You can sharpen your woodworking skills with helpful tips and techniques from the editors of Woodsmith and ShopNotes magazines. Get a FREE tips sent to your email address each week! Got to Woodworking Tips.com and sign up today.

Here’s last week’s tip from Woodsmith online editor Ted Raife:

Whenever I use screws to assemble a project, I hide them under wood plugs. Cutting the plugs and gluing them in place is the easy part of the job. The bigger challenge comes once the glue dries — trimming the plugs flush to the surface.

For me, this is a two-step process. First, I use a small back saw to trim off the bulk of the protruding plug. Then I sand or plane the remaining portion flush to the surface. But my lack of care with the back saw often led to problems. If I tried to cut the plug too close, I would scratch or gouge the surface, making more work for myself.

But as is usually the case, a small problem had a simple solution. I dug up a scrap of plastic laminate and made a flush cut shield. The laminate shield has a hole drilled through it slightly larger than the diameter of the plugs. You place the shield over the plug flush to the surface and then saw away without worry (Figure 1). The thin shield allows you to give the plug a very close trim and all that’s needed to finish the job is a little sanding (Figure 2).

For more helpful project tips, techniques, and plans, visit Plansnow.com.

Good Woodworking,

Ted Raife
Online Editor, Woodsmith

With the Bombe completed, Tommy is ready to dive into another project - a full bedroom set. This will not be a step-by-step project but more of an overview. In this installment, Tommy talks about the wood he has selected and how the completed set will look.

In this entry I talked about the Craftsman 8" Drill Press model 315.11970 that I had purchased off eBay.

Since I've been doing some turnings, I've needed to use a drill press to make accurate holes in the workpieces.

Too bad I don't have a press capable of drilling accurate holes!

I mentioned that it was "unstable as hell". I recently took it apart to determine why it was so unstable. After all, who would sell a drill press that's unstable when new?

Craftsman would. That's who.

I found that the red plastic housing is the entire framework. There is no metal to metal connection between the drill motor and the post.

Note to engineers: Cheap plastic does NOT provide rigid connectivity in a power tool!

I made a slight improvement by wedging a piece of wood scrap into the tool between the post bearings and the plastic housing. It helped, but not much.

As far as I'm concerned, this thing is completely useless. I get more accurate holes using a hand drill.

If anybody wants to donate something that ISN'T a complete piece of crap, I'd be more than happy to accept!

Many of my projects use shellac in at least some part of the finish. It was the first finish I was able to apply well, it's a natural and renewable product (at least, when mixed yourself... Off the shelf stuff may not be fully natural), and it looks great.

The only downsides are low abrasion resistance and low liquid resistance. That's it. Not so good for table tops, great for pens!

The pencil shown in the photo at right is made from kingwood finished with several coats of 1# shellac. This was my first penturning attempt and I still use it every day. The finish is still great.

Shellac.net has some good info on shellac. Their "Why Shellac" article is good:

Shellac is a good choice for
furniture, smal craft, and wood instruments because it is ..

And they missed one of the most important reasons: It's a renewable resource and fully natural!

Shellac is made from secretions of the Lac bug. It is sold either prepared or in flake form that you mix yourself with denatured alcohol. Shellac is used for more than just wood finishes. It can be found in medicines as a pill coating and packaged foods to add a shine to glazes or candies. It's completely edible when cured and safe around children.

If you haven't tried shellac yet, get a small can of prepared shellac and play with it. If you like it, buy some flakes and alcohol and start mixin' yer own.

Today I want to share with you two strange desings.

The first one is a very nice pair of earrings, made of wood beads (they´re beautiful). It seems they belongs to an indian, isn’t it?

The following desing it´s a spiral. I love spirals! I made the wire structure first and then embroider the beads.

See you next craft!

The Stanley Tool company is legendary in hand tool circles...  It is their planes that a large majority of us woodworkers cut their teeth on.  They have been making the most popular line of woodworking planes since the late 1800's - at least until the quality of their product began to suffer after WWII, ultimately reaching their low point in the 60's and 70's where the level of quality has remained until today.  Yet there are so many examples of Stanley planes out there remaining from pre-WWII days still in use today that they are still setting the standard by which others are graded even to this day.  It wasn't limited to just bench planes either - one only has to look at Patrick Leach's pages on Stanley planes to see the breadth of their product line from the day.  The sheer extent of their product offerings is testament to their popularity.   Only recently have independent toolmakers - as a collective - even begun to breach a portion of it.

