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?????/ picture frame making

07/29/2008, 05:19 | Masashi's woodworking diary

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The first-year students of Gifu Academy are making a picture frame.
It is not mitred but mortise and tenon construction. They are their first machine-cut mortises and tenons.
They learn various joineries and how to use machines through making such small products.



00/00/0000, 00:00 | Wood Rings by Simply Wood Rings
Ancient Kauri wood and pure fine silver ring


This ring is made from Ancient Kauri wood and 99.9% pure fine silver.

The Kauri wood is the world's oldest wood at 50,000 years old. When I work with a wood that is this old it puts things into perspective in a very real way. I think of life without our minds trappings. Not empty but more full of what life really is. Imagine for a moment what nature has done for us to have this natural miracle of our life from so long ago. This ring gives you a connection to an extraordinary time of pre-historic sunlight, rains and life from so long ago.

Chisel Use DVD

00/00/0000, 00:00 | David's blog


I am excited about the latest DVD as it concentrates on techniques for chisel use.

Chopping and paring ...

Building the Woodshop: Part V - The Foundation

12/20/2007, 04:02 | Norse Woodsmith

Part V 

One of my favorite lines in a movie was in one of the Naked Gun movies (with Leslie Nielsen) where Ricardo Montalban was playing the villain.  When asked by Priscilla Presley how he could be so evil his response was something like:

"You forget I spent two years as a building contractor!"

Of course that's in jest (?).  You know - there are, of course, good and bad contractors, and I've dealt with my share of each - and the concrete contractor I used for this project was quite unfortunately of the latter persuasion.  I was really disappointed in his work - and I even gave him a second chance the next year to pour the slab out front of the shop for me - but that's for a later entry...  If you are looking for a general contractor, or even just a "sub" contractor, make sure you check references and investigate your choices with the local builders' association.  Above all - you will need patience and perseverance to be successful.  Don't expect perfection - but be ready to stand your ground when needed - and pick your battles well.  Know what's important, and what's not. At the time, there was a shortage of available contractors for me to hire, and I was not patient... 

But first, I should go over the design of the foundation in a bit more depth...

The Design

There were two different foundation systems I looked into using.  My first consideration was to pour what's known as a "monolithic" slab - that's where the footings, stem wall (if there is one) and the finished floor are all poured at once, in one big pour...  The section through such a system looks something like this:

Footing Detail

There are several advantages to a system such as this.. It is the most efficient system, combining the footing, wall, and slab all into a single, large system.  There is considerably less labor involved in the pour, but the earthwork needs to be done more precisely to save fill requirement.  And finally if termites are an issue in your part of the country this type doesn't allow anyplace for the nasty little buggers to penetrate from underneath.  It does have a couple of disadvantages as well...  One is that the bottom of the wall is more prone to water damage, as the top of the concrete can be only slightly above grade level...  and because of that, it also does not work as well on a sloped lot.  Though it's hard to see in the photos below, my lot slopes down from right to left (east to west) about a foot in the width of the shop.  It might not seem like much, but it is a lot of fill to bring in.   I prefer to work with the slope of the land rather than fight it...

Another disadvantage - at least for me - is that I wanted to have the entire floor of the slope 1/8" per foot from the back end to the front - a drop of about 4", so it would drain and I wouldn't have water puddling up in the center of the floor if I parked a snow-bound car inside.  That would make it difficult to frame up so it is level... This might not be an issue for you, but my experience has been to keep the space as flexible as possible - and that means uses other than woodworking.  The next owner of my shop might want to work on cars, for example - and so will I, for that matter.

The final disadvantage is I wanted to be able to hose down the slab in the main section of the shop if for some reason it needed it...    I can seal a rubber base down for some walls, but doing all would be too much.  So - it meant I would opt for the more expensive version (of course) - a stem wall type foundation.  Here's a typical section for that style of  foundation:

Footing Detail 

You can see that now the foundation wall is independent of the floor slab, so with this system I can slope the floor and not worry about framing the exterior walls plumb and level.  The slab at the far back of the shop would be about an inch below the top of the foundation wall - and about 5 inches below it at the front.  This works out well for the driveway slab to be poured out front of the shop - it will work out to be about the right height so the foundation wall can be above finish grade level by about 8".

