Yesterday, I mentioned all the, er, ‘fun’ had by Ian and Nick (no relation) when they realised that the new wood was correct in width, but not in depth.

This had two knock-on effects.  The first was that the bolts didn’t appear to be long enough to go through the depth of wood.  They got round this by counter-sinking into the wood wider than the width of the nut, thus:-



As you can clearly see here, when viewed from the outside of the greenhouse, the nut is sat inside the extra thickness of the wood.

And yes, I realise that the nut is on the outside, and therefore a possible security weakness, but as the door won’t actually be locked on the greenhouse and there’ll be no actual tools or anything of value stored there through completely clear polycarbonate ‘glass’, so potential thieves will be able to easily see there’s nothing there, we thought it wouldn’t be a problem.

Despite all this, Nick (no relation) later decided that the head end of the bolt, whch has a non-standard fitting may well be the best way.  It would match the first one that did fit without the countersink anyway…

The next, er, challenge Ian and Nick (no relation) faced was that with the new wood being just too thick, it wouldn’t fit ‘inside’ the aluminium extrusion of the louvre mechanism:-



The famous line quoted on the ill-fated Apollo 13 Mission sprang immediatley to mind:-

“Er, Huston, we have a problem.”

Why would this be such a problem?  Well, if you think about it, if the extrusion wouldn’t ‘sit’ properly flush with the wood surround, it would make the gap between louvres smaller.  In this case more than about 6mm.  Given that the measuremnts taken were pretty precise, then this would be a problem -the ‘glass’ wouldn’t fit.

Luckily, Ian and Nick (no relation) immediately spotted this yesterday and Ian brought his ‘bastard file’ (…No! That’s not swearing, honest!  …Though if truth be told there were moments went the air went blue…) to remedy the problem.

Nick set about ‘taking a corner’ off the wood, and soon enough, it all fitted prefectly, so the rest of the wood on all the louvres was filed down.

Corner, wax and stain

Corner, wax and stain

While this was happening, Ian was busy sealing up the top of each wooden post with melted candle wax.  Diane insisted that Ian use green candlewax, so after this was applied and Ian had given them all the first coat of water-based woodstain, they looked something like this:-

Two mouse-clicks to get it to a decent size, and you can clearly see Nick’s chamfer, Ian’s wax and the wood stain.  Neato, eh?

More soon!

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