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Now that I got my lighting back and functional, here's a better pic of the pencil shown in the previous post.

I've been asked about how I photograph my projects. When I think of it/am not too lazy/have batteries I use this rig.

It's a portable small item studio purchased at WalMart for $50. It includes two color corrected incandescent "hot" lights, the tent, blue and gray backgrounds, a little tripod, and a carrying case.

I also have a handheld strobe attached to the PC socket in my Kodak Z7590 digicam. The camera is held by a really REALLY old Graflex tripod.

In the photo is a roll of shipping tape. I use that as a lint catcher because there's always dust and lint and crap that settles on the background cloth. Adhesive tape is the easiest way to remove it on the spot.

Some people are luckier than the rest of us. When it comes to winning contests, Patricia and Mike Mortimer fall into the lucky category. Patricia entered Highland Woodworking's Win a Festool Package Sweepstakes and was the lucky winner out of thousands of entrants. She's shown here being congratulated by Chris Bagby, Highland Woodworking's owner and co-founder. It wasn't just the first contest Patricia has won. Among other things that she's won are a flat screen television and an all-expense paid trip to Bejing, China to attend the 2008 Olympics. We asked her how she did playing the lottery and she replied "I don't play the lottery. You have to pay to do that!"

The Mortimer's new power tool package includes Festool's Kapex KS120 Sliding Compound Miter Saw, the first miter saw with variable speed, which enables the user to match the speed of the blade with the requirements of the material. The Kapex Sliding Compound Miter Saw combines a large cutting capacity with a compact lightweight design. Of course the perfect mate to their new Kapex Sliding Compound Miter Saw is the Kapex MFT3 Multifunction Table which is designed specifically for use with the Kapex Sliding Compound Miter Saw. It features additional holes in the perforated top plate for positioning the feet of the Kapex and for mounting with clamps. Also included as part of their Kapex prize package is the Festool CT22E Mobile Dust Extractorwhich comes with HEPA filters that remove dust particles down to .3 microns. A tool-triggered switch with smooth start-up and shut-off delay, and adjustable electronic suction control make this the ultimate vac to connect to any hand power tool.

Mike works professionally doing commercial repair and finish restoration on furniture, cabinets and interiors. He is actually known for being quite the "magician" when it comes to recreating grain patterns and surfaces that have been damaged or distressed. When asked, both admitted that they were not really sure what projects they would attempt first with their new woodworking equipment. One thing for certain is that they'll definitely have room for it, as they have a 2400 square foot shop! After mentioning projects like chairs and end tables, they both joked that given the space they have, perhaps they would make a gazebo for inside the shop.

Since Highland Woodworking is well known for its Education Program, which includes a wide variety of classes for both beginners as well as advanced woodworkers, hopefully we will see both of them soon in some of our
upcoming classes for a chance to study woodworking with our knowledgeable instructors.

Visit Wood News, our monthly online woodworking magazine

Our very own guest expert Hendrik Varju has returned for another visit here at Matt's Basement Workshop, and this month we're mixing things up a little bit.  Rather than our usual question and answer show, we're talking a little more philosophical and asking the question "Why do we woodwork?"

This is the wrap-up to our discussion and once again after you listen to it I'm willing to bet that many of you feel the same way about why it is we woodwork as we did. 

You're welcome to send in your own comments to the discussion or even pose a few more questions too.  Just contact us either by email at mattsbasementworkshop@gmail.com, leave a comment at the website, or call and leave a voicemail at 231 354-2338.

If you'd like to get more information about Hendrik checkout his website at www.passionforwood.com.

If you have the time, please take the new listener survey.

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If you are a regular visitor you will notice that my website has a completely new design.

This is very exciting as it coincides ...

One of the best parts of visiting the home of Popular Woodworking last week is that I was able to assure Chris Schwarz and Megan Fitzpatrick that I was just messin' with them about their contest to write Out of the Woodwork features.

I have to admit that Megan knows how to take a joke, and just to show there were no hard feelings, she let me pose for a photo with the Leigh Jig that they are giving away to the person who submits the winning article.

Nice, Megan. I think you were saying that my being disqualified from the contest for submitting articles under Gail's name isn't so unpardonable a sin as to preclude my ever appearing in the magazine again. It's just that the photo below is the closest I will get to winning a prize.


Megan has been assessed a 15 yard Unsportsmanlike Conduct penalty for "Taunting." The penalty will be assessed on the kickoff.