You can also see why more labor is required to make it...  Instead of one pour for the entire foundation and slab, the work now has to be divided into three separate pours...  First you must form up the strip footing so it is below frost depth and pour it - then you must form up the stem walls and pour them; and then, finally, you pour the floor slab.  Three separate pours...  It uses the same or more concrete, and your contractor must have the form work to be able to pour the stem walls.  There are many concrete contractors out there that do only flat work - they don't want to invest the money into the forms required, and most often they can get away without investing in too much heavy machinery.  If you do it yourself, you can easily make your own forms, and rent your own machinery... but it's an added expense, and not a small one.  You could use the forms afterward as sheathing - but you need to coat the forms with a release agent (usually an oil) that can make it less than desirable for use as sheathing.  My neighbor rented a backhoe to do his shop, and by the time he was done with it, he'd spent $1100 or so just for it.

What determines how deep you put your foundation is set by the local building department and is what's known as "Frost Depth" - the depth at which the ground does not regularly freeze.  Freezing ground is bad for a foundation. Water expands when froze, and as a result lifts and stresses the foundation, and over time that stress can result in the foundation failing.

Frost depth in my area is about 2'-0" below finish grade.  With an 8" deep strip footing at the bottom, that means we can use a 2' deep stem wall - which will give us two feet below grade if we keep the finish grade at a maximum of 8" below the top of the stem wall.   Frost depth varies around the country... in warmer climates, there isn't one, just a requirement the footing be on inorganic undisturbed soil or compacted structural fill.  Where I grew up in the Dakotas, it was a full 4' below finish grade.  It's one reason you will see so many basements in the north vs. the south - you are required to go so deep anyway to get down to frost depth with your footing, there's no good reason not to make it just a couple feet deeper to make it a basement.

Optimally, I would have used the detail above, with a 6" wide stem wall.  Structurally, it's plenty strong to hold up the building. it also keeps you from having problems with applying the finish material - when you install the drywall (or plywood, or whatever finish material you have) the inside of the wall will line up with the concrete.  What I ended up with was more like this, however:

 Footing detail

Note the foundation is 8" wide, not 6".  One other difference that is shown on that detail that I don't have - insulation.  I got none.  Nada.  It's a sordid tale - I'll let you know as I go through the photos of the construction below just how I arrived with that detail.

Strip Footings

The first job after you dig the trench for the footings is to form up for the strip footings.  It's pretty simple, really - your biggest concern is setting them at the right height.   You want the footings resting on undisturbed, inorganic soil (or compacted structural fill), just below frost level.  Your building department will be able to tell you just how much your soil can support, and thusly how big your footing needs to be.  You can check with them to find what frost level is in your part of the country.  You then want to form so the top is level and gives the footing a minimum depth (in my case 8").  You can use the excavated soil for the sides of your forms at the very bottom - but it's best to have most of it formed with footer boards to make sure the edges are held in place correctly, which will allow you to estimate just how much concrete you need.  It's always better to overdo the forms rather than under-do them, as nothing sucks more than a blowout during a pour.

The easiest way to set the level is if you have a builder's level or transit and a pole, which can be rented for fairly little money.  You set stakes in the ground at strategic points and with the aid of a helper, shoot the top of the stake, then drive it down with a sledge until it's at the right height.  Do this with each successive stake, then using a string line, a plumb bob, and batten boards, drive a pair of stakes in about every 24" or so (more or less depending how good your soil is) and nail the footer boards on the inside of the stakes - which you've placed just for that purpose, using one of the sides as a guide.  Once in place, you can reinforce the footer boards by putting nailers across the top to help keep them from spreading apart while pouring, as this crew did:

Strip footing formwork

For reinforcement, mine has two #4 rebar (#4 means 4/8" or 1/2" diameter) running the length of the tooting.  An additional rebar can be added perpendicular to these every four feet or so, but I am fortunate enough to have soil with a great load carrying capacity, so it wasn't necessary.  The next step is to pour them, obviously...  but I wanted to show the photo below for another reason:

