Tapering, pattern cutting, coves, kerf bending, and raised panels. Those are just 5 of the things you may not have realized you could do with your table saw. During the Woodsmith Woodworking Seminar podcast, Ted Raife, associate editor for Woodsmith and ShopNotes, gives us safe, fast, and efficient tips on completing all five techniques.

Be sure to check out the Woodsmith Podcast Store. If you’re interested in picking up a downloadable copy of the seminar guide, so you can follow along during the podcast, you’ll find it there. Plus, there’s a link to a good deal on the Forrest Woodworker II Premium table saw blade that Ted used during the seminar.

John Singley of Tucson, Arizona sent us a reader’s tip for ShopNotes magazine. In his letter, he mentioned that he volunteers for the Old Pueblo Trolley Museum.  John says,

“The trolley I am working on is the Lisbon/Aspen P&MU. It was taken down to the frame and we are replacing most of the woodwork. We have been working on it for 2 years and expect to have it complete and in operation in about another year.”

Needless to say, there is a lot of woodworking that has to take place to restore these vehicles to their former glory. Check out some of the restoration work at the museum’s web site.

As I was stepping out to do a seminar on hand planes and scrapers at the Woodsmith Store last week, I noticed a couple of new items on Randy’s desk. He had just received two new planes from the Blum Tool Company, a small firm in Walnut, Iowa. The owner, Gary Blum, was kind enough to send Randy a smoother and a jack plane. They were strikingly beautiful with their all wood bodies of maple and cherry. And they had a very unusual blade and adjustment arrangement, But I’ve seen good-looking wooden planes before and been a little disappointed. For a lark (and because I thought they’d at least make good window dressing at the seminar) I took them both with me to the store.

After setting everything up for the seminar, I had a little time to spare. So I dug out the instructions on the Blum planes and gave them a quick glance. I wasn’t planning on doing an extensive setup or anything, but I wanted to at least see how they worked. After all, they had a different design from anything I’d ever tried before.

You see, they don’t have a conventional plane iron. Instead they use a small blade which is attached to a massive (¾”-thick) adjustable, frog-like device. Sounds complicated, right? Not at all. A star knob on the back loosens to allow adjustments of the blade depth. You just set the depth and angle of the blade with two knurled screws, tighten the star knob and you’re off. 

After five minutes of tweaking the smoother, I was taking whisper-thin shavings off a birdseye maple board. Okay, now they had my full attention. I already liked the way they felt in my hand (very light weight with a comfortable tote), and clearly they were serious tools—not just eye candy.

Gary makes only four designs at this time, the smoother and the jack that I tried out and a fore plane and jointer. Prices are more than reasonable, ranging from $199 for the smoother to $245 for the jointer. (Although Gary charges a little more for rosewood versions of these designs.)

To find out more about Blum Tools, check out Gary’s website.

Gun cabinets seem to be a popular project among woodworkers.  Gun owners like to show off their collections.  The problem is, most gun cabinets are nothing more than a cabinet with a glass door.  That make’s it easy for thieves to “smash and grab” the contents.

Nestled in the heart of an Amish community is a small shop that makes high-end gun cabinets. But these aren’t your standard cabinets.  They use an exclusive locking mechanism that makes it very difficult, if not impossible, to steal the guns. 

The cabinets are made using traditional woodworking tools, but with a unique power source.  The Amish don’t use electricity. So there’s a complete cottage industry in the Amish communities that converts power tools to alternative forms of power.

You can get the whole story here.  It’s worth the read.

A while back, in a previous post, I talked about the news that Shopsmith was in financial trouble. The news today confirms it. Robert Folkerth, the president was quoted as saying,

“…the company ’significantly reduced’ its reliance on sales representatives who often travel to shows to sell Shopsmith’s tools and accessories.” 

Wait a minute. Did he say they cut their sales force? What that tells me is that they don’t see much hope for the Shopmith product that we’ve known and loved since the mid-70’s.  Has the competition for lower-priced standalone woodworking machinery pushed the Shopsmith out of the market? Sadly, I think it’s just a matter of time before Shopsmith goes the way of other woodworking machine manufacturers. Soon, the only place you’ll be able to read about them will be on the Old Woodworking Machines web site.

