Initial Workspace

I have started making preliminary CAD models of the Corner Entertainment Center.  I first created an assembly in Alibre Design, and then added a part called Workspace to the assembly.

In this workspace part, I drew the area of the room in which the entertainment center was going to sit.  Basically I drew a corner of a room.  Nothing dramatic here, just two walls and a floor.  I did this to help visualize the area in which the piece was going to live.

I then created a new part called TV.  Using dimensions given on the stores website, I drew the television as best as I could.  As long as the overall sizes are close it will serve its purpose.  I really just needed a visual representation so that I can get a sense of scale.

Components

I also made parts for the different components that needed to fit into the entertainment center itself.  These were basically just “boxes” drawn to scale.  Again, I found the dimensions for each component either on the website where the component was purchased, or the manufacturers website.  All of these components, including the TV, were placed into the assembly and moved “roughly” into position.  Of course, now they are just floating in the air in the corner of the room.

At this point, I really needed to start roughing in the entertainment center itself.  First I drew the top and angled the ends in order to see how this was going to fit into the corner.  I started out making the top the maximum length that would fit in this particular space.  I didn’t want to get too detailed in drawing the main carcass for the entertainment center quite yet, so I started out by just drawing a box and then just sketched in some details in order to visualize the end product.  Until I get the overall shape and size  to look right, I am not going to start drawing any individual parts.

Finished Workspace

Shown to the right is what I have come up with for a concept design.  What I have decided to do is to make the entertainment center “reversible”.  Because of the angled ends, I think it will look better up against a flat wall if the back becomes the front.  This will present some design challenges when I get down to the details, but for now that is the plan.

Also, I decided to do a few renderings of the entertainment center for a couple of reasons.  First, to help get a better sense of what the final product might look like, both front and back.  This will help me get a better sense of what it will look like if I turn it around and put it up against a wall.  Secondly, well, because it was just a lot of fun. 

Shown below are some of the different renderings that I did. Rendering 4 shows what the entertainment center will look like when it is turned around.

As with any of the images on the site, click on them to enlarge them for a better view.

Rendering 1

Rendering 2

Rendering 3

Rendering 4

After that, I will continue the Workshop design series as well.  I ran into a bit of a snag with that design;  I have to start the design completely over.  I no longer have access to that particular CAD system that I was designing it on, or even the CAD files for that matter.  That is a really long story that I am not going to get into here.  Once I get the design in Alibre back up to where I was before, then I will continue the article series.

Anyway, I just wanted to let everyone know what was going on.

The first step will be to list all of the design requirements, and the first requirement is going to be about the space in which the piece will be  sitting.  The piece will be sitting in a corner of a room, rather than directly up against the wall, hence the name “Corner Entertainment Center”.  The unique design challenge here is that eventually it will be placed up against a wall and not in the corner.

What this means is that this cannot be a “built in” cabinet, it will need to be a movable piece of furniture.  My initial thought is to make a credenza style entertainment center.  The problem is that a credenza doesn’t really look good in a corner of a room.  However, if I were to angle the ends of the credenza it would be a better fit in the corner.

But, what would this look like up against a wall?  This might look a bit odd because now the ends would angle inwards toward the wall.  I am not sure if this would be aesthetically acceptable or not.  I will have to do some sketches and some mock up CAD work and see what it looks like.

The next requirement is that there will be a 55″ HDTV sitting on top of the entertainment center.  The TV is about 52″ wide so the top of the entertainment center has to be at least that long.  The diagonal measurement across the corner is 81″, so the length can be between 52″ and 81″.

The next requirement is going to relate to storage capacity.  It needs to be  able to house several components such as a DVD player, Stereo, DVR, and a Wii gaming system.  It also needs storage for DVD’s, CD’s, Wii games and controllers.

So, here is the list of requirements that I have so far for the corner entertainment center.

• Movable piece of furniture (not built in)
• It needs to look good in a corner as well as up against a flat wall
• The length needs to be between 52″ and 81″
• Lots of storage capacity

Now, off to the drawing board! Or should I say the computer.  Hmmm.  I am already there.  I guess I better get to work.

Alibre Design

To fully answer why I chose Alibre Design I should probably give you some of my background with CAD/CAM systems.  I started out about 20 years ago designing plastic injection molds and programming CNC machines to cut these same molds.  The CAD systems that I have used over the years have always been considered very high end systems.

I currently used Unigraphics NX at my day job.  A single “bare bones” installation of NX will cost somewhere around $5,000.  On top of that, we add in assembly functionality, drafting functionality, and a mold design add-on.  This all adds up to about $20,000 for a single installation.  These systems that I have been using professionally are very high end, very powerful, and quite easy to use.

