The Solution

Now all my local specialty shops are closed, at this point, and even if they were open, 1) I'm looking for something they very well may not have and 2) I'm done shopping for the day!  I'm DONE going out and procuring anything further!

The one screwdriver that fits these screws is the large common jeweler's phillips.  You, like me, probably have a drawer of these.  You, like me, have also perhaps discovered that if you over use your hands to torque down screws, you will ultimately cause yourself not only nothing but pain for days afterwards, but also a permanent lifetime injury to your hand.  The powerdriver is here for a reason!  What did I need? A large Jeweler's Screwdriver bitset, in my powerdriver!!

I reached for the closest driver and tried to remove the twirl end with a pliers, then two pliers, and then...well, I just gave up.  This is some TOUGH metal!!!  I though a bit about a hack saw or a jeweler's saw, and then it hit me: Dremel Cutoff Wheel!

About a minute of grinding later - it took a long time to do it, and the tool DID get pretty warm! - that knob fell off and I had a straight phillips bit!  I threw it into the powerdriver chuck, and there I had it, a perfect fine phillips jeweler's bit, backed by the raw awesome power of a corded power drill!!!

I pulled the trigger and amused myself with how perfectly straight this particular bit is - there is practically no travel in the tip whatsoever!!

You'll notice the speedchuck with the 1/16th drill bit in it at the bottom, the black/blue part in the middle is a rubber grip that goes back and further but not round and round.  As it so turns out, this makes a rather nice pin vise of sorts.

I should add, as a result of today's procurement run, my air compressor works perfectly!  [Yes, I got the parts I needed to chuck it up and throw some air around!  Finally!!!]

The Bonus Extra...

And here's the project I've spent the last four weeks of free time working on, whilst dodging out for two weekends with the Girlfriend.  it's a box for a Chess Set, stoneware, heavy, and I'm ready to be done with it!!!

After two weeks, I finally had the boards routed and the panels cut.  then I'd discover my covers were not true 90s, because my miter saw needs adjustment, so off to the store I went for a bench grinder!!!  It seems like every time I do a project, I end up with more tools.  This all started with a layout, long ago, and a set of cordless tools.  Then came saws, routers, sanders, clamps...this project netted me a bench grinder, a couple clamps, and everything I need to get the Air Compressor fired up!! [for blowing out the sawdust on my tools!!]

Finally, I get the box done...and discover i screwed up the top, it's canted over about a 1/8th in inch one way on the top and the opposite way on the bottom.  What more, the top split, so I had to replace the boards any ways.  Ugh...

But the components all fit!  I took a bit out of a day one weekend and cut that foam...tedious!

I thought for a moment I may never see this sight - but there it is!!

And here we are today, with all the fittings in place, minus the side latches and the corner plates.  Yes, I have an affinity for Ryobi... except for that sweet Delta Miter saw!  $45 when a friend had to PCS, what a good deal!

Round 1 stain.  I was extremely smart this time, I rolled out the brown paper under my work area before I started working.  yes, there have been times when I Didn't Do that, and regretted it later!!  the beauty of hte brown paper, is when i finished, I simply threw all the trash and the brushes and such into the middle and rolled it all up, and that was the end of it!  Yes, I said brushes, I buy the $1.00 brushes and when the job is done, I toss em!  Is my time worth cleaning them out, plus the added expense of the cleaner/thinner?  NO!

And so I rubbed off the stain, as required, cleaned up my work area, and arrived at this point here this morning:

Time for Polyurathane...I also discovered to my horror that I forget to reset the white-balance when I came outside.  Ugh...those little details, you know?!

For your viewing pleasure, the final product, minus a couple minor details...they'll be done tomorrow...

The inside...

The inside supporting latticework, which I've decided will simply float.

The Chess Set, finally in place!  Yes, I have not yet cut the upper, I got fatigued with the project for the night, so I just threw some in there for photographic effect.

Inside the boxes, we find the pieces...

All Done, save two projects. 

Obviously yes, I have to cut the top felt and then a layer of felt for the bottom of the inner boxes.  I also need to find felt circles, for the pieces themselves.  But these projects are not pretaining to the box, so there are two projects.  First, I have to drill the holes for the handle all the way through so I can add a brass back plate and 4 nuts, along with machine screws that go all the way through, for added strength.  second, I have to get 8 little 45 triangles, one for each corner, so the topside/bottomside retaining screw on the corner plates has some place to rest.  Tomorrow, or maybe...Sunday!

With this project done, I'll be free once more to get back to trains!!

You are craftsman

Nice work

Benny. But I think your missing a picture of the table saw to saw those long pieces to size and those large square pieces square and to size.

Bernd

Definitely Craftsmanship!

Maybe you could offer layout custom baseboard building in your area as a sideline business opportunity? With your talent for delivering an optional furniture matching finish, you have great appeal for  those folk who have to have their smaller layouts in shared living space and need to keep their partners happy.

I WISH I had a shop!...

Art,

I agree with that, as does my girlfriend.  Right now I have to use the front porch and my kitchen floor, and this place is already tight!  A shop is the one thing I'm missing right now, besides other things like...

Bernd,

I don't have a table saw, and yes, I wish I did have one - something with a 4'x4' or so table!!  But where would I put it??!

I used my handheld circular saw to cut the large sheet - throw down a pencil line, block it up on enough 2x4, and then cut it over the ground keeping a nice straight path.  The long square pieces are 3/4" square, they're available from the hardware stores here in no short supply.  I could have made them on my router table, though - cut the top with the thin channel bit, then flip the sheet over and run it through again!

Andy,

This is my second contract piece.  I dare say If I had a shop, it'd be much more fun doing these projects.  The main problem, though, is the time they take - it's non-trivial!  The other trouble is how much to charge.  My free time is realistically invaluable - but yes, I Can do it! 

What about a mobile shop

Get an enclosed trailer. Probably not enuff room to set it all up in, but you could store your tools in it. Have drop down shelfs on the inside and outside. Drop the outside shelf set the chop box there. Rather then getting a table saw get a  slide arm cutting saw that leans against the wall.I think Home Depot uses one like that when they do custom cuts.

Just a thought.

Rob Teed

Trailers...

A trailer would be one thing, but they're really not right for my area.  For starters, it gets hot here.  But the biggest problem is that people here will steal your trailer just to get the trailer, and know a modular club somewhereabouts had their trailer of modules stolen. 

A full wood working shop worth thousands would be icing on their cake.

Someday, I'll have a real shop.

It turns out a large number of my trainclub are also in woodworking.  I guess it's what happens after you build enough benchwork - it just becomes second nature!