I remember watching my Dad work around the house and in his basement shop when I was a young boy.  Most all of the tools he had back in the 60’s and into the 70’s were Sears Craftsman.  At some point in time he managed to get a Porter-Cable circular saw and the occasional Skil tool.  But really, there wasn’t a whole lot of choice in readily available tools for woodworking. Nowadays, you can go online or pick up the phone and order almost any tool from anywhere and have it delivered directly to your door.

But not only have tools changed over the years, our attitudes and methods have changed, too.  To get an idea of what I mean, look in on this discussion on WoodNet.  Add your 2¢ on how woodworking has changed in your lifetime.

Here’s something you’ll want to put on your calendar. PBS will be airing a show entitled, “Craft in America: A Journey to the Artists, Origins, and Techniques of American Craft.” It will air in three episodes beginning on May 30. The most notable artist to be featured—as far as woodworkers are concerned—is Sam Maloof. You can see a list of other artists to be featured here. The web site has a cool virtual exhibit that will show you some of the work of the artisans.

To find out when Craft in America airs in your local area, click here.

In a former life, I worked in an industrial laboratory and later, in many manufacturing facilities setting up labs.  We ordered a lot of supplies from Grainger.  You’ve no doubt heard of Grainger.  We source them a lot in Woodsmith and ShopNotes magazines for some hardware items you might not be able to find at your local home center.  They established their roots as an industrial/commercial supplier. 

They have a subsidiary company that specializes in supplying laboratories — Lab Safety Supply (they have some cool stuff you can use in the shop, too).  I used to order a lot of lab supplies from them.

Turns out that Lab Safety Supply is broadening their market.  They recently acquired McFeely’s.  You know McFeely’s from their cartoonish catalog covers of Jim Ray, the owner.  They rose to fame in woodworking circles by supplying square-drive screws.  I love to use square-drive screws in my shop.  And if you use pocket hole joinery, you already know the benefits of square drive screws.  McFeely’s has an interesting history that you can read about here.

According to this press release:

“McFeely’s will be marketed as an independent brand by LSS, the leading direct marketer of targeted, specialty business products in the safety, industrial, environmental and homeland security markets. Through a similar direct marketing model, McFeely’s serves over 70,000 active customers including serious woodworkers, handymen, home improvement professionals, construction companies and cabinet makers.”

Some woodworkers consider a band saw the most useful tool in a woodworking shop. You’ll learn why Doug Hicks feels this way during this week’s Woodsmith Woodworking Seminar Podcast. During this podcast, you’ll get some tips for buying a band saw and blades. Plus, you’ll learn how to properly set up a band saw and a few techniques you can perform with this versatile machine.

If you’re interested in picking up a downloadable copy of the seminar guide (in case you want to follow along during the podcast), be sure to check out the Woodsmith Podcast Store. Also this week at the store, you’ll find a link to some good deals on a few band saw upgrades that Doug mentioned during his seminar. And as always, all of the great information provided during the seminars comes right from the pages of Woodsmith magazine. If you like what you see in the podcasts, click here for a free preview issue of the magazine.

(Photo courtesy of DesMoinesArtsFestival.org)

The Des Moines Arts Festival, rated among the Top 5 in the U.S., celebrates it 10th year in 2007. Featured will be over 150 premier juried artists and 24 “emerging” artists from the state of Iowa. Artists will exhibit in 14 categories, including wood, metalworks, and sculpture.

I think this is the second year that the festival will be located in Des Moines’ new Gateway Park, just down the street from the August Home Publishing offices. I’m excited about attending this year and so I’ve spent a few hours looking through the galleries of all the artists that will attend. I always get a lot of inspiration for my woodworking hobby from shows like this, and I’ll even go through a phase occasionally where I’ll work only on boxes or chairs for a period of time after I see something I like at a show.

For the last several years the Des Moines Arts Festival has attracted over 200,000 people and it’s also become a great place for young artists, like Matthew Obbink (whose tables are featured in the photo at the top of the page), an Iowa State University student competing in the Emerging Iowa Artists Program category.

It seems like part of being a woodworker is repairing old furniture, whether it’s your own or someone else’s. You’re probably already aware that working on old pieces like that can present some health concerns (lead paint exposure, for example).  As it turns out, there are some other things you should be concerned about when repairing or even moving some antiques.

Discovery News is citing some info from the CDC (Centers for Disease Control) about the hazards of heavy metals in antiques.  Old mirrors may have been backed with mercury and tin. And clock pendulums or lamp bases may contain mercury. You know…it’s the stuff you used to play with when you were a kid. It’s since been found to be a health hazard.

