I found a few plastic versions on the internet. Although they looked like they would work fine, they are from $4 to $8 each. We needed a hundred or so (putting a few per row). As normal, we had no budget for this. So I decided to try to build some. Sorry I don't have exact specifications any more, but maybe this blog will give you some ideas:
I got some red-oak from Home Depot. Any wood would be fine, but I would suggest a hard-wood.
Here's a sample of the wood cut:
![WP_20140501_002](https://drowland.files.wordpress.com/2017/08/wp_20140501_002.jpg)
Here's how I cut the area for the cards in each holder. I just clamped borders on 3 sides, of my tablesaw. I installed my dado blade. The goal is to quickly rip out the un-needed wood. This could have also been done with a router.
![WP_20140501_003](https://drowland.files.wordpress.com/2017/08/wp_20140501_003.jpg)
This shows the process of cleaning out the wood. Looking back, this makes me nervous. At the time, I didn't have a Saw Stop. I currently have a Saw Stop JobSite saw. At least if I screwed up, hopefully the Saw Stop would catch it... Here's a link to the Saw Stop: SawStop JSS-MCA Jobsite Saw
![WP_20140501_004](https://drowland.files.wordpress.com/2017/08/wp_20140501_004.jpg)
Here's a pic of the holder flipped around after the wood was cut away. As you can see, the bottom is super clean, but it doesn't matter and that part doesn't show.
![WP_20140501_005](https://drowland.files.wordpress.com/2017/08/wp_20140501_005.jpg)
Here's my jig I made for drilling the holes for the pens. I put one on each side. NOTE: After drilling with the drill-press, I had to drill deeper with a handheld drill. There wasn't enough travel in the drill-press to go deep enough.
![WP_20140501_006](https://drowland.files.wordpress.com/2017/08/wp_20140501_006.jpg)
Here's the holder after both sides were drilled for pens. NOTE: I have actually cleaned up my benchtop since this pic a few years ago. I'm embarrassed to see how messy it was...
![WP_20140501_007](https://drowland.files.wordpress.com/2017/08/wp_20140501_007.jpg)
OK, so a few sections were skipped (no pictures). I routed the sides, to add some decoration. I also setup a jig to drill the screw holders with the drill press. I used a countersink bit make sure the screw heads kinda disappeared.
![WP_20140502_001](https://drowland.files.wordpress.com/2017/08/wp_20140502_001.jpg)
Here's a look at a few of them. I was testing the size with a standard offering envelope.
![WP_20140503_001](https://drowland.files.wordpress.com/2017/08/wp_20140503_001.jpg)
Here's my test-fit I did. I hadn't painted/stained the holder yet. Just wanted to get approval from senior staff/board before moving forward. Offering Envelope Matthew 10:8 (Package of 100)
![WP_20140502_005](https://drowland.files.wordpress.com/2017/08/wp_20140502_005.jpg)
Once I was to the point of installing them on the chairs (after they were painted), I built a jig to make sure they were installed at exactly the same spot on each chair. Also, please NOTE: make sure the screws don't go far enough into the chair to stick the person sitting in the chair. Especially someone fairly large. They may compress the pad quite a bit... But at the same time, make sure the screws are long enough to keep the holder in place. Since I was normally sitting at the sound booth, I could see when these were in use. Smaller kids would use the holders to pull up. So they have to be fairly well secure. But as far as I know, none have came off. They are also thin enough not to interfere with stacking the chairs...
Here's a stack of ones I built. Seeing this picture remember how much work this was. But it turned out very very good.
![WP_20140515_009](https://drowland.files.wordpress.com/2017/08/wp_20140515_009.jpg)
I built a sanding jig: Basic Sanding Jig I used it to smooth all of the holders.
![WP_20140515_010](https://drowland.files.wordpress.com/2017/08/wp_20140515_010.jpg)
unfortunately, I can't find a final picture of the product once installed. I painted them a very very dark brown. It actually looks black once installed, but a tiny bit of wood grain comes through. The cost of this only came out to be the cost of wood. I think it was less than $40...
If you have built some, I would love to see them.
No comments:
Post a Comment