If you find there is any copyright abuse, contact us as soon as possible, thanks.
Announcing the winner of our Festool Giveaway Sweepstakes
11/13/2008, 19:35 | Highland Woodworking Blog
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.
Woodworking Tips for Sharpening Hand Tools
11/05/2008, 21:02 | Highland Woodworking Blog
A Guide to Sharpening Chisels and Plane Irons
User Review: Work Sharp 3000 Sharpening Machine
Hollow Grinding: Necessity or Relic?
Q & A: Not Ready for Prime Time?
Waterstone Sharpening: Care & Use of Japanese Waterstones
Guide to Sharpening and Using a Woodworker's Best Friend - The Scraper
Sharpening #80 Cabinet Scrapers
User's Guide for the Makita 9820-2 Sharpener
Tormek vs. Jet and Standard Bench Grinders
GATEWAY TO OUR ONLINE CATALOG OF SHARPENING TOOLS
Visit our huge archive of woodworking tips, articles, and Q&As
Visit the latest issue of Wood News, our monthly online magazine
A New Woodworking Season Begins
10/15/2008, 19:56 | Highland Woodworking Blog
As autumn leaves brighten in color, woodworkers are inevitably making their way back to the woodworking shop in their basement, garage or outbuilding to resume the work they love: making practical and beautiful things out of wood. In these troubled economic times more than ever, possessing woodworking skills and the tools necessary to exercise them can help enrich and enliven a woodworker's life. Besides the joy and satisfaction that comes from creating something by hand, the opportunity exists to supplement your income by concentrating on practical projects that your local marketplace needs. Tables, chairs, shelving units and cabinets never go out of style and everyone needs them. Woodturning projects make excellent gifts, and everyone will be looking for unique gifts to give this holiday season. Woodcarving is great for this too.
We welcome your suggestions for specific project ideas that your fellow woodworkers around the country might use to generate income locally or save money on gifts that would otherwise need to be purchased. If you have some project ideas to share, please describe it by posting a reply to this blog entry.
The latest issue of Wood News Online, our monthly woodworking magazine, features an excellent article by Doug Bittinger that kicks off a series on taking the plunge into full-time professional woodworking. Whether woodworking is a hobby, a part-time moneymaker, or full-time occupation for you, Doug has some thoughtful ideas that are worth considering.
Here is a link to the full October issue of Wood News Online. An excerpt from Doug's article follows below:
Taking the Plunge into Professional Woodworking
by Douglas Bittinger
I cannot say that I know anyone who was going through life with no woodworking experience and simply said to themselves "I think I'll become a professional woodworker," signed up for some courses to learn what they needed to know, and then went looking for a job as a woodworker. Not to say it doesn't happen. I just don't know any.
All of the professional woodworkers I know discovered a talent and desire for woodworking and nurtured it. Some discovered it while young, some not so young, but they found it. Some got into it out of necessity: they wanted things they couldn't afford to buy and decided to make them. For others it started as a relaxing hobby. At some point they said, "You know, it would be great if I could make my living doing this instead of [whatever]."
If this thought has breached in your brain, let me issue a caution: When you take a hobby and turn it into your occupation, is ceases to be a hobby. Along with this change come responsibilities that weren't there before. Your hobby becomes your JOB.
If you possess certain capabilities and resources, it can indeed be a rewarding and fulfilling job, leading to a more pleasant life style. If not, it can turn into a stress filled nightmare. What are these capabilities?
At the Newsstand
04/15/2008, 05:01 | Musings From My Shop
I?m still in a mode with very little time for woodworking. That?s not a complaint since the project keeping me out of the shop is a great opportunity and incredible fun. But there is some news from the shop.
About a year ago I made a new arts & crafts kitchen table with a tile inlay top. I wrote about the process for Woodwork magazine. The article is in the June issue, available now.
Soon I?ll be able to post about the current project. I hope you?ll agree that it?s worth the wait.
Shameless self-promotion
02/09/2008, 07:40 | Musings From My Shop
The April issue of Popular Woodworking is on it?s way to subscribers and will be available on newsstands before long. In this issue is an article I wrote about the Greene & Greene chest that has been mentioned on this blog several times before. While the full article isn?t yet available, the on-line extras are. I?m very proud of this piece. Have a look.
Welcome to the Wood Shop
02/01/2007, 19:44 | The Wood Shop| |
|
Wood Talk Online No. 42
00/00/0000, 00:00 | Matt's Basement Workshop Podcast
Status Report: Marc talks about his recent router table injury and his experiences with both the Laguna Resaw King bandsaw blade and the Final Cut tablesaw blade.
Matt just completed the chisel plane build and confessed that he purchase pre-made legs for an office desk. He is also continuing his experimentation with spokeshaves.
Around the Web: The all-wood X-Wing Fighter!
News: Rockler offers new cast iron router table. Sears offering Craftsman benchtop spindle sander that looks a lot like the Delta Boss unit. Lee Valley intros two new planes: Side Rabbet Plane and the Skew Rabbet Planes.
Hot Deals:
25% Off Bessey F-Style bar clamps at Woodcraft 6" - 30" long versions thru Sept.30, 2008.
Bessey K-body clamps at Woodcraft 24" & 40", buy 3 get 1 free.
WoodRiver Carbide Anti-Kickback Router Bits 10 piece 1/2 shank bits Woodcraft $50 or $5 each bit.
Bora Clamp-N-Cut Edge Guides (Mentioned in listener voicemail)
And a very special offer from Highland Woodworking. FREE SHIPPING to listeners of Wood Talk Online on any order over $50 through 10/03/08. Listeners just need to put "wto" in the Discount Code field during checkout. Terms, conditions and details are here.
Voicemail: Roberto had a question concerning tablesaws with built-in router tables. Ray wanted our opinions on Gorilla Glue. Chris wanted advice on clamping straightedges and cutting large sheets of ply.
Tom's Tip: Uh oh, you dropped some screws!!