Pouring the footings

 Look at that nice, green lawn.  By the time the concrete was done - they had torn the living snot out of my yard.  I tried to keep them from doing too much damage, and I even roped off the area where my drain field was located to keep them from driving their 574 ton trucks over it - which could easily crush the pipe.  Or should I say did?  For some reason, I'm telling you - it was like trying to keep flies of of s__t.  I came home after bringing dad to a doctor's appointment to find they drove right over my little tape barrier like it wasn't even there.  Not only did this happen once, but it happened several times over the time they were there.  My drain field still works, but it's capacity has been cut about in half from what it was - no more "super" loads in the washer for us...  and a healthy repair bill someday when I do half to replace it.  The one guy I was most worried about - the kid with the skid hoe - was easily the most careful and professional and did by far the least damage of any of them.

Stem Walls

So after the footings were poured and allowed to dry for several day, the concrete guy's crew comes back and sets the forms for the stem walls:

Stem Walls

It was at this point that I went out back and measured them only to find out they had set them for an 8" wall and not a 6" wall, like was in the drawings.   The concrete guy wasn't to be found anywhere, this was entirely done by his crew...  Ugh.  Is it really that hard to do something I ask?  It's not like I was being disagreeable, or hard to get along with, or anything.   I bring it up to him, and he's like, well - we can tear it down and do it at 6", but then I'll have to schedule it for later because that crew's already on another job.  Jeez, can't these guys come up with something more original?  In the end, I said screw it, let it be 8".  I'll just deal with it later, and let it remind me of why I should never hire bozos like this guy again (yet I don't even listen to myself - more on that in a later entry in this series).

Reinforcement was just as described in the detail above - a #4 rebar every 4'-0" vertically, and a #4 within 6" of both the top and bottom of the wall.  Anchor bolts were placed every 6'-0" and within 12" of each end of each wall.

 After they poured the stem walls, the kid with the skid hoe came back and backfilled around the stem walls, stripped the topsoil in the center, and no - I don't know why he did it that way, but it didn't take him all that long to get the sod out and down to good soil, so what the heck?  As long as it got done right, I wasn't concerned.  There wasn't enough good fill to use on the inside of the walls to support the slab, so I ordered structural fill brought in to bring the sub-base up to grade.  They brought in a type of fill that doesn't require compaction, which I think is interesting - it's a product I was familiar with but had never seen it done before, a material called CLSM (Controlled Low-Strength Material).  It looks mostly like really sloppy wet sand, and it is brought in in a concrete truck and poured out and leveled almost like concrete. 

It's usually made up of a mixture of portland cement, fly ash, and aggregate mixed with water.  Lots of labor saved in that you don't have to compact it, and it can be put in place so very quickly...  I did need 2-1/2 truckloads of it, each costing $200 though (I ended up having to buy 3 truckloads full)  I had the remainder put out so I could use it as fill for under the driveway slab that would eventually be placed out front of the shop.

Backfilling

So, I think in my case, I paid dearly for it.  But at least it was ready for the floor.  I did have one problem - there was a lot of soil left over in a big pile - sod, rocks, organic soil - pure garbage to me and I had nowhere to put it.  The kid with the backhoe offered to take it - seems he was filling some ditch on his property out in the back woods, and could put it there. He loaded it and hauled it out himself, so there was some consolation. I rewarded him by getting him to put in a gravel driveway back to the shop and to redo the one out front.  He did a particularly splendid job, for a fair price.

For more information on CSLM, visit the Portland Cement Association's web site.