I remember a few years ago, my wife and I found an old bottle of mercury that had belonged to my mother-in-law, a nurse.  Being the responsible citizen, I took it to our local township volunteer fire department/police station.  I was essentially told to “get it out of here…we’re not responsible if something happens…you’re on your own.”  Wow!  I explained that I had several children in the home and I didn’t want it in my house.  It didn’t matter.  They insisted I remove it from their premises immediately.  So, I took it home.  I ended up having to call the county hazardous materials department.  They sent a guy out.  Turns out he was an old classmate of mine in high school.  He laughed when I told him what my local fire department told me, but he donned heavy rubber gloves, removed the bottle from the house, wrapped it very carefully, and stored it in a well-insulated, shock-protected styrofoam cooler.

Then there was the local elementary school that had to shut down for a day when a child dropped a mercury thermometer on the front steps while returning from an outdoor science class.  You would have thought there had been a bomb blast with all the emergency vehicles and personnel.

So, the next time you need to move Aunt Sue’s antique clock, exercise caution.

Sometimes there’s nothing better than tinkering in the shop and making something just for the sake of doing it. For me, it’s often making my own wood hinges. For Canadian engineer/woodworker Matthias Wandel, it’s wooden gears, geodesic spheres, and other fanciful, if not always practical contraptions. His most recent creation is a Binary Marble Adding Machine, the latest in a series of “rolling ball sculptures.”

Why build a marble machine? Well, according to Matthias, “My Marble Machines are complicated and ingenious, but utterly useless pieces of toy machinery that automate the process of playing with marbles. With toys like these, mankind is free to pursue more productive ends, while leaving the playing with marbles to his trusty automated machine servants.”

I couldn’t have said it better myself.

I don’t know about you, but when I have to do some work around the house or somewhere away from the shop, I usually use a five-gallon bucket with a Bucket Boss to transport my tools. I’ve been using that for years and it has worked fairly well.  It’s great for hauling my portable drill, screwdrivers, hammers, chisels, etc.  

Over on WoodNet, Bob Strawn (aka “CedarSlayer”) is showing off his portable “roll-up” tool tote.  He even went so far as to use a home-brew finish on it. 

Here’s what Bob said about the construction of the tote:

All the details are there, and it is a good first work. It gives you a place for tools and most of the materials are inexpensive. The leather strap can be a bit more expensive. I made mine out of pine, brass screws, brass tacks, epoxy, screw posts and horse butt. The horse butt was the most expensive, but then I can strop with the straps. I would advise going to a saddle shop and getting vegetable tan leather for the inner fittings, so that you don’t have too many salts in the leather eating your tools. Getting straps from them or using belts from a resale shop would do well.

As far as the one I made goes, The Hex end on mine has 4″ long sides. The boards are 24″ long and 1/2 thick. The end peices are a touch thicker. The inside straps are 1″ wide, the outside straps are 2″ To avoid near impossible clamping issues, I taped the whole thing together and marked boards and ends. I predrilled the three fixed boards, screw holes, to the end pieces. I used masking tape to avoid a mess with the epoxy, and used a slower set epoxy and brass screws to hold the sides together during gluing.

I wanted a rougher finish than the mirror smooth one that came out of my thickness planer, so I sanded at an angle across the grain with 80 grit, to give the look and feel I wanted. Sort of an old sawmill look. This way dings and scratches add character instead of ruining the appearance.

Click here to read more and see more photos of this handy tool tote.

Pocket holes are one of the simplest forms of joinery in all of woodworking. All you need is a pocket hole jig to drill the holes and some special pocket hole screws to connect two pieces together. They’re great for avoiding problems with laying out your workpieces and with alignment. Plus, they eliminate the need to clamp up a lot of pieces during glue up. During this week’s podcast, Phil Huber will show you some tricks for using pocket screws and he’ll build a complete patio table using pocket screw joinery.