Stephen Shephard's new site
00/00/0000, 00:00 | Traditional Tools & NewsWood Talk Online #41
00/00/0000, 00:00 | Matt's Basement Workshop PodcastHey everyone Marc and I are back after an extended summer break. And we just finished the latest episode of WTO. Lot's to talk about...
Listen to today's show by clicking on the player below
Status Report:
Where have we been for nearly 2 months?!?!?! Marc gives a Gadget Station update and talks about the âproject humpâ. Matt announces that his next project will be a bedside table for Madison.
Around the Web:
Working Wood by Tom Fidgen
Luthiercast
Upholstered Chair Project Video
News:
Final Cut sawblades.
Amanaâs In-Tech router bits with replaceable cutterheads.
Steel City introduces spiral head lunchbox planer.
Auriou rasps back in business!
Hot Deals:
50% OFF ROUTER TABLE STARTER PACKAGE
Regular Catalog Price $239.97 E-Direct Special Offer $119.99
Bessey Tradesman Bar Clamps Buy 2 - Get the 3rd FREE!
Topics:
IWF Review- DeWalt TrackSaw, Delta Unisaw, General Internationalâs adjustable height bandsaw.
Intro to Spokeshaves - low-angle vs. standard - flat vs. round bottom
Tomâs Tip: Keeping the shop clean.
Building a Bookcase
00/00/0000, 00:00 | Woodworkers ResourceIn 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
Building a Bookcase Part II
00/00/0000, 00:00 | Woodworkers ResourcePart II of our Building a Bookcase video series covers the topic of face frames. We talk about ways to construct face frames (mortise and tenon, and pocket hole joinery) along with things to consider when figuring out what size your face frames need to be.
We'll even show you how to make sure your face frames fit your bookcase perfectly every time.
For more information on woodworking and to be alerted to future videos podcasts, go to our website and sign up for our newsletter.
www.WoodworkersResource.com
Thanks for watching!
Craig Stevens
Building a Bookcase Part III
00/00/0000, 00:00 | Woodworkers ResourceIn this episode of the Woodworkers Resource Video Podcast we're continuing the topic of building bookcases. This time we look at cutting and installing crown molding on our bookcase.
We will show you how to use simple off the shelf crown molding you can find at most "Big Box" hardware stores to really dress up your bookcase.
Ever had problems getting tight joints when install crown molding? I'll show you a simple way to get perfect looking miters every time!
If you would like to be notified when new espisodes come out, sign up for our newsletter at:
www.WoodworkersResource.com
And as always, if you have any questions or comments, you can email us at:
contactus@woodworkersresource.com
Thanks for Watching!
November Newsletter Posted
00/00/0000, 00:00 | DMWA Club NewsWood Talk Online - Episode No. 43
00/00/0000, 00:00 | Matt's Basement Workshop PodcastStatus Report:
Marc has FINALLY finished the gadget station and plans on delivering it next week. While in the area, he is also going to have a visit with the one and only David Marks. Matt decided to rearrange his shop tools recently and is apparently going to start writing a new book entitled, "The Feng Shui Workshop".
Around the Web:
Check out Keith Cruickshank's awesome videos at Woodtreks.com Popular Woodworking Magazine and Woodworking Magazine have had a little facelift recently. FineWoodworking.com also seems to have had a few tweaks.
News:
Don't miss your chance to enter The Wood Talk Online Giveaway. Lee Valley provided us with two of their new Skew Rabbet Planes and next week we will select two lucky winners. Enter Here!