When I decided to look for a CAD system to use for Maple Grove Woodworks projects, I realized that I was quite spoiled when it came to the CAD features that I was looking for.  I really wanted to find a system that had similar features, the same ease of use, but not the cost of a high end system.  Well, I knew that I was going to have to sacrifice on some of these things, but I was bound and determined to find the system that gave me the closest thing to what I really wanted for the least amount of money.

One of most important features that I wanted was for the CAD software to be both a three dimensional(3D) and two dimensional(2D) system.  What I found was that many of the low cost CAD programs out there were only 2D.  I know that some people like to draw in 2D and use software like DeltaCad or CadStd and that is perfectly fine for them.  It is just not the way I like to do things.

My own design process usually starts out with a 2D sketch on a piece of paper. At that point I will try and draw it three dimensionally in order to get the joinery figured out.  Sometimes, I will prototype something at this point in order to clarify the scale or refine a shape.  Once I have everything drawn 3 dimensionally, I will then make a set of working drawings to take out to the shop, although, lately I have just been taking my laptop out to the shop and using the 3D model to take measurements.

The 2D systems just were not going to work for me.  I would rather get the old drafting table out with a T-square and triangles.  (Remember, I’m spoiled).

I then decided to then look into Google Sketchup.  It certainly meets my cost criteria for a new CAD system and there are a lot of woodworkers using it.  It is also a 3D system.  I proceeded to design a few projects with it, and Sketchup is … well … fine.  I know it works for a lot of others out there, but I found it very cumbersome.  (Again, I’m spoiled)  I was able to design pretty much anything I wanted to, but the “ease of use” criteria was just not there.

This is certainly a matter of preference because I know that there are a lot of woodworkers who do very well with Sketchup, such as, Bob Lang at Popular Woodworking.com, or Tim Killen and Dave Richards over at Fine Woodworking.com.  These guys have really mastered Sketchup and have taken it to new levels.

Coffee Table

One of the features that I was really looking for that the higher end systems have that none of the lower end ones have, including Sketchup, was parametric feature design capabilities.  What this means is that everything that I draw has a history of every operation that I used in creating a particular part.  In other words, if I create a 1/4″ fillet on a piece and then later on decide that the fillet should be 1/2″, all I have to do is edit the fillet feature and change the dimension.

It also means that if I design a Mission Style Coffee Table and then realize that I would like a matching End Table, I could simply change the length dimension of the table top and the corresponding length dimensions of the cross members would automatically change as well.  As an added bonus, all of my drawings would update with the new dimensions too.  (I am planning on making a video of this at some point to better explain this).

I decided to keep looking for the perfect software for me.  I finally came across Alibre Design.  Alibre has 3 versions of the CAD design

End Table

software.  The low end version is called Alibre Design Personal Edition (PE).  At the time of this posting the PE version retails for $99.  This falls in the range of my cost criteria.  It is also both a 2D and a 3D system.  All of the Alibre Design products are also parametric, so it also meets my criteria of having some high end features.  The coffee table and the end table shown are from the same design and by just adjusting the length dimension I now have 2 designs.

I decided to download a trial version and test it out.  I really liked how it worked.  Its approach to designing things very much mimicked the higher end systems that I was used to.  This meant that it met the “ease of use” criteria.  I have since purchased Alibre Design and have designed several projects in it now and I am completely hooked.

So, that was the long winded explanation of why I chose Alibre Design as my CAD system for Maple Grove Woodworks.  And, like I said earlier, I am planning on make a couple of videos of how Alibre Design works and I will post them here when they are complete.

Besides all of the visual changes, you’ll notice an open space in the upper right hand corner of the home page labeled “Featured Video”.  I am planning on some videos soon for the site and the most recent will be featured in this location.  Some of the videos will be “how to” woodworking videos filmed in the shop, and others will be design oriented.  The design videos will be Computer Aided Design (CAD) oriented, and will hopefully be helpful to some people.

Another noticeable difference is that the blog has been taken off of the home page.  Don’t worry, it’s still here.  It now has its own page on the site and can be accessed through the menu at the top of the page.  I wanted the site to be “more” than a blog, although I am still contemplating what the “more” will really be.  I just thought that it made sense, at this point, to move it off of the home page to make room for the “more”.

Feel free to look around at what I have so far.  I am always open to constructive comments if you have ideas about how something could be improved.

Front View (Click for larger view)

Here is a quick update of where I am on the workshop design.  If you remember from my first article, the footings and frost wall already exist so I cannot modify anything with them, but every thing else is fair game.

I am not quite as far along as I had hoped to be at this point with the design, but here is what I have so far.  As you can see from the pictures, I have the wall studs up on 3 of the sides.  I have to research the rough opening sizes I’ll need for the doors before doing the fourth wall.