As usual, all of the links to articles, seminar guides, and products that you’ll see being used during the seminar podcast can be found at the Woodsmith Podcast Store. They include a link to the seminar guide, a couple of great project articles from Woodsmith magazine that feature pocket hole joinery, and several great Kreg Tool Co. products for sale. Be sure to check it out by clicking on this link: Woodsmith Podcast Store

I got a treat on Sunday. The Heritage Carousel at Union Park in Des Moines, Iowa was celebrating its tenth anniversary.  As part of the celebration, they invited the original builders of the carousel, The Carousel Works, Inc., to attend and demonstrate their carving and painting skills.  I got to speak with the owner and his wife (Art and Marilyn Ritchie) about their craft.  It so happens that they’re from Mansfield, Ohio, close to where I grew up in Ohio.  He’s been carving for over thirty years.  His wife does some of the painting.

As we stood there chatting, he was using his Pfeil carving tools to smooth out the body shape of a horse figure.  You could tell his tools were very sharp.  He was effortlessly taking thin chips out of the basswood figure.  I asked him how he keeps his tools so sharp.  He uses a buffing wheel to hone the edge as needed.

One of my boys asked him how many times he’s cut himself.  He smiled and pointed to his tool roll you see here on the left.  He includes bandages as part of his tool kit.

As time went on, he commented to passers-by that they’ve got seven full-time carvers on staff at the shop.  He said that the figure he was carving on that day is going to be a training aid for his carvers.  As we were talking, he flipped the figure over to show how he had carved the musculature and rib cage of the horse on one side.  His point is that unless a carver knows the anatomy of a horse, he’s going to have a difficult time carving one.  The detail was fascinating and realistic.

The discussion turned to painting.  He says they use three coats of primer, sanding between coats.  Then the colors are brushed on.  Finally, five coats of clearcoat are applied for durability.

Besides building new carousels using wood figures, The Carousel Works also does restoration of old carousels.  To me, it was refreshing to see that there are still companies out there working hard to keep craftsmanship alive.

When they say it’s hot in Vegas, they aren’t kidding. And even though the show floor is air-conditioned, there are some hot new products heating up the arena.

Porter-Cable is set to announce a whole lineup of new tools tomorrow night at a press briefing. I’m going to see if I can sneak in the back door and let you know what I find out.

I got to spend some time at the Rikon Power Tools booth. I met and spoke for a few moments with Erin Riley, president. She said that the company is relatively new (around seven years old) and that Rikon tools have only been around for a little over four years. Steve Mangano, vice president, took some time to show me some of their products. They’ve got some innovative features on their band saws, and I was impressed with their table saw with sliding table. At just under $2,000, I think it’s a bargain with all the features and capabilities. They even have in their product line a couple of radial drill presses. I have an old Rockwell radial drill press that my dad gave me. I think every woodworker should own one. You can read all about their products on the Rikon Power Tools web site.

And Bessey Tools has got a new clamp that’s got my attention. It was originally introduced a few years ago but went away for a redesign and was re-introduced a few months ago. Look for the new DuoKlamp at your Bessey retailer. The product is so new, I couldn’t find it on their web site, but be on the lookout for it.

A chat with John McInerney, VP Sales/Marketing at Amana Tool was worth the time. He say’s they’re redirecting some of their sales efforts to broaden the product line for the home woodworker. Some products that are more used in a production shop have just as much appeal to a hobbyist woodworker. For example, a number of their router bits will be available with replaceable carbide inserts. This has a lot of advantages, according to John. For one, they can use a harder, finer grade of carbide since it wouldn’t be subjected to the heat of brazing it to a steel body. That means a sharper, longer-lasting edge — two other advantages for woodworkers. The initial investment might be a little more, but the costs of replacing the inserts will be considerably less than the cost of a new, traditional-style bit.

Well, I’m off now to see what’s up with the Kreg Tool Company.

Stay tuned for further developments.

I finally got a chance to walk part of the AWFS show floor here in Las Vegas and take in some of the new stuff for woodworking.

Makita is coming out with some exciting new “black and white’ cordless tools that will appeal to the home woodworker and do-it-yourselfer. They’re 18v tools with 1.5 amp-hour batteries that will recharge in 15 minutes, according to Wayne Hart, Communications Manager for Makita. To me, these tools look the same as their traditional teal-colored tools. The only difference is the smaller battery size to make them lighter in weight. The larger, higher-capacity 3 amp-hour batteries can also be used on these “black and white” tools. One thing about Makita tools that becomes apparent when you pick them up is their quality. The operation of the cordless drills and impact drivers is smooth. The trigger action is effortless. The combo kit you see pictured here retails for around $329. That’s a bargain, considering the drill alone retails for around $200. This kit includes a flashlight, drill, impact driver, radio, and an “intelligent” battery charger (each battery has a built-in CPU to monitor voltage and prevent over-charging).