Hot Deals:
DeWalt 18V Cordless Drill/Driver Kit Sweepstakes ends October 13th thanks to Tool Snob. Makita Orbital Finishing Sander only $39.99, save 27% at Highland woodworking while supplies last. Aluminum Assembly Clamps from Lee Valley set of 4 (2) 18" & (2) 24" $85 regularly $108 fast-acting sliding jaw with a locking handle mechanism (similar to locking pliers). Makita 14.4 V cordless impact driver at woodcraft $189.99. Select Norton Combination Waterstones Save 20%! Now Through October 31, 2008!
Voicemail:
David has a good question concerning bandsaw blade width.
Tom's Tip:
Tired of using guesswork every time you set up your dado stack? Tom has some advice.
Is Shopsmith Breathing its Final Breath?
00/00/0000, 00:00 | WoodworkingONLINE.com
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.
‘Craft in America’ to air on PBS
00/00/0000, 00:00 | WoodworkingONLINE.comHere’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.
Grainger Subsidiary Acquires McFeely’s
00/00/0000, 00:00 | WoodworkingONLINE.com
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.”
Art Festivals as Inspiration
00/00/0000, 00:00 | WoodworkingONLINE.com(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.
Hi-Yo Quicksilver!
00/00/0000, 00:00 | WoodworkingONLINE.comIt 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.
Christmas in Erie PA
00/00/0000, 00:00 | Sauer & SteinerThe usual suspects were there - Jim Leamy, Paul Hamler, Patrick Leach, Don Rosebrook and Martin Donnelly to name a few. I also had the pleasure of finally meeting Roy Underhill. He gave a talk on Saturday night. Early in the show he was walking around in the tool display and demo area and I had to do a triple take to make sure it was him - he was not wearing his hat.
Paul Hamler is just finishing up what I believe is his last set of miniature planes - a Sandusky Center wheel plow. There were several different configurations - Ebony with ivory arms, Rosewood with ivory arms and even a few solid ivory versions. It was a little overwhelming trying to keep track of them all - and when Paul sent me this photo a week ago - I missed “it”.

On Saturday morning, Riley walked over to me at my bench and handed me a small bubble wrapped package. He said “Happy Fathers Day dad”. As I unwrapped it - I found myself holding a very small African Blackwood bodied, left-handed Center wheel plow. Riley answered my question even before I had a chance to ask it - “I got it for a buck”.
I knew something was up, and judging from the smiling faces around me - their plan had worked.
The plane is magnificent to say the least, and if it you left out familiar objects to give a sense of scale - it could pass for a full sized plane. Paul, my deepest thanks for this stunning and personal tool.
Here are a few photos of the pair of left-handed center wheel plows.


And a few shots to try to give some sense of scale. The rebate plane is 1/2" wide and 3-3/4" long.


And some detail shots as well.