HI Folks
There's a new recruit on the block. Welcome, please, my new "Shop Cat".
She's called "Cupcake" and she's 10 weeks old. Obviously she has a lot of Health and Safety stuff to learn but hopefully she will become a regular helper in the workshop.
If only to chase spiders ;)
Cheers
Philly

Every once in a while I'm asked if I could restore or make a saw for a fellow woodworker. Unfortunately, my current employment situation allows me little time for personal endeavors (like finishing my shop!), much less that for others - so I've had to severely cut back work I do for others.

Gladly, I'm certainly not the only game in town, and my response is invariably to recommend one of the others I know that are in the business. It seems that just a few years ago when I first posted the article about making your own saws, there were only three premium sawmakers with product on the market(perhaps more, it depends on your definition of "premium"). Now - it seems - there are many, many more to choose from. When asked, I usually steer someone towards what I believe would fit them best, and wanted to compile that list in a single location - here, obviously. If I don't mention everyone that's out there, please forgive me - these are only the ones I've had some direct experience with.

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If you’ve checked out a copy of Woodsmith or ShopNotes in the last couple of years, you may have noticed that articles about hand planes and their use have been showing up a little more often. That’s mostly because we have an editor who takes an active interest in promoting their usage — Randy Maxey.

Randy will spend an hour during this Woodsmith Woodworking Seminar Podcast to give us his tips for tuning up a hand plane, a very important procedure if you’ve ever tried to use one. As you may know, an out-of-tune plane, with a dull or nicked iron, can be a real pain to use. This seminar is for “users,” not “collectors.”

Be sure to check out the Woodsmith Podcast Store for links to a few products that Randy used during this seminar. There are also links to Seminar Guide at PlansNow.com

It's the first Friday of a new month and that can mean only one thing here at Matt's Basement Workshop...IT'S TIME FOR ROUTER BIT OF THE MONTH!!!!

Once again the great folks at Whiteside and Woodcraft sent us another router bit to tryout and giveaway.  So for all of June ,Woodcraft is featuring Whiteside's Shaker Style Rail and Stile set.  A great set of bits that makes quick work of helping you build beautiful Shaker Style doors for whatever project you have coming up.

Unlike other Rail and Stile sets.  Whiteside's set is designed to cut grooves that accept a 1/4" plywood panel without the rattling and loose fitting that others leave you with.  And considering that it's on sale at Woodcraft for 25% off all month long...it's a deal you shouldn't miss.

 

REMEMBER!  If you have any comments, questions, suggestions or you want to enter for some free schwag drop me a line at mattsbasementworkshop@gmail.com or you can always leave a voicemail at 231 354-2338.

Hendrik is back this month and we're talking about "Why we woodwork".  We'd love your feedback on why it is that you woodwork also, so call or write in to the show.

Don't forget too that Hendrik is wrapping up his annual finishing seminar:  Part 3"Antique Restoration Techniques" - June 7th.  Also, coming up on June 14th, Hendrik is conducting a seminar based on his book "Starting and Running a Woodworking Business"at his Acton, Ontario Workshop.  If you'd like to attend or just get more information about these seminars contact Hendrik at info@passionforwood.com.

If you have the time, please take the new listener survey.

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The Teak is incorruptible. It hold its own against all that life throws at it.
See more here Teak Wood Ring

In this episode of the WoodworkersResource.com video podcast we're going to be looking into building simple bookcases. In this first part, we look at different joinery methods to construct our bookcase. We'll talk about advantages and disadvantages of using butt joints, rabbits, and pocket hole joinery to construct bookcases.

In part II we'll look into constructing face frames and ways to make sure that they fit perfectly, everytime.

If you would like to be alerted to when we release new episodes, simple go to our website and sign up to receive our newsletter. Just for signing up, you'll receive a special "Bonus" from us as our way of saying, THANKS!

www.WoodworkersResource.com

Craig Stevens

I had recently acquired a barely used planer from Sears. It was one of those deals where the price was right and I couldn’t pass it up.

When I first brought it home, I fired it up and ran a few boards through it. It seemed to work great, but I didn’t need it right away, so I stored it under the bench. Let me say right here that when Sears calls this a “benchtop” planer, that’s an outright lie. This monster is heavy. I’ve got to build a stand for it one of these days. But I’m getting sidetracked.