Of course, the big buzz on the show floor concerns the “stone-faced” tools from Steel City Tool Works. I spoke at length with Mark Strahler, President of Steel City about his new line of tools with granite tables. The table saw with granite table is based on their hybrid saw. This gets around the problem of mounting the trunnion assembly to the table top as with most contractor saws. The granite tops are really flat…dead flat. So flat in fact, that one of Steel City’s customers requested that Steel City supply them with some granite surfaces to use as reference tables in their machine shop. The other advantage is that they will never rust.

Granite will be available for only a small upgrade charge on their table saws, band saws, and jointers (for the fences). Steel City will guarantee the granite for ten years. It’s an interesting concept that proves that Steel City is thinking “outside the box” when it comes to the design of their tools.

Speaking of thinking outside the box, Mark showed me a pre-production sample of the new Steel City “Dust Collector in a Box.” It is literally small enough to fit inside a small shopping bag. It’s designed for benchtop planers in shops that don’t have a traditional dust collector. It’s a small blower motor and housing that attaches with a flexible rubber connector to your planer. The dust chute exits into a large bag off to the side. The expected retail price will be around $99. Pretty cool.

Perhaps the most interesting thing I’ve seen today is made by Penn United Technologies, manufacturer of Penntek tools. These are the guys that originally produced the Robo-Grip pliers which have been redesigned into the newer MagnumGrip pliers. They also licensed the Versa-Clamp and are producing it. But the most unusual thing they had was a new hammer call the PowerPull. The first thought I had was, “How can you improve on the traditional hammer?” They took a traditional framing hammer and added a pop-up “foot” that provides extra leverage when pulling nails. When retracted, it looks just like a “button” on top of the hammer head. When extended, it gives you several addtional pounds of leverage to pull that stubborn nail. It gets around the problem of having to use a scrap piece of wood for extra leverage. Very unique.

Tonight, I’ve been invited to a “press party” by Porter-Cable. As I said yesterday, they’re going to be announcing some new products. More on that tomorrow.

Changes are a comin’. Delta/Porter-Cable announced at a gathering at AWFS last night a major revamping of their product line. Lower-end products are going away. Newer products are on the horizon. The focus will be on quality with an emphasis on a new look and major efforts in industrial design of the products. One example cited was a new Unisaw with both wheel cranks on the front of the saw. It’s a unique concept that should have been done years ago. The new Unisaw will also have upgraded guards and all upgraded internal components. (It was interesting to note that the guard on the prototpye looked suspiciously like the guard on Bosch’s new benchtop saw.)

They announced a “re-branding” of sorts where you will see the Delta/Porter-Cable names together more and more as time goes on. Their design center will remain in Tennessee and they are sourcing major components from U.S. suppliers and not necessarily from Asian suppliers.

Company executives admitted that there have been some bumpy roads for the two brands since their purchase by Black and Decker three years ago. They expect that the dollars and man-hours that have gone into re-engineering their product lines will have benefits for the woodworker and their bottom line with improved sales. They may be facing an uphill battle, but hopefully we’ll see some new, quality innovation in tools. Both brands have a century of reputation in quality and hopefully, they’ll be able to regain that respect.

P.S. — I would have posted photos of some of the tools, but company execs prohibited cameras. Some of the products shown are prototypes and all features shown may not necessarily make it into production models. I can understand and respect that. So stay tuned. As we hear more, we’ll post it here.

UPDATE: See the Press Release from Delta/Porter-Cable here: REVOLUTION Press Release

The flood is starting already. In addition to launching a new web site (www.deltaportercable.com), Porter-Cable today announced the availability of a new plunge base for their 890-series routers. From their press release:  

The plunge base is offered as part of multi-base kits, models 893PK, 894PK and 895PK, as well as an accessory, model 8931. With machined brass brushings and steel guide rods, the upgraded base offers an extremely smooth and durable plunge stroke for greater user control and accuracy. In addition, a through-the-column dust collection system supports efficient dust removal, and yields improved bit and cut-line visibility when used with a durable, clear Lexan® sub-base and dust shroud, which come as standard.