That little brass thing the skate is sitting on... one of the bronze buttons I insert into an infill cap iron.
Paul was also delivering some of his scraper plane inserts and gave a talk on Friday night about its history and evolution. As a fellow toolmaker, it was very interesting to see how it evolved, the prototypes and those “aha” moments that happen at the weirdest times. The spring is the (brilliant) key to this insert - and turns it into an elegant and highly functional tool. I can’t wait to get a No.6 so I can use it.
I have been “working” too.
00/00/0000, 00:00 | Sauer & Steiner
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!
I just beat the 4 year anniversary...
00/00/0000, 00:00 | Sauer & Steiner
... of starting the kitchen (by 2 weeks!). I guess technically - it is not quite done - the pulls are not finished - but... it feels pretty great to have it to this point. The above photo is made up of 3 shots spliced together in photoshop - it was the only way I could get the whole thing in.
The doors themselves went together quite well - and were easier and faster than the drawers. I used a Zona saw to cut the shoulders for the hinge mortises - and a small router plane to clean them out. I was a little worried about cutting the mortises in the cabinets, but it worked quite well. I am still a little bitter that I did not have the foresight to pre-cut mortises for knife hinges like I used in the mudroom cabinets... but I will get over it. These are oil rubbed bronze hinges and worked quite well with the walnut (and the future African Blackwood pulls).

I need to thank Jim Shaver for reminding me of a great technique for keeping doors closed. I used 3/8" rare earth magnets buried in the bottom of the door rail and another in the face frame. They are epoxied in and covered with a piece of walnut veneer (planed flush with an XSNo.4 of course:). It worked perfectly.

In hindsight, there are a few things I have learned.
Firstly - building your own kitchen cabinets is not for the faint of heart. I underestimated the size of this project by at least 200%. It was totally worthwhile, I learned a tremendous amount and I would do it again (if I had to), but I was nuts to think I could do it in a year.
2. Taking the time to find quarter sawn wood for door frames is the right thing to do. In the grand scheme of the project and the immense time it requires - the extra expense of quarter sawn is a drop in the bucket, and you will thank yourself repeatedly because everything is so stable and is visually harmonious.

3. Hand cutting the dovetails in the drawers is extremely time consuming... but worth it if for no other reason than the the learning experience. It took several months of “spare time” to get them done, but my confidence in cutting them has really improved and has positive implications for a lot of other woodworking skills. And - they just look wicked.
4. Door panels that are 7/16" thick are flexible enough to be persuaded into a frame.
5. Air dried walnut is a wonderful wood to work.
6. Sanding sucks. There were a few places where I was not able to plane a surface so I hauled out my ROS. It was a perfect reminder of why I make planes.

The doors around the sink window have beveled glass in them to mirror the side lites of our front door (see below). The doors worked out very well - but the beveled glass on the top 4 doors is a little tough to see given the dark interiors.

The kitchen island was made several years ago - it was installed Christmas day 2005. The boxed dishwasher was the island with a tablecloth thrown over it. What prompted the island construction was a phone call from Sears (where we bought the dishwasher). They were calling to suggest that we might want to consider extending our coverage because the one year warranty was about to expire. Jill just laughed and told them we would pass - the dishwasher was still in the box.

Never a dull moment
00/00/0000, 00:00 | Sauer & Steiner
When Jill and I decided that we would take the plunge and pursue this road less traveled - I was worried that full time planemaking would get boring and heaven forbid... monotonous. In the beginning, the excitement and challenge of building infill planes was incredible - the thrill of actually being able to do it was more than enough. Some of that “thrill of learning” has dissipated over the years, but I am happy to report that I still love making them. And these last two A5’s perfectly illustrate why.

The first plane is stuffed with English Boxwood. This is the second Boxwood filled plane I have made - the first was an XSNo.4. As far as I am concerned - English (or Turkish) Boxwood deserves to be placed alongside Brazilian Rosewood as far as workability and joy to use. I have a deeper appreciation as to why it is so prized by turners. Working with the Boxwood was such a fun departure from all the dark woods - I felt like I was building a brand new model.

The sole and sides are 01 tool steel, the blade is 2-1/4" wide high carbon steel and the bed angle is 50 degrees.

The second plane is also special because it has specs that I have not combined before. It is a really small A5 compared to all the others I have made. It is also extremely comfortable in the hand. The infill is Brazilian Rosewood, the sides and sole are 01 tool steel.

