I took the clamps of Section One. Perfect! Well, close, anyway. It really did come out well. A few little glitches were showing, but it was strong and level. Just what I needed. It is much heavier than I thought it would be, but still manageable with one hand.
Last time I put the heavy sides on first, which warp and caused issues for the first Section. This time we'll put the inner slats on first.
I then put on the side panels, still made out of plywood since it was available. Once it was checked and in place with GLUE ONLY, I put in the remaining small slats. A few places were clamped temporarily to help the glue set. Then I left it on the table to dry.
In twenty minutes I had everything but the radius boards on. I want to make sure the frame is very dry and solid before putting on the radius boards. I'll also countersink & screw the frame to the side boards tomorrow.
Each time you cut out one of the frames, you get this odd shaped piece. A long time ago I was taught by my mentor David B. Mueller, Sr. (a great American) that you do not waste anything. So I ripped these up at the 3" mark and made more slats.
My saw is not the best in the world, but like Uffleman commented, I may not be the best sawyer either. To keep the dust out of the house I drag the saw out into the back yard and annoy the neighbors. Carefully I rip up several of the round scraps and make a pile of slats.
My dog is running around like a nut as the sawdust flies. In no time I have the rest of the slats that I need to finish the sections. Well, except the radius slats. My wife and daughter came home and distracted me, so I put away the saw and forgot to saw them! Shit. Well, I'll wait until tomorrow.
On to Section Four, the final section. Actually this is the FIRST frame that I cut out. I saved it for last and with good reason. The webs on the frame were an inch smaller than the others (I changed the measurement after I saw how flimsy they were) and it required some special care. The big problem is that the 1" webs tend to warp. Actually, they DO WARP. During assembly I had trouble getting the wood to lay down even though I've had it laying flat on concrete for a week. A heavy pail helped to hold it in place, but I won't put it in the list of tools!
Where are the legs? Harbor Freight sent me a card saying they had been sent, but they still aren't here.
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