The Floor Slab

So - another appointment for dad, and I knew they were going to pour the floor - when I got back, this was the scene:

Pouring the slab

It was a good thing I got back when I did...  I noticed two things were completely wrong.  First - there was no insulation laid down around the perimeter.  Second - he hadn't dug out for the two pier footings I would need for the two columns I had designed for the structure.  You know, I don't think he actually ever looked at the drawings...  Guess there might have been too much information there for him to handle.  Anyway, it was already too late for the insulation, but I did at least get him before the concrete had reached where the pier footings were to go - and stood there while he dug them out and made sure they were the right size, even as the concrete was flowing closer to the pit.  Essentially, the pier footings can be poured as a part of the floor, like a monolithic slab would be - so it's fine if done that way.  It would have sucked if he hadn't done them though - I wouldn't have known about it, and would have wondered why the floor slab cracked so badly around the columns later...

The finished floor

At long last - I had a foundation on which to build my shop.   Woohoo!  The rest would be all up to me and me alone.

 

Up next - walls!

Tell Mom You Love Her in Wood

00/00/0000, 00:00 | Custom Wood Carvings of Your Pictures with Unique 3D Raised Lettering



A Greeting plaque for mom - A gift that lasts forever.
$97

Relaxing with Mimes

00/00/0000, 00:00 | Skiving Off

My wife and I subject each other to a lot of second hand noise.

As Gail sits in the living room knitting, she deals with the background noise drifting up from my basement woodshop. She also has to deal with my scream of testosterone-induced rage as I don one of my Old Man sweaters, stand at the front door shaking me fist, and yell at the neighborhood kids to “STAY OFF MY YARD!!!” Probably once or twice a year she has to tolerate the sickening sound of the bitchslaps I put on the migratory mime troupe that comes through on their way up to Mackinac Island. (I call this event Silent Scream.)

The second hand noise I tolerate isn’t quite as offensive. Let’s face it…Gail’s knitting isn’t very loud. However, each morning as I sit with my laptop in the dining room desperately trying to feed all of my Webkinz before I start my day, I am forced to listen to the cable news show Gail religiously watches. It’s not just the perky talking heads that I have to hear…it’s the commercials from hell, too.

I first heard this commercial yesterday, and my brain semi-consciously registered a What the $@#%????? However, this morning the replaying of this commercial solidly lodged in the conscious part of my brain and chiseled out a ledge where it has painted a sign that calls it out as one of the nuttiest things I have ever heard seriously marketed.

(Pleases note the “…” in the title below creates a pregnant pause of almost a second and a half from the voiceover actor as he narrates the television commercial).

The Most Relaxing Classical Album in the World...Ever!

Honestly, it’s a real title. You can get it here.

Wow, there are a lot of unsubstantiated statements in that title. Well, it’s my belief they are unsubstantiated. Perhaps there are competitions among albums to see which is most relaxing.

They get really bubbly waitress types, pump them full of ephedrine and caffeine, then strap them into La-Z-Boy’s and force them to listen to music through headphones. Whichever album creates the largest total reduction in heart rate, respiration, and certain non-essential brain waves is considered to be the Most Relaxing Album. Obviously, competition among Classical albums is more intense than in the EuroTechno or ThrashMetal categories. In fact, the Classical competition is the main event; those ringside seats command Super Bowl ticket prices from scalpers.

I still have questions. Does one competition really determine the winner for the ENTIRE world as indicated by this album’s title? What if there is an unheralded classical album making the rounds in a village outside New Delhi that is putting people to sleep left and right?

Finally, I am skeptical of the use of the word “Ever.” Does the word “ever” in this title mean “from the beginning of man up to this point in time” or does it imply all future time as well? Even if it is possible to gather all of the music that has come before and rank it for relaxation value, it is not possible to know something won’t come along next Thursday that will make narcoleptics of all of us.

You know what…I just realized I am probably not the right guy to be complaining about sweeping generalizations like ones used in the title of this album. After all, am I not the guy that Chris Schwarz links to with the subtitle, “Is Jeff Skiver the funniest woodworker ever? Yes. Yes, he is.”

I suppose I should just be happy Chris chose to accentuate my sense of humor as opposed to my ability to put the smack down on non-verbal artists.

Interpreting Historic Crafts

07/15/2008, 20:24 | Arts & Mysteries with Adam Cherubini - Blog

As many of you know, I demonstrate early woodwork at Pennsbury Manor. We were visited a few weeks ago by a reporter from a local newspaper who wanted to see why we do what we do. You can read his column here.