To further enhance precision and ease of operation, the base features a six-position adjustable turret stop for stepped plunge cuts; a single, flat side on the base that allows routing to be done in tighter spaces while also providing a straight reference point; a lever release for quick motor transitions between bases; and rubber overmolded handles for a comfortable grip.

The versatile plunge base, which accommodates the existing 890 series motor, is ideal for a variety of woodworking applications, including general purpose cutting, dado stops, fluting, rabbetting stops, and hinge cutting. The plunge base, model 8931, and multi-base kits, models 893PK, 894PK and 895PK, will be available for purchase in July 2007 for $115, $269, $289 and $289, respectively.

I remember about a year or so ago, Tony Schrank called me. His uncle had patented a new type of clamping system called the VersaClamp™. Tony and his brother designed it for manufacturing. I had him send me one to take a look at. I recall at the time that it was unique in its ability to transform from a clamp to a vise with the addition of a couple of brackets you can mount to your bench. 

Since that time, Tony has licensed the VersaClamp to PennTek Tools for manufacturing. (I wrote about PennTek Tools in this post.) 

Here are some of the key features of the VersaClamp:

• Cam Locking Feature is easily activated with the Easy-Grip Handle and locks the work piece in place with up to 400 pounds of force
• Power of the clamp is not limited by the hand strength of the user
• Handle has multiple positions and pivots out of the way as needed
• When mounted as a vise, jaws turn to work at any angle 
• Soft, non-marring jaws firmly hold the work piece
• Available in 12”, 20”, 36 and 48” openings – comes with mounting brackets and hardware
• Patented Cam Locking System
• Made in the USA
• Limited Lifetime Warranty

You can order the VersaClamp from Garrett Wade, Woodcraft, or directly from the VersaClamp web site.

I’ve always been impressed with Makita tools. My dad has always been a fan of their tools and I sort of grew up with them. He’s got an early model benchtop planer he’s had for over 15 years that’s still running strong. The quality of Makita’s tools is hard to beat.

Makita has recently announced some new tools, and you’ll be reading more about them here. The first one on the list is their new variable speed, orbital jig saw. The 4329K jig saw features a compact design, three orbital settings plus straight cutting, with a powerful 3.9 AMP motor for use in a variety of materials. The new jig saw features an ergonomically designed rubberized grip to provide more comfort and control, while the variable speed dial control (500 – 3,100 SPM) delivers optimal cutting performance in a variety of materials. The die-cast aluminum base bevel cuts 45 degrees right or left with a positive stop at 90 degrees for solid cutting performance. A through-the-body dust port provides optimal dust management with use of clear dust cover and vacuum.

The saw is ideal for professional woodworkers, cabinetry makers, and specialized residential construction workers who require a best-in-class engineered jig saw in a compact size. The saw uses Tang shank blades only, plus has an on-board hex wrench for easy blade changes. The saw includes a blade and tool case.

Read more about Makita tools here.

Erich Lage has been a senior illustrator (and editor) for Workbench Magazine for 12 years now.

Before that he owned his own remodeling-design business. In 1977 he started his journey in residential construction as a concrete finisher and ultimately worked as a trim carpenter and service manager in the Home Building Industry in the Midwest. During this month’s Woodsmith Woodworking Seminar Podcast, Erich will provide you with suggestions on how to troubleshoot all your home repair questions. During the seminar he’ll talk about everything from basement window repair to installing box beams in a family room.

Once again, the seminar guide is available for sale at the Woodsmith Podcast Store.

At the AWFS Fair in July, I had the wonderful opportunity to get a close look at some extraordinary woodworking exhibits by some very talented students. AWFS sponsors the “Fresh Wood” competition that spotlights outstanding student works being produced at some of the best high school and post-secondary woodworking programs in North America.

I had a chance to chat with one of the exhibitors, Chris Hedges. His furniture project (a high-boy/secretary) was getting a lot of attention. And it should have. Chris won three awards with his project: First Place in the Reproduction category, the People’s Choice award, and Best of Show.

He’s 32 years old originally from the Circleville, Ohio area. He says he’s happily married and has a 3 year old daughter. When not making furniture and spending time with his family, Chris enjoys trap shooting and golfing. Chris says, “Although my wife and I lived in Athens, Ohio for 12 years before relocating to Knoxville, Tennessee. I earned a Masters from Ohio University (I taught sociology for four years after graduating) and then spent two years at University of Rio Grande in the Fine Woodworking program.”