What was “new” is the 47.5 degree bed angle coupled with a 7-1/2" long sole. Until this plane, all the 47.5 degree bedded smoother had a 7-7/8" sole. I have made a lot of A5's with 7-1/2" long soles - but they have all had a york pitch. The york pitch raised the blade just enough to allow for the handle to be pushed in closer to the lever cap. This in turn allows the sole to be shortened. This may seem a bit over the top -but when you are trying to fit a handle to a persons hand size - every 1/16" matters!

A Scottish visitor with California plates
00/00/0000, 00:00 | Sauer & Steiner
I first met Stuart Page at The festival of the Tree last August. He was there for the full 3 days and spent a good portion of his time bouncing between Rob Cosman, John Lloyd and myself. He was very enthusiastic, full of great questions and insight - we all loved having him around our respective booths.
Many months ago, Stuart contacted me to let me know he was planning a 3 month travelling tour of North American furniture makers and toolmakers and was wondering if he could stop in for a visit. It was great to hear from him again and I was quite excited to have him over.
On June 23rd - Stuart arrived in Los Angeles. He has been keeping a blog - curiously named, One hairy arm goes west. One of his first stops was to see Sam Maloof - and I am very envious of that visit. Sam is on that very short list of people I would dearly like to meet (along with Harrison Ford and Maynard James Keenan). And after Stuarts description of their time together - I am all the more green.
He arrived on Tuesday afternoon (July 23rd) around 3. I was on the main floor working away on an A1ss panel plane (more on that in another entry). He had just driven from Calgary... and to use his words - was a little “road worn”.
Stuart was very direct about his intentions the minute he walked in to the shop. He did not want to get in the way of my regular schedule and workday... but was hoping for a “fly on the wall” approach. I was pleased (and a little relieved) to hear this - and it turned out to be a wonderful experience.
At one point, Stuart offered to help in the shop with things that are challenging for someone to do on their own. Hmmmm... a shop helper....?
I need to back up a bit. I have two amazing sets of planes that I am itching to start into... but I am waiting for the last few % of moisture to come out of the Ebony. Quite frankly - I am really tired of waiting... so I started thinking about building a kiln. In the June 2006 of Woodwork magazine (No. 99), Ejler Hjorn-Westh wrote a wonderful article about building a kiln for under $500. This seemed like the perfect project for Stuart and I. I handed him the article and he just smiled... perfect.
Hmmm... where to put it?
We walked around the shop to find an empty spot for a 20"x 20"x 7' item. The best location was the first one we discussed - above one of the 48"to 60" shorts storage areas.
I had some scrap plywood from previous adventures - but we needed two 4'x8' sheets of plywood. I figured I would treat Stuart to the full North American experience and introduce him to the often understaffed “Orange Box”. I shouldn't complain... they did cut the two sheets to size for us.
Anyway - a few hours later - we had a kiln. Here are a few photos.

It tucked in perfectly above the shorts storage - and I didn't even have to move the phone or the furnace switch!

Here it is with the door open.

The baffle is a 1/4" piece of peg board.

The opening on the right is the dry air return to keep the air circulating.
I will be drying a test piece of Ebony to see how it goes. I will certainly post the results - regardless of how it turns out.
Thanks again Stuart for all your help with the kiln and keeping me company between piening, lapping and shaping.
Oh, and the one hairy arm... it really is ONE hairy arm... the other is pretty clean shaven.
That green mallet
00/00/0000, 00:00 | Sauer & Steiner
Over the last several months, quite a few people have noticed and asked about the “green mallet” in the background of many of my photos. Here is the story...
I have never used or owned a proper mallet and when my friend Andrew Dix heard this - his wheels quietly started spinning. A few months later a package arrived.

Everything about this simple looking tool made sense to me and more importantly - every detail had been carefully planned out... nothing was accidental. The shape of the head was elegant, but also performs its function perfectly. The slight taper put a bit more weight at the top - where maximum force can be applied while striking. The handle is shaped in a way that your hand holds the mallet in a balanced position.

