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Ken Martin

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Hi Friends

Wanted to share with you our latest order.
A lady from Sweden ordered 30 of our little planes from the Toymakingplans.com toy plans called the "Little Village Toy Plans for Table Saws"

We were and are excited about the order, but 30 of anything is a lot of parts.
These little airplanes will be flying out of FuzzyDuck's Shop tomorrow.

DSC06910_mini.JPG 
JL is having his 3rd birthday in May and Mom wanted to have a special toy for each of his friends coming to his birthday party.  She asked if we could paint the birthday boy's plane and his brothers green and yellow, and if we could mark the wings for them somehow.
This is what we came up with.
DSC06923_mini.JPG 
I sure hope these planes survive the flight to Sweden.  We will be packing them up tonight.  Will let you know how the flight goes.

DSC06925_mini.JPG 
Doing this big a project really made me appreciate Cindy big limo bus build she did at Christmas time.

Let me know what you think.  Thanks


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Kenneth W Martin
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Udie

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Reply with quote  #2 
Ken - Wow, what a great armada of planes, they look absolutely great, great colours and nice touch in personalizing the birthday boy's and his brother planes.
So, how much time did you take to set up the photo, that had to be fun. I can just imagine you using a laser for perfect alignment and spacing. LOL.
ctowne

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Reply with quote  #3 
VERY nice Ken.  great sale!!  I like the initials in the plane wings to personalize them.  The finish on all look perfect and colors are great.  How much time do you think you spent?  What was the main thing you learned from a large order?
Cindy
Ken Martin

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Reply with quote  #4 
Hi Udie and Cindy and thanks for the nice comments about the planes.

Udie I did not use a laser to set them up with, but now that you mention it, it would be a good idea.[wink]
I tried to set them up as straight as I could because I knew you would be looking with your Udie scoop. 
I did not think the two dark colors would go together all that well, but that is what the lady picked out.
The colors ended up being good, because they are some of the easier colors to paint with.  Painting was done with Krylon spray paints.
The brown was the best.  I used Lloyd's painting tips for the brown parts and they came out really good.
The red was a little harder to get the look I wanted, but it is OK.

Cindy I am not sure about how much time it took because I did not pay that much attention to it.  I was working on several other orders at the same time.  I would think it took about a week.  Cutting the parts was easy, once the table saw was set up for each part.  Sanding was another story, and took the most time of anything.  I did round all the corners of the wings on the disk sander, and sanded all the flat sides on the belt sander with 120 grit paper.  Then we re-sanded the sides with two lighter papers, and did all the edges with the nail file sanding sticks.  Painting was not to bad, but the biggest thing was where to you put all the parts while drying.  30 of anything takes a lot of space.
For the small parts I used Udie's trick of the hot glue on the head of a nail to give  me a handle to hold while painting.  As you can see I stuck the nails in the tops and sides of foam coolers to hold them.
DSC06856_mini.JPG 
 For the bodies I used a dowel thou the axle hole as a handle then hung them on the peg board on my cabinet doors.
DSC06853_mini.JPG    
 There needed to be 68 axles cut and painted and 136 wheels painted.
DSC06863_mini.JPG  DSC06860_mini.JPG 
Biggest lesson is to be patient, because doing any part of a big multiple job is going to take a while.
The second lesson: I was glad we started making multiples of toys some time ago (like making 5 to 8 of each project) because it helped me be ready for this bigger build.
Another lesson is to be careful what you wish for.  Big orders are nice to get, but you are going to be very busy for a while.

Thanks again for the nice comments above Udie and Cindy.


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Kenneth W Martin
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Bucko

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Reply with quote  #5 
Very impressive indeed and no doubt of the "patience ". Awesome follow up with the pics, I'll come back and check them out better later.
Udie

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Reply with quote  #6 
Ken or should I say Gepetto Ken
It's like looking thru a window into Santa's Workshop, parts everywhere. Great idea using the pegboard as you did, what a space saver. Glad the nail trick helped you. For sure it allowed you to paint the surface, bottom and edges more easily.
Your photos really give us incite into large quantity builds and the space required to support such a build.
Thanks for posting.

Couple of questions: Spray painting - how many cans of paint were needed for this project and did you prepare each part with a sealer or primer?
Any idea how much the combined parts will weight for shipping, that's going to be a big package.
Ken Martin

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Reply with quote  #7 
Hi Udie

Thanks for the kind words.  Yes there may be parts everywhere like Santa's Workshop, but unlike his workshop mine is a mess.  I did have 3 other projects on the benches while working on the planes.