While I was in the process of building the project mentioned in this previous post (where I injured my thumb on the table saw), I needed to plane some 3/4″ curly maple boards down to 1/2″ thickness. (Yes, it broke my heart to see 1/4″ of those boards go to waste as chips.) As I was planing, I noticed that there was a wide, shallow groove along one edge of the boards along the entire length. Since the two boards I was planing were cut from longer stock, I thought that the boards were rough-planed that way and that’s how I brought them home. A couple of shallow passes later it dawned on me that the groove wasn’t going away. “Great,” I thought. I was going to have to tear down this planer to see what was going on.

Fortunately, this planer is designed to make it fairly easy to get to the cutterhead. A few screws remove the dust shroud to gain access to the knives. As I rotated the cutterhead around, I couldn’t believe what I saw. The gib holding the knife in place was bent outwards and the remaining cavity between it and the knife was crammed full of chips. You can see what I mean in the drawing at right. (I tried to hightlight the area in red.) The item labeled ‘65′ is the gib. Item ‘64′ is the knife. (Item ‘60′ is the cutterhead.) Now, what to do?

Figuring that the worst-case scenario was ordering a new gib, I attempted to straighten it. I clamped the bent area in heavy-duty vise and torqued it as far as I could go. That took care of the majority of the bend. Then some carefully placed taps on the leading edge of the gib with a wood block and hammer took care of the rest. Some minor filing was all it took to get a smooth, straight edge. I re-installed the blade and gib and ran a few boards through it. No sign of a “groove.” I was relieved and glad that I was able to repair it.

But the question remains…what caused the gib to bend in the first place? It’s possible that it was like that when I first bought it. But the mystery remains. When I talk to the other guys in our shop, no one can come up with a plausible explanation. Very strange. If you’ve got any thoughts, leave a comment here.

If you’ve read Woodsmith and ShopNotes magazines for any length of time, you know that we’re a fan of threaded inserts. They make it easy to build jigs and fixtures and knock-down furniture or projects. They’re a great way to add machine threads for attaching screws and bolts.

E-Z Lok is a manufacturer of threaded inserts for a variety of industries and applications. And I’ve recently discovered that their web site is a valuable resource of information you can use when building projects that make use of threaded inserts. Their web site contains PDF documents that contain detailed dimemensioned drawings and complete charts listing dimensions and recommended hole sizes for their inserts. (They caution you to try out the insert on a scrap piece to get the exact hole size.)

Click here for a chart of their inserts for hardwood.

Click here for a listing of the knife-thread inserts for softwood.

I like to use press-in “Finserts” whenever I can (see photo at left). I don’t have to thread them and risk not getting them in straight. You can simply press or tap them in place. Click here for more information on finserts.

If you scroll to the bottom of these pages, you’ll see links for PDF documents of drawings and charts.

E-Z Lok’s products are sold through a variety of distributors like McMaster-Carr, Reid Tool, and MSC.

I had a chunk of cocobolo left over from my other projects. Too short for a pen, too nice for the trash, I was determined to find a use for it.

As I was digging through the "box'o'candles" (everybody's wife has one of those, right?) I found a seriously fugly rocking horse candlestick holder. It was plated pot metal, with a screwed on candle cup sticking out of the top. It was plated with a gold color that was partly worn. It really looked crappy.

I removed the cup from the rocking horse and chucked it in my lathe. The cup was pressed steel, and had pressure ridges, scratches, etc. I sanded it to 2000 grit paper to get it smooth, then hit it with the buffer and white diamond compound. Polished steel looks much better than cheap "gold" plating.

I chucked the chunk of cocobolo and turned the simple shape shown in the photo. Sanded to 800 grit and applied two coats of thin (1# cut) shellac followed by a couple coats of Hut's Crystal Coat.

A note about Crystal Coat. It's crap. It can add a nice deep shine to your turning, but durable it isn't. Just removing the piece from the lathe can dull the finish! I left this piece on the lathe for an hour before removing it to drill the hole for the steel cup's mounting screw. I still ended up marring the finish. Once I had the hole drilled and the screw run through a couple times so it would go easy later, I re-mounted it on the lathe and applied another coat of the finish.

I left it on the lathe overnight before taking it off and mounting the cup. I then immediately placed it on the shelf in the living room where it sat for a week before I had the courage to take it down again to photograph it.

I have no experience with other friction polishes, but Hut's Crystal Coat isn't worth the bottle it's sold in, unless all you're going to do is take pictures of your work.

The EAIA meetup last weekend was held at the recently renovated Dills Tavern, originally built in 1794. The weathermen promised a warm, sunny day, but it was cloudy and frigid, which prevented me from staying for all the day's activities. I was sorry to have missed Jim Leamy's afternoon lecture on making plow planes. The ivory plow plane was one of many of his exquisite planes that were on display.