When I asked him how he got started in woodworking, here’s what he said: “I really had no experience with woodworking as a child, other than nailing end grain to make ‘bookshelves’ for my dad. Most of the training I have before starting Rio’s program was theoretical — meaning I read as many books as I could. Although I could take apart a table saw in my head, I didn’t actually touch one until I started at Rio.”

As for the secretary Chris built, as a second year student he was encouraged to build something that was both technically and academically challenging. Having seen a number of similiar secretaries in the DuPont collection at Winterthur, Chris was highly intriqued by their swiss army knife-like nature and thought that building the secretary would truly challenge his acquired skills. “While plans were provided, I felt it would be to my benefit to stray as far from those plans as possible in an effort to distinguish myself from the rest of the pack,” Chris said. 

All in all, the research and production process took nine months, including the creation of scale drawings from photographs, designing the upper case, getting materials, then building the project. Chris used curly quartersawn cherry (from Irion Lumber Company) as the primary wood and madrone burl for the veneer from Certainly Wood. All secondary wood is poplar.

All wood was dimensioned to within 1/32″ of the final dimension with power tools and finished up with hand tools. As for joinery, all dovetails were cut by hand. Mortise and tenons and sliding dovetails were cut using power tools. While most of the work was done at school, a lot of the hand work was done at home, including dovetails, carvings, and turnings. “At the time that I built the desk, all I had at home was a lathe and a bunch of handtools,” Chris stated.

I think Chris has an excellent future as a woodworker based on what I saw. His craftsmanship is excellent and his attention to detail is impeccable.

Some folks aren’t aware that they can get a free woodworking tip in their email inbox every week. It’s something we’ve been doing for years and has proven to be very popular. A lot of woodworkers have been printing their favorite tips and storing them in a 3-ring binder.

If you’ve wondered what tips you’ve missed, we’ve got some handy links for you look up any of our past eTips. For our older eTips (prior to August 2003), click here.  For more recent tips, you can click here. Between these two web pages, you’ll find a complete list of all our past eTips.

Remember to sign up here for free eTips if you don’t already receive them.

One of the fundamental definitions of a sharp edge is the intersection of two flat surfaces that meet at some angle. Whether it’s a chisel or plane iron, if one of the surfaces isn’t flat, you can’t expect to get a sharp edge.

There’s a running discussion over on WoodNet about if, when, and how you flatten the backs of your chisels. Then there’s the question of what “flat” really means.

Personally, when I buy a new chisel, I’ll use wet/dry sandpaper on a granite tile and work through the grits until the back is polished. Then I’ll work on the bevel to get a sharp edge. After that, the only time I work on the back is to remove any burr after I’ve honed the edge. I’ve had good success with that method and my chisels seem to be plenty sharp. The same holds true with my plane irons.

With western chisels, I only worry about polishing the last ½” or so of the back. Japanese chisels are hollowed out on the back side, making them easier to flatten.

Head over to WoodNet and leave your 2¢ worth.

Kenneth Owen of Tulsa, Oklahoma is proud of his wife. And he has every right to be. They were looking to outfit a new bedroom and fell in love with a Moser-style bed. So she decided to build one. That’s right — she did the milling and gluing and bending and clamping.  Everything.  And the results are outstanding.

Ken posted photos of the process of building this bed. You can read all about it over on WoodNet. It’s an amazing story of how the project was completed and Ken gives all the details of how his wife progressed from start to finish.

Back in March, the folks from ProTool (the folks that make the Drill Doctor) came into our offices to show us their new Work Sharp system for sharpening woodworking tools. You’ll be hearing it advertised on the Paul Harvey show.  They left their WS3000 for us to play with in our shop.

One day not too long ago, I went to use the Work Sharp to hone some chisels for our new public television show, The Woodsmith Shop (more on that later).  Well, I couldn’t find all the parts to the Work Sharp, so I resorted to honing the chisels by hand using wet/dry sandpaper.  A few weeks later, I asked Steve Johnson, our shop craftsman, about the Work Sharp’s missing parts. He said that they weren’t missing and walked me around the corner of his work area and showed me the box that contained the “missing” parts. Turns out he had the Work Sharp squirreled away to keep it from disappearing.  He says he uses it all the time for touching up his chisels. For example, when he’s chopping mortises or cleaning up mortises, all he needs to do is walk over to the Work Sharp, and in just a few seconds he’s got a sharp edge.  He thinks it’s a great addition to his shop for keeping an edge on his tools.