I never feel I do a good job speaking to the press. On a recent interview for a podcast, I took a simple 20 minute question and answer and turned it into an hour long bore-fest. One needs to answer clearly and succinctly and quickly. It's a skill I don't have. Guys like Schwarz are great at this.

Anyway, my concern about the fellow from the newspaper was that he was going to paint us as freaks and geeks. And tho some of us may fit that description, I thought that would be dismissive. And in Pennsbury Manor's case, many of the volunteers are highly skilled. I don't think it's fair to describe their motivation as "wishing they were back in time".

Looks like I got quoted a lot, which, given the controversial nature of what I was saying, is to be expected. The first quote:

?Some of us might have made unsatisfying career choices,? Cherubini said, ?or maybe the woman controls the house; so in the workroom, we want to be able to make that .0001-inch slice so we can say we control something ? 17th-century woodworking demands that kind of precision.?

This is my theory of why 17th c work or period work in general is not as popular with woodworkers. What I actually said was something to the effect that as we get older, we find ourselves recognizing that we cannot effect the changes we want at work, our children make choices we wish they didn't, our wives make all of the important decisions for our home and family, and the general sphere of our influence shrinks. And for some, it may come as some comfort that at least in our workshops, we can control the cuts we make to .001" precision. We may not welcome the axe to decide the shape of a piece. To let the grain dictate form is a sort of controlled crash that I think many woodworkers simply can't abide. I enjoy that uncertainty. I think it's authentic to the period. Feel free to disagree, but that's where I was going.

?Sure, you can pretend you're at a Star Trek convention when you see people like us,? said Cherubini about re-enactors. ?First, I don't consider myself a re-enactor. We are craft demonstrators.?

In this quote, I was just trying to make the point that the clothes we wear are there for the visitors, not to establish a character we are role playing (like a re-enactor perhaps) or to establish ourselves as members of a clique (like folks may at a Star Trek convention). I went on to explain the differences between first person interpreters (who essentially role play), third person interpreters (what I do), and docents or tour guides. Coincidentally, one of the first people to define and differentiate these terms was fellow Pennsbury volunteer interpreter Stacy Roth, who's book , remains a seminal must read text on the subject.

?And we're not a subculture,? said Cherubini. ?We're not all nostalgic for the past ? not that most people really think about whether we have real lives when they see us here anyway. What's important is that we need to balance our lives. ... We've worked in high-stress jobs, or we don't have enough control over our lives. When we come here, we get to decide for ourselves, be deliberate and share.?

This last quote is a combination of different conversations (during which I was riving and planing stock, btw) and the last sentence is a bit too succinct for me to believe I actually said it.

In terms of why we do what we do, I think there's a common motivation to present our crafts. In my case, I want to represent not my woodworking skill, but the skills and values of early craftsmen. I don't want folks to see me struggling with my tools, or fussing with a plane that isn't sharp. I want my visitors to see what I think the craft looked like then. Fast and efficient.

In terms of balance, I've noticed anecdotally, that a lot of the hand tool folks I encounter come from high tech jobs. The need for balance was my guess as to why. Personally, when I'm done working on a computer all day, I don't want to sit in front of one all night.

I don't want to pick on the journalist. I think it's great that he chose this subject and I think whatever preconceived notions he had coming in, he did a good job writing what he heard. I think it's an interesting, and very complex subject. What I've written above is my sense for it. If you are an interpreter, I'd like to hear yours.

Adam

Episode 27 - Episode 27 - Tuning a Plane

00/00/0000, 00:00 | T Chisel - The Rough Cut Show!
Taking a break from building the Bombe, Tommy tunes his hand plane by taking it apart and sharpening it. He demonstrates the power of the plane, showing how to flattening an uneven piece of wood. Using paraffin wax to glide the plane, he gets the piece of gnarly wood in perfect shape.

