Building A Gypsy Wagon -- Part 7 / Learning To Frame Stained Glass Windows

In spite of the cold weather and the short days of winter, work on the wagon continues...

After working a short time in the semi-darkness of Siobhan's sleeping loft, we both decided it needed more light.  So we got out our original wagon plans and modified them slightly, adding a small window to each of the side walls to match the window at the back.  Both of the back windows previously installed were built by a  local man who, to our dismay, kept them 7 months before completing them.  Not wanting to go that route again, we decided to build these windows ourselves-- using antique stained glass panels and red oak to framing to match the others. 

We purchased two antique stained glass panels (11" x 13") on Ebay, ordered two more sets of brass awning hinges, bought several lengths and widths of red oak boards, and headed for the shop to get started....

Now, neither of us have ever built anything with mitered corners, and we quickly realized it would be no easy task.  We stained our boards and back to the house we went... We watched an online instructional tutorial on miter cuts, and again we headed to the shop...

Siobhan and I have always used a miter box and hand saw for making diagonal cuts, but this time we decided to try Liam's new Porter Cable miter saw instead--mostly because he was out of town (hah! hah!).  The saw  worked beautifully!  In no time at all we had cut 4 pieces with 45 deg. angles and corners that at first glance fit together smoothly.  But what next?!   Back to the computer we go for more tutorials...




The next time we headed for the shop, we went with the idea of building a squared work frame from wood scraps, and clamping it to the work table to use as a guide for gluing and clamping.  On our first try, we got the work frame right--square and clamped tightly to the table--and lay our first two frame pieces  against it...And OH NO!!! The mitered corners fit together, but they weren't square!!   Quickly we checked the others, and none were square.  Back to the drawing board...





After more online research, we decided the fault had to lie with Liam's new saw.  Everything seemed to be set correctly--locked in on 45 deg., and the laser guide fell directly on every cut edge.  But when we placed a square against the saw blade we found the problem-- the fence guide wasn't straight ( not a true 90 deg. angle from the saw blade). It wasn't off so much as to be obvious to the eye, but it was enough to throw off our corners. We loosened the appropriate screws, and with a few minor adjustments and the help of two squares, we were able to correct the problem.





Next Siobhan and I re-cut every angle on all 4 pieces, and this time when we checked, the cuts were true 45 deg angles.  We set them aside until the next morning, when Liam could saw a 1/4" recessed ledge on the back inside edge of each piece.

After Liam did our custom sawing for us, we placed the pieces within the wooden frame guide, clamping and gluing the frame's corners. While the glue was drying, we measured, cut, and mitered a 1/4" x 1/4" piece of hardwood into the necessary size pieces to fit into the recessed ledge.  We drilled holes in the inner-facing side of each 1/4" piece, and stained them to match the rest of the frame.

 After letting the glue dry overnight, we removed the clamps and inspected our work.  The miters fit smoothly together, and the corners appeared to be tight.  However, when one side was tugged gently the glue popped free.  Once again, we were back to the drawing board (and the internet)...     


After reading a few more how-to articles, we decided to try a different type of clamp and fasteners.  We ordered both from a framing supply store, and as soon as they arrived, we went back to work on our  project...


This time we had opted to use a strap clamp because it will adjust to a wider range of sizes than other clamps, and v-nails on the mitered corner joints for better stability. 





Success at last!  The strap clamp and v-nails did the trick--finally our frame was square and had nice tight corners.  Next we gently placed the stained glass panel  in the recessed opening, and fit the 1/4"  x 1/4" pieces around the glass edges.  We secured each piece with small brass screws, and the first framed glass panel was complete.

(I  can't believe we did it...)  Bring on the next window!




 

Building A Gypsy Wagon-- Part 6 / December Update... / Sliding Loft Ladder, Hidden Table...

Now it is December...

 Since last wagon update, Siobhan and I have finally completed the middle panel/left side, and secured it in place on the wagon. We purchased a tube of clear silicone caulking, and used it to seal between the upright middle panels (both left and right) and the horizontal interior ledges.  We allowed the caulking to cure overnight, then we nailed down stained trim pieces over the caulking.  
                                      

Wagon viewed from the right side, showing completed middle panel and partial framework for top panel.

                                                                        
  We then attached hand-carved trim pieces to the loft ladder, to add stability as well as for appearance.  We finished installing the tread reinforcement rods beneath each step, and added slider feet to the bottom surface of the ladder legs (along with the felt pads applied earlier).
                                                                               

Loft ladder with reinforcement rods and carved trim.

                             
Siobhan and I put down wall-to-wall rugs in the main room, as well as in both sleeping berths, to protect the floors; we used carpet tape to hold the rugs securely in place.  We stained and nailed down the baseboards to each side of the entry door, as well as the vertical trim pieces from floor to ledge.
                                      

Rugs in main room; view of pull-out table and loft ladder in background

        
                                                                        

Rugs in upper sleeping berth.

                                   
A flurry of snow flakes fell on Nov. 11... But the following week, temperatures reached 70 degrees on several days, and we worked like mad on the wagon. Since paint will not cure well in colder temperatures, Siobhan and I decided to take advantage of each warm day, using it to paint any wood that we might need in the next few weeks.  Then on days that are too cold to paint, we can saw and hammer.  At least, that is the latest plan!

We have now stained enough 2" x 2" lumber to build the remaining two panel frames (top side panel/left and top side panel/right); we have painted enough siding boards (interior and exterior surfaces) to cover each panel.  On our last trip to Lowes, we purchased enough 2 1/2" wood screws and 1" panel nails to assemble both panels.

While we were staining and painting, we applied an extra coat of polyurethane to our pull-out dining table, and added an extra bracket to the rod the table hooks onto-- just for additional support.
                                           
                                          

Concealed door for pull-out dining table; concealed brass piano hinge and door support.

Pull-out dining table, 2' x 4'

                                                                                  
                                        

Hand-painted design on table top.

Hinged folding legs with locking mechanism; brass casters on each foot

                                       

Hand-carved oak handle on front end of table, for easy removal from storage compartment.

                                             

Siobhan and I have finished building and staining the framework for the last 14' panel on the right side (the top right panel ).  A 6'4" section of the 14' framework will serve as the upper berth's right wall; this section is now secured in place.  The siding boards for this section are ready to install-- both sides painted and sealed with polyurethane.  With a little luck, we can nail up this wall tomorrow.  Once the 6'4" section is complete, we can attach and secure the 8' section of framework, then nail on the remaining siding boards to complete this panel.

**At this point, the window opening in the 8' section will only be roughed in.  When the remaining panel (top left) is built--mirroring the right--and secured, then we will hang the two windows, (using brass awning hinges), and build the window frames and screens.  Then we will build the concealed tracks and hang the exterior sliding shutters.
                                                 

Antique stained glass window purchased for top right panel of wagon; still partially wrapped in plastic and surrounded by pink foam...

How our work will progress in the next few weeks is anybody's guess...So much depends on the weather (which is always unpredictable).  And Christmas is just around the corner (our favorite time of the year!)   And then there is New Year's Eve.  Hmmm...  Maybe I'd better get back to work!

Until next post...



Hekta!
(Make haste!)