I also have one of roof trusses drawn.  Actually, I haven’t decided if they will be premade trusses or if I will just build them on site.  You can now see what I mean by a center aisle horse barn.  The difference here is that my workshop will not be raised on the interior, the raised section will house the second floor.

Iso View (Click for larger view)

The next step will be to finish the front walls and the rest of the roof trusses.  Then I will start adding the sheeting on the outsides of the walls and drywall on the inside of the walls.

Mary Kay Give Away Display

A couple of years ago, I had a client who sold Mary Kay cosmetics.  She wanted me to build her a display that she could place near the cash registers at local businesses.  People could fill out an entry form and place it inside the display in order to win prizes.

She wanted the display to be a little nicer and have more class than the usual cardboard box or fish bowl that you normally see for these types of things.  She also did not want it to have a very large footprint.  Business owners would be more likely to let her place it on their counter if it didn’t take up too much room.  It also couldn’t be too small or else it wouldn’t be noticeable.

The display also needed to have some sort of “back” to it so that a pad of entry forms could hang from it.  Above the entry pads, their had to be enough room for a sign explaining what the entry forms were for.

I decided that even though this project was not going to be a very large one, I really needed to go through the entire design process.  The design needed to be more than just a rough sketch before I started building it.

Cad Design

The first thing I did was to make a prototype out of some cardboard.  This was just to determine the overall size of the display.  I wanted to get a good visual of the size to show my client.  I ended up making a couple of different sizes to present.  This part of the process really only took about 1/2 an hour.  I basically cut up a few pieces of cardboard and taped them together to form a box for the different sizes.  I also mocked up the “back” with some cardboard as well.

Once this was done, I began modeling the design in my CAD software.  This allowed me to get all of the joints figured out, as well as give a nice visual representation of the style for my client.  Between the cardboard mock-ups and the 3 dimensional CAD design, I felt that I had enough to show the client and see if she wanted to move forward from there.

Display Closeup

From the very beginning, I had a certain image in my head as to what the box should look like.  I didn’t consciously design it with an Asian flair, but that is how it turned out.  The curved legs, and curved edging of the top accomplish this.  I also wanted to add some marquetry to it as well.  I decided on a very simple rose pattern for the front of the box.

I have always liked the contrast between walnut and maple and decided to use them on this project.  In this case, I would use some curly maple that I had left over from another project.  I would also use purple-heart and cherry on the rose.

Rear View

My client loved the size and design that I had come up with, and gave her approval for going ahead with the project.  It was at this point that I decided I would need some jigs and patterns made up so that I would be able to make several of these.  In order to come up with the jigs and patterns, I built a prototype of the box out of MDF and pine.

The prototype allowed be to work out some of the challenges of creating some of the curved pieces and the joinery. The legs of the piece are curved on two faces, not just tapered.  Once the prototype was complete, I began making boxes.

This worked out well until we decided to move.  In 2004 we built a new house out in the country.  The new house had an attached garage which was large enough for a small workshop and both cars.  I decided, though, that I would like a dedicated building for a workshop that was the same size as the garage.

So when the concrete was being poured for the basement of the house and garage, I also had the footings and frost wall poured for the workshop.  At that point we finished the house and garage, but due to financial reasons the workshop was left as is… just a short cement wall sticking out of the sand.  My kids have had a great time playing in what I call “the most expensive sandbox around”.

I am now planning on building the rest of the shop next summer.  So I though I would start the design process, and have everything planned out before construction begins.

Workshop Floor

The outside dimensions of the frost wall are 24ft by 32ft, giving me just under 768square feet of floor space.  As the design progresses I will update the the blog with new images of the design.  so far, all I have drawn are the footings, frost wall, and the cement floor (in the image the green represents a little grass around the outside).

As you can see there is a break in the wall for a large garage door and an entry door.  The next step will be to start throwing some lumber at it and constructing some walls.

My day job actually helps my woodowrking business.  I use a Computer Aided Design (CAD) workstation to design tools for the plastic injection molding industry.  I have been able to design projects on my CAD workstation during lunch hours, or coming into work early.  This has been a huge help when figuring out complicated joints.

The CAD software I use is called Unigraphics.  It is quite a high end piece of software.  I don’t know for certain, but I think it is around $20,000 for a single license.  It is not something I would buy for a small single man woodshop.  But as long as I can use it for free it works great.

The initial purpose of this blog (I say initial because the purpose may change as the site evolves) is to document how I design and build my projects as well as a showcase for them.  Feel free to make comments or ask questions about any of my postings.  I hope to learn as much as I can from the woodworking community at large and help anyone else on their woodworking journey as well.