Episode 23 - Bombe Series - Pigeonhole Dados

00/00/0000, 00:00 | T Chisel - The Rough Cut Show!
Back on track after the doubler do-over, Tommy routes out the dados for the main piegeonhole assembly using MDF as a fence. Setting the two center partitions is the key getting the assembly process started. Once the dados are run, Tommy inserts the main partitions with a nice simple bead detail.

Flattening Traditional Oilstones

00/00/0000, 00:00 | David's blog
I have been watching Larry Williams excellent new dvd on the making of traditional side escapement wooden planes, which has just been published by ...

USA trip

00/00/0000, 00:00 | David's blog
I depart for the Marc Adams School class on 1st of May and will be back 22nd May.

We are filming a DVD on ...

Episode 75 - Bombe Secretary - Upper Pediment III

00/00/0000, 00:00 | T Chisel - The Rough Cut Show!
Tommy discusses how he tackled the most difficult part of secretary so far, the compound return angles at the top of the pediment. The moldings in the front and the side look the same but are completely different. He moves to the bench to illustrate the problem and how he cut the moldings to fit. As viewers can see from the disastrous state of his shop, this problem was a tough one.

Cabinet back...

00/00/0000, 00:00 | The Refined Edge
I've been working on the frame and panel for the back of the cabinet. This frame is composed of the same wood, European beech, as the cabinet. The components of the frame and panel back are two outside stiles, a center stile, and the upper and lower rails which are continuous along their length. The width of the individual components is approximately 2 inches or thereabouts, and I based this on aesthetics along with availability of clear quarter-sawn beech stock on hand.

The type of joinery I have selected for this back is the mortise and tenon. The stiles are of equal length, so are the the respective tenons at either end of each stile, which also fit into the grooves in either horizontal rail. In the photo, the frame is temporarily installed in the cabinet back recess for a test fit. I am in the process of creating the panels to fit into each of the frame halves.

Some judicious planing is involved in creating a perfect fit of the frame and panel into the back of the cabinet, but I had already allowed for this with a very small fraction of an inch in extra width of the frame. Another factor in the decision for the stile and rail widths is the factoring in of any small wood movement of the rails and stiles in their widths. The wood I have selected is fairly quarter-sawn so movement is substantially reduced and the fairly narrow widths of the components reduces the remaining movement considerably.

The panels will be floating with a small gap around each edge to allow for wood movement. Once I have this frame and panel back installed, the cabinet will have developed an entirely new look, that of a cabinet without front doors.

Design - in the Balance

00/00/0000, 00:00 | Furnitology Productions

The Element of Design.........Balance usually starts and ends in discussion with a piece having visual balance and structural balance.

Lets take the element of balance one step further in the Design process. A place where its never thought of.

Formats available: Quicktime (.mov)

Introduction to Fly Rod Making - Saturday, June 14 at Highland Woodworking

00/00/0000, 00:00 | Highland Woodworking Blog

Saturday Mornings at Highland Woodworking

Saturday Mornings at Highland complement our woodworking class & seminar offerings. Join us at our store in Virginia-Highlands on Saturday mornings at 10am EST for FREE, live demonstrations featuring a wide variety of woodworking skills, tools & techniques. These 1 to 1-1/2 hour-long demonstrations feature our knowledgeable staff and instructors, local clubs & guilds, guest authors, and others. Upcoming events include woodturning, woodcarving, care & use of hand tools, joinery, book signings, an introduction to woodworking design software, and much, much more.

Introduction to Fly Rod Making with Doug HallSaturday, June 14, at 10:00am—Most believe that the finest example of tradition in the world of fly-fishing is a finely crafted bamboo fly rod. It combines craft, time and tradition into something that you can literally hold in your hand. Doug Hall has been making bamboo rods as a passion for over a dozen years and also teaches rod making. He will demonstrate how raw Tonkin cane is split, planed and ultimately transformed into a stream ready bamboo fly rod. Through examples he will introduce you to the principles of handcrafting split-cane rods.

All demonstrations take place in Highland Woodworking's retail store in Atlanta, Georgia and begin at 10:00am EST.