As for the cans of paint, we used 3 cans of Krylon's spray white primer, 4 cans of Krylon's spray cherry red(because of the wheels) , and 3 cans of Krylon's leather brown, and 1 can of Krylon's Triple clear coat.  Cost per can at my local Wal Mart is about $3.62 per can.
I used the triple clear coat on the red wings only, because I did not like the look I was getting with the cherry red.  The brown body, cab, and tail looked great with just 2 coats of the leather brown(I was using Lloyd's way of spray painting) and I did not want to take a chance with the clear coat on them.  Sometimes the Clear coat, because it sprays so fine, and you need a heavy coat, it is hard for me to get it on right without runs or the clouding effect you sometimes get with it.  So I decided not to take a chance with the brown parts, because everything was going to get a coat of Cynthia's Beeswax/Mineral Oil paste was before shipping anyway.

I did not know about shipping weight until today.  However, to get an idea of the cost of shipping I had taken one of the this type of plane to the post office and asked them to weigh it.  Then we took the weight times 30 to get an estimated weight, then gave him the estimated size of the box, so he could give me an estimated cost.  Several weeks ago the estimated cost for the shipping to Sweden was $65.00.  I got confirmation and payment from the client for the toys and the shipping then started building.  All though the build I was worried about the cost of shipping, what if it was a lot more?
Today when I went to ship the planes the cost of Shipping was $65.35 and will take 10 days.  Boy was I relieved.  The weight of the box ended up being 10lb 12.6oz.  I had decided to use Redwood for this build because it was the lightest wood I had.  Glad I did.

Building this set was quit an adventure in building and shipping.  Now we just need to see if I packed the box well enough to stand up to the shipping.

We will see in about 10 days.

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Ken Martin

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Reply with quote  #8 
Thanks Bucko
This was an interesting build.  Good thing for me it is a simple build, because I am not very good with a table saw.  I was able to cut everything with the table saw except the slot in the body for the front wing to sit.  That slot I cut with the scroll saw.  I know my friend Udie will be rolling his eyes[rolleyes] saying you could have done it with a table saw, but it is easier for me on the scroll saw.
Thanks my friend for the kind words.

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Bucko

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Reply with quote  #9 
Great write up to go with the pictures, makes me wonder what Mom would like made for next years Birthday for JL ?
john lewman

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Reply with quote  #10 
This is a professional toymaker set up and the production quality is tops. Have you sent these photos to your customer? If not, please consider doing so. The photos are impressive.
Ken Martin

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Reply with quote  #11 
Hi John

A big thank you for the overly kind words about the little planes.

I send photos to my customers as I build their projects, especially when they are custom orders.
It is my way of keeping in touch with them so they know I am 1; working and 2; have not forgotten them.
I sent photos of the plane bodies when they were hanging on the peg board drying.
I sent photos of all the parts on Udie's nails with the hot glue while they were drying.
I sent her a photo of all the wheels, because that impressed me.
Then I sent her photos of the letters carved in the wings, just to be sure I had both right.
Then just last night I sent her a photo of all the planes on the table ready to ship.
Last I sent her a photo of the box showing her name and address and the box markings to be sure we had everything right again.

The hip is great for customer awareness, and keeps me focused on doing the right thing.

In other words I do send photos to my clients.
Thanks for bringing that point up.  I think it is a good idea for all of us to do, but I never thought about posting it.

Again thanks for the kind words.

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ctowne

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Reply with quote  #12 
Ken and John - great idea of sending photos as things progress. 
Cindy
Udie

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Reply with quote  #13 
Ken - Thanks for the break down on spray cans used and all the rest. Really gives the members an idea of materials other that wood required, project time and things like that.
Great tip about keeping the customer involved during the build with photos, shows progress and no way they can be surprised on what they will be receiving.
Ken Martin

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Reply with quote  #14 
Thanks all.
As far as sending the photos to clients while building, you are absolutely right Udie.  Not only does it keep them informed, but it protects you from them saying after the get the toy, "oh, that is not what I was expecting."

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JTalbot

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Reply with quote  #15 
Great work Ken! One thing I would like to add here, it does not hurt to pre make parts for your items, and keep them in bins. That way, when a big order comes in, all you really are doing is assembly and finish. Love the paint job!
Jeremy

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Jeremy Talbot
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