Work Sharp has come out with a homeowner/DIY version of their system called the WS2000.  It uses the same motor as the WS3000 but doesn’t have the built-in speed reduction and doesn’t come with the finer grits of abrasive that you’d use for honing.  It’s meant for grinding a quick edge or, as one homeowner did, ground a sharp edge on his garden shovel.

You can read more about the Work Sharp systems here.

When the Dremel folks stopped by our office a couple of weeks ago, one of the products they were showing us is the new MultiVise. I’ll admit that my first thought was, “This can’t be a serious tool — it looks like it’s made out of plastic.” But I was soon to be impressed. The way this thing can twist and contort to clamp almost anything is amazing. 

It clamps to your workbench or table. A ball-and-socket joint can rotate the clamp 360° and tilt up to 50°. I was skeptical that this ball-and-socket couldn’t be locked too securely. But once you tighten the blue ring, it’s there to stay. The clamp itself as a 7½” capacity. And it has removable “soft jaws” for clamping delicate or irregularly-shaped objects. I was impressed.  Really.

Now, as a woodworker, the first question I had was if the clamp was available in longer lengths. The Dremel reps said that they honestly hadn’t considered it but really appreciated the comments. I suggested that they offer “accessory kits” with longer clamps for us woodworkers. The reason is that the clamps are great by themselves. They’ve got large “feet” that sit on your benchtop and won’t topple over as you clamp down. The only problem I had with the clamp was that the screw was rather stiff and took some effort to turn. But I suppose it would loosen up over time without compromising it’s clamping ability.

Oh…I almost forgot. It comes with an adapter and wrench so you can fasten your Dremel rotary tool to the vise. It’s great for grinding or sanding operations.

I’ve got to get one of these for my own shop.

FOR IMMEDIATE RELEASE
August 15, 2007
Release #07-275

Firm’s Recall Hotline: (866) 761-5572
CPSC Recall Hotline: (800) 638-2772
CPSC Media Contact: (301) 504-7908

Robert Bosch Tool Corp. Recalls Skil® Circular Saws Due to Laceration Hazard

WASHINGTON, D.C. - The U.S. Consumer Product Safety Commission, in cooperation with the firm named below, today announced a voluntary recall of the following consumer product. Consumers should stop using recalled products immediately unless otherwise instructed.

Name of Product: Skil® brand Circular Saws

Units: About 811,000

Manufacturer: Robert Bosch Tool Corp., of Mount Prospect, Ill.

Hazard: The trigger switch on the circular saw can be locked on or the switch can be turned on without the use of the safety lock-out. This can cause unexpected operation of the saw, posing a risk of laceration.

Incidents/Injuries: The firm has received five reports of the saw staying on after the user released the trigger. No injuries have been reported.

Description: The recall involves Skil(r) brand circular saws with model numbers 5650, 5700, 5750 and 5755. The model number and date code are printed on the nameplate located on the front of the saw. The recall includes the following date codes:

28101 - 29231
38101 - 39231
48101 - 49231
58101 - 59231
68101 - 69231

No other models or date codes are included in this recall.

Sold at: Home centers and independent hardware retailers nationwide from January 2002 through December 2006 for between $70 and $80.

Manufactured in: United States

Remedy: Consumers should immediately stop using the recalled saws and contact the firm for instructions on obtaining a free repair.

Consumer Contact: For additional information, contact the Robert Bosch Tool Corp. toll-free at (866) 761-5572 between 7 a.m. and 7 p.m. CT Monday through Friday, or visit the firm’s Web site at http://www.skiltools.com/en/CustomerService/SafetyInfoRecalls/

To see this recall on CPSC’s web site, including pictures of the recalled product, please go to: http://www.cpsc.gov/cpscpub/prerel/prhtml07/07275.html

A European company called Miniot
is selling a nice wooden case for iPhones.
They offer a little bit of protection for your
phone and it looks cool. It’s carved from a
single piece of wood and available in oak,
paduak, cherry, mahogany, or walnut. The
price is around $80. If your cell phone is
dinged up half as much as mine is, this
might be a good investment!

Oh by the way, if you don’t have an
iPhone yet, they also make a case for iPods!