Episode 74 - Bombe Secretary - Upper Pediment II

00/00/0000, 00:00 | T Chisel - The Rough Cut Show!
With his new hi-def camera, Tommy reviews how he worked with the rake. He shows how the application of the molding makes the outside corner and the top of the rake more pronounced. Tommy then wonders how he will work with the compound angle at the top, which is going to be difficult.

Episode 24 - Bombe Series - Planing the Dividers

00/00/0000, 00:00 | T Chisel - The Rough Cut Show!
Preparing the stock for the pigeonhole dividers isn't as easy as it looks. The stock needs to be milled to a 3/16" thickness, but in making it that thin it's way more likely to crack or split. The solution: support the wood as it runs through the planer. Tommy does this with a piece of MFD clamped down to the planer which provides the support the stock needs to stay in one piece as it passes through. Once Tommy has the stock milled to the correct thickness and the sides of the cabinet routed at the precise height, the dividers slide in "like butter."

Something's Different...

04/14/2008, 01:47 | The Village Carpenter
Now, I know I haven't built anything in my shop for over a month, but I'm pretty sure the last time I was in there, I didn't leave a plant, 2 dog toys, and a bird bath lying around.
Has this phenomenon happened to any of you?

The Guitar Shop

11/29/2006, 08:07 | The Wood Shop
The Guitar Shop?


Photo Courtesy of PhatTone Electronics

I have been “working” too.

00/00/0000, 00:00 | Sauer & Steiner
When we were in Erie last weekend, someone commented on their recent visit to this site and wanted to confirm that I was in fact still making planes. I assured them I was, but the comment has been rolling around in my head ever since. When we got home, I checked the site and sure enough... there has not been a “planemaking” post for quite a long time. Here is what has been going on in the last two months.



Front to back; A Brazilian Rosewood filled A5, an English boxwood filled A5*, an Ebony filled A6, an Ebony filled A1 panel, a Brazilian Rosewood filled No.4, a Brazilian Rosewood filled A5, a Brazilian Rosewood filled A1 and a Brazilian Rosewood filled A2 jointer.

A shot from the other side.



And some detail shots.



This is a family of 4 planes infilled with Brazilian Rosewood from a single plank. The No.4 is bedded at 52.5 degrees and has a 2" wide blade. The A5 is a York pitch with a 2-1/4" wide blade and the 14-3/4" long A1 and 22-1/2" A2 are bedded at 47.5 degrees. This is going to be a fantastic set of planes to use.




* This is second boxwood filled plane I have made. The first was an XSNo.4 I made last years and I have been dying to make another ever since. Boxwood is a real treat to work with - it cuts like hard butter. I also want to thank Bill Carter for generously supplying the piece for the handle. Finding genuine boxwood is really tough, let alone something large enough to make a handle with.



This past Friday, I shaped this Brazilian Rosewood handle. Above is a shot I took when I started shaping, and the black streak came alive. To me - this is what dreams are made of! Below is a photo of the handle fully shaped, sanded and ready to have the adjuster fit.



The two Ebony filled planes are at the tail end of the french polishing process - they each have 9 coats at this point and are looking magnificent.

Next update - the kitchen doors!

Do You Wear a Respirator?

00/00/0000, 00:00 | WoodworkingONLINE.com

I’m keenly aware of the affects of breathing in too much dust thanks to an unfortunate attempt years ago to carve a duck decoy with a moto-tool! Now, whenever I’m sanding or routing (or doing any job that produces a lot of fine dust) I wear a dust mask. The problem with your typical dust mask is that they don’t work very well.

Mediawebserver.jpgBelieve me, this is not an area where “good enough” suffices. You certainly don’t want to scrimp on dust protection, but too often I’m using an old mask that’s past the point of effectiveness. That’s why I recently spent the money on a half-mask respirator (photo at left). I like this 3M product for several reasons, including the fact that it’s comfortable to wear and economical (they retail most places for around $10 - $12).

