam Chair

Concept Award: Stephanie Ng Hui Sien - Halo Light

Green Award: Toby Nowland - Fold and Peg Stool


 

Amass Workshop - Progress Update 2

So over the weekend the rest of the weatherboards went up on to the workshop. There was a bit of fiddling around with some particular weatherboards according to the existing gutter on the brick garage next to it. We installed the door jam and made sure it was parallel and square ready for a custom made door to fit. The height of the door is standard at 2040mm high, yet I decided that the door had to be wider to accommodate machinery and timber being moved in and out on a constant basis.

The weatherboards will now need a rough sand down and another coat of paint. Also the side opening of the workshop will have to hinged doors to allow timber and other stuff to be stored on the cord component of the truss work.

The other side opening of the workshop which faces the house will be covered with Polycarbonate sheet to allow light in.

There is still plenty to do!


 

One of the last Baltic Pine Weatherboards to go up!

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It is looking really good now!

Peace out! More progress shots coming soon!

Amass Workshop - Progress update

So over the past couple of weeks a lot has been done on the workshop. We drew a template on the floor of the workshop and used that to make each roof truss exactly the same and to ensure strength and durability! The roof truss work were later attached to the wall top plates, ready to support the corrugated sheet metal. In the middle of the roof we put in one sheet either side of corrugated Polycarbonate with a tint to allow the natural light to come in. We put foam tape underneath each screw, this will stop expansion and contraction creeping noise that occurs. The workshop will be insulated to keep it bearable in summer and winter months. 

I made up the window jams to suit, primed them after routering out a rebate for the glass to sit in and then gave them one coat of Dulux weathershield (also self priming, 100% Acrylic paint) Patina colour. Which is a greeny blue colour. All the window jams and door jam are made from 'Design Pine' which is treated and primed aswell. I've made sure that these window and door jams are properly sealed from the elements to ensure no rot for decades to come! Also the great thing about 'Design Pine' is that they use short pieces of Pine stock and finger joint them, this reduces the movement and twisting in the length of the timber and adds strength.

Ok so that is a brief low down on the workshop for now! Enjoy!

The workshop with not cladding or roofing!

The batons necessary to support the corrugated sheet and to connect each truss frame

The truss were spaced out every 600mm. Overhang was 200mm over wall top plate

We used gangplates and nails to connect each component

Heritage red Colourbond roof, Polycarbonate, gutters!

We opted for Baltic Pine 170mm wide weatherboards

Window jams are overhang 30mm to butt up against the weatherboards.

Keep posted for the next update. By then we should have finished the weatherboards and sealed the ends of the roof along with everything else that needs to be done!