Tailgating with vendors who were selling antique tools started early, and was followed by presentations by the man in charge of restoration —Sam McKinney—and a decendant of the family who purchased the tavern in 1800—Bob Eichelberger.

The three years it's taken to bring the tavern back to its original form included removal of many Victorian elements and additions that were added in the late 19th century. The kitchen needed to be gutted and other rooms needed major work, but as much as possible of the original architecture and flooring was salvaged. That which could not be saved was either replaced with elements that were purchased from other period buildings or were authentically reproduced by the men who conducted the renovations. On display were a plethora of antique moulding planes that they employed during construction.

"We basically removed anything that used common nails" explained Sam, who in my opinion is part detective—because of his ability to uncover the clues that enabled him to restore the historic building to its original state—and part visionary.

The tavern, outbuildings, and grounds are being fashioned in the same pattern as Eastfield Village, where Sam has taken classes since 1983. His vision is to replicate the original Dills Tavern setting, including distillery (ironic, since Dillsburg is currently a dry town), and to offer workshops that teach 18th c. techniques in stonework, timber framing, basket making, wool dyeing, and open hearth cooking.

But that's not the best part.

They have recently started construction of an 18th c. timber frame woodwright's shop, in which the 3 men who have so diligently reconstructed the tavern will build authentic reproduction furniture, including my favorite, PA German. Their pieces will furnish the tavern and will also be for sale.

With only a 15 minute drive to Dillsburg, I plan to conduct many drive-by droolings as the shop is being constructed, and occasionally stop to talk with the builders. One gave me his card and said to "stop by anytime." (honest!)

I will try my best to practice restraint and not make him regret having told me that....lest I be labeled the Dills Tavern Stalker.

It's April and Hendrik is back to answer more of your questions.  This month we're talking about dealing with troubled stock.  Since nothing is worse than dealing with cupped, bowed, twisted or crooked boards we answer your questions about how to tame these problems or maybe even avoid them.

Today is part 1 of our discussion, and since it's Friday that means it's Feature Friday so one of you lucky listeners is winning some free schwag!  Are you the lucky listener??

For anyone interested, coming up on April 11 & 12, 2008 there's a great little tool demo and woodworking school openhouse going on at J. Miller Handcrafted Furniture in Chicago. The details can be found at Lie-Nielsen.  There will be some great demos by a number of well known woodworkers and I'm planning on checking it out myself.

Remember for comments, questions and schwag entries drop me a line at mattsbasementworkshop@gmail.com.

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I wrote once before about the generous gift I received from Kori Capaldi, Operations Manager of the Gamble House. I met Kori when I was in Pasadena for Pasadena Heritage Craftsman Weekend in October. Because I spent quite a bit of time at ?THE house? for various tours and receptions, I got a chance to talk with Kori for a while. I told her about the chest I was building and that the lid would be restrained by a leather strap. A month or so after I returned home Kori sent me an email and asked if I?d like a piece of the leather that was used in the Gamble house when the leather straps on the lighting fixtures were replaced several years ago.

Of course I said ?No? and that was the end of it. OK, maybe I said ?Yes? and tried not to appear overly anxious in the process. You see, the Gamble house is tantamount to a religious shrine for those of us afflicted with serious cases of Greene-itis. It is indescribably beautiful. I mean that literally. No attempt to convey, using words, that amazing vision can end in anything but utter failure. Thus, to have a tangible link between the core of the G&G universe and one of my pieces of furniture is very special indeed.

Though I?ve had the leather for some time now, I?ve just completed installing it. I didn?t want to be hasty -- it had to be just right. I spent hours scouring the internet for the perfect rivets to use to attach it and the search paid off. I found a product even better than I had hoped for. Screw posts are similar to rivets but because they screw together they are removable. So if I ever have to remove the lid of the chest I won?t have to cut the leather (Actually, I wouldn?t have been able to cut the leather I would have asked my wife to do it. When I wasn?t home.). And with persistence I was able to find them in solid brass with an oil-rubbed bronze patina. With that final piece of the puzzle in place, the installation is complete. And it was worth the wait. Thanks Kori.

By the way, this chest is the subject of an article to appear in the April issue of Popular Woodworking (available early March). Unfortunately, I didn?t have the Gamble leather when photos were shot for the article -- in the magazine you?ll see a piece of upholstery leather leftover from a Morris chair project.