Making curtain rods
I patterned these after this corner curtain rod because it worked out well and I liked how the rings slide past the mounts.
I cut these from one of the long oak boards left over from when I made the baseboards for the house.
I used a 1/4" round over bit to round all the corners.
The next job was making the curtain rings. I needed a lot this time. I decided to make a more durable steel bending jig out of a scrap of metal, consisting of just a hole in one side and a corner cut off the other side.
This worked, but not as well as I had hoped. The nail bent away from the metal as I bent it around the jig so the corners ended up very rounded.
I also ran into problems of the nail breaking at the last bend nearest the head. That part of the nail is particularly work hardened from the manufacturing process. The 90° bends nearer the tip didn't break any nails, but a few broke with the last 45° bend.
I started by grinding off the tip of the nails. First using a bench grinder (like this one), but then I tried my belt grinder and that ground much faster and cleaner. I'm starting to see why people like belt grinders.
The heating of the nails left them tarnished, so I sanded them back to a shiny. First by spinning it in this drill while holding sandpaper around the nail, but the stepped speed control of that drill was just infuriating. I'm starting to hate that drill.
Then I tried my strip sander and that worked much faster.
I made about 80 of these. I dipped them all in some varnish (this varnish), which also works on metal, makes it slippery, and to some extent prevents rust. I hung them off a string to dry.
I put the nails (rings) in a paper bag. Pulling one out, the nails sometimes interlocked and formed clumps and chains.
Then cutting a tenon on one end using my pantorouter.
And sanding everything smooth on my belt sander.
I cut mortises into the curtain rods for where the mounts attach, using my slot mortiser.
A short piece of dowel goes into the end of the curtain rod to keep the rings from sliding off.
I made rods for four windows. The two bigger ones also have a mount in the middle. I assumed the studs were right next to the windows and a header above to screw into. But of the ten mounts, I found a stud where I expected it just once!
On the smaller windows the studs were further apart than anticipated. I cut off the mounts ad made new mortises for mounts further apart (lucky I made a few extra mounts) In the living room there was a header above the window, but it was not directly behind the drywall. Longer screws were able to reach it, but I wasn't sure about the leverage pushing against the drywall with no wood behind it, so I glued an extra piece to the bottom of the mounts for more support. For the master bedroom I glued a small block to the side of one of the mounts to hit the stud. The one on the other end of that was the only one that hit the stud as expected, And for the middle one, I resorted to using a drywall anchor.
If I did it again I'd locate the studs before attaching the mounts to the rods. I originally considered attaching the mounts to the rods with screws. That would at least have given me the flexibility to move them where I needed them.
Next it was Rachel's turn to make a whole lot of curtains.
A different colour for every room. We had been cautious picking out the colours when we had the house painted. We wanted bright colours, and strong colours are darker and can become overwhelming over large areas.
But with all the walls fairly close to white, we went for bolder colours with the curtains.
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