But the thing I like best about it is that there are a wide variety of filters available. There are cartridges and filters designed to be used when working with sawdust, as well as fiberglass insulation, pesticides, lawn chemicals, and spray finishes. The respirator I purchased didn’t come with a cartridge included, so I was able to save a little by buying just the ones I needed.

I picked up my respirator at McFeely’s.com, but they’re available at several locations including Ace Hardware and Lowes.

New fishtail chisel from Bluespruce Toolworks

00/00/0000, 00:00 | Traditional Tools & News
Dave Jeske at Bluespruce Toolworks is now offering a fishtail detail chisel. Very cool!

Planer Snipe…with a Twist

00/00/0000, 00:00 | WoodworkingONLINE.com

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.

Wax lyrical

00/00/0000, 00:00 | Musings from the Workbench

Big Bugs made out of Wood

00/00/0000, 00:00 | WoodworkingONLINE.com

Beetle.jpgI recently traveled back to my hometown in central Ohio to see family and our new granddaughter. While I was there, my wife discovered the Big Bugs exhibit by David Rogers at Inniswood Metro Mantis.jpgGardens in Westerville, Ohio.  As you can see in the photo at left, a beetle is about to amputate my son’s leg. The most impressive bug we saw was the praying mantis, shown on the right.

As noted on his web site, David sculpted these creatures using various combinations of whole trees found standing or fallen dead, cut green saplings selectively harvested from the willow family, dry branches, and other forest materials. The different shapes, colors and textures of these materials provide these sculptures with character, definition, and a sense of motion.

If you get a chance to see this exhibit in your area, it’s worth taking the whole family. Just keep your kids away from the jaws of the beetle.

Episode 30 - Bombe Series - Drawer Shaping

00/00/0000, 00:00 | T Chisel - The Rough Cut Show!
Satisfied with his selection of wood, Tommy delves into the beginning stages of creating the drawer fronts - laying out the dovetails. After cutting the blank into a shape, he takes his shoulder plane to smooth rough ends and "sights" to make sure they're level.

Episode 97 - Ask the Masters 16

00/00/0000, 00:00 | T Chisel - The Rough Cut Show!
Boats, logs and claps - Oh MY! In Part One of the federal table wrap-up, T-Chisel visits Steve Brown, head of the Cabinet and Furniture Making Department and a 1990 graduate, of the North Bennet Street School. Steve provides a little last-minute how-to information on getting the embellishments perfect and critiques the table as the end of this project nears.

Episode 7 - Bombe Series - Shaping the Lower Cabinet Sides - Part 1

00/00/0000, 00:00 | T Chisel - The Rough Cut Show!
Tommy surfs the long board in the shop and then tackles the first cuts of the bombe secretary cabinet sides. This is a critical part of the secretary since it determines the real look and feel of the piece of furniture.

Sharon Becker's Tasteful Cookbook Collection - Interview

01/01/1970, 01:00 | ephemera

Woodworking: The Perfect Hobby

04/17/2008, 23:40 | The Village Carpenter
At least it is for someone who loves variety. Woodworking is an inexhaustible source of learning. There is always another technique or talent you can acquire or challenging project you can build.
When I first started woodworking, I built rustic furniture. The wood was free (fallen limbs in the neighborhood), it required few tools, and it involved basic joinery. From there, I became interested in building New Mexican furniture because the carving looked like fun. Then, I migrated toward Mission furniture, then Shaker furniture, then learning how to handcut dovetails, then how to make handplanes, and now PA German furniture.

I?m crazy-interested in learning more handtool techniques.

Recently, I bought a video on marquetry from Jane Burke and a video on sharpening handsaws from Tom Law. A year ago I learned how to make string inlay, for a line and berry design, from Steve Latta.

But it doesn?t end there.

There are a multitude of other types of woodworking and ww techniques, including wood bending, veneering, carving in the round, chip carving, furniture design, making handtools, mastering complex joinery, finishing, building musical instruments, and woodturning, just to name a few.

And my list of ?to-build? projects. Well...I will never reach the bottom of the list.

But that?s what I love about woodworking. It?s impossible to learn everything or build everything you'd like to, so it's constantly exciting and it's impossible to be bored.