But the above photo is what really did it for me. This tells me the person who made this tool is aware of function first, but the aesthetic is just as important. Andrew took the time to rotate the endgrain of the handle so it lined up with the endgrain of the Verrawood head. And the Padauk wedge bisects it perfectly. This may seem like an insignificant detail - but this is the sign of a toolmaker who is passionate, thoughtful and knows when to add a “touch”.
I have been using this mallet daily ever since it arrived, and I have not a single complaint or comment to improve on it. There is a lovely dark band around the head where it has struck the ends of many of my Imai chisels. Aside from the discoloration - there is no damage. I suspect Riley and Lucas will be using a pristine mallet when I am long gone.
Very shortly after this mallet arrived, I contacted Andrew to (strongly) suggest that he consider making these available to the public. He was at first a little surprised and reluctant - but every time someone sent me a note to ask about the mallet, I contacted Andrew to let him know of the interest. I am thrilled that he has gathered appropriate materials and is now prepared to take on a few commissions.
The base mallet has a Verrawood head and either Cocobolo or East Indian Rosewood handle (any wedge material) . The price for this mallet is $250 US. He also has a good supply of African Blackwood, Kingwood, Ebony, Palisander Rosewood, Brazilian Tulipwood, Bois de Rose and Zircote as alternative handle material. The mallets can range from 16oz. to 24oz.
Andrew Dix can be reached by phone (804)678-9246 or email; dixja@vcu.edu
If anyone is interested - an offcut from your plane would make a wonderful wedge in one of Andrews mallets.
15-1/2" A1ss panel
00/00/0000, 00:00 | Sauer & Steiner
A short post - just to show some photos of a very recent plane.



A quick kiln update. It is currently running and water is being removed. It is a dehumidification process by way of a household dehumidifier. I will check the moisture content in a few days and report back. There are a few pieces of Ebony in the kiln right now and I am most curious to check the results. If it works - my shop will turn into a flurry of Ebony and stainless steel parts.
One file to rule them all - and in the Ebony dust bind them.
00/00/0000, 00:00 | Sauer & Steiner
Over the last 8 days, I have fit the front buns and rear infills of 7 coffin smoothers. Two XSNo.4ss's, three No.4ss's and two A5ss's. Six of these planes have Ebony infills. Needless to say - my hands are disturbingly filthy. The fitting process goes something like this;
1). Waste out the bulk of the infill using saws (thanks again Mike!).

The above shoulder cut that defines the overstuffing still feels “dangerous” - even after 100+ times.
2). With the bulk removed - I turn to files, rasps and chisels to further refine the shape.
3). Once the footprint is close - I add in my 1/2" wide, by 3-3/4" long shoulder rebate plane to get the fit of the shoulder to mate perfectly with the sidewall. There is still some refining of the footprint involved - but at this stage it is a bit of a dance between fitting the footprint and the height of the shoulders of the overstuffing.

The above photo is one of many tests of the fit between the overstuffing and the sidewalls. The thing that makes coffin shaped planes a bit tricky is there is very little wiggle room with regards to the fit. On a parallel sided plane, the infill can be slid in from either end. With a coffin plane on the other hand - it needs to drop down from the top.
Take an A5. The handle is already shaped, the bed angle is established, the slot for the adjuster is cut and the section of wood that connects the top of the handle to the bed is already defined. There is really not much of an allowance to move the infill forward or back before any of these aspects will be fatally compromised. Anyway - it requires all of my wits being present to do this task.
Back on topic. Until now - the rasp and file stage took the longest. I was typically using about 6 different files and rasps for this stage, but it was never quite perfect. One of the issues was finding a tool that would remove material quickly, but do so in a very clean manner. Generally - this is not done with rasps. I love rasps - but the cutting action leaves deep V shaped grooves as opposed to a file which leaves a more level surface. Rasps are great for stock removal - but it is sometimes difficult to accurately gauge the depth of the bottom of the V shaped cut. When fitting infills +/- .003" can be the difference between the perfect fit and disaster. So I turned to files because the surface was more level. The trouble with files - they are much slower and tend to clog up much more quickly - especially when used on exotic woods.
Enter this file made by Toshio Fukazawa.


This was unlike anything I had seen before. The teeth one side were completely unfamiliar. They were not like a rasp or a file... but rather a bit of a blend of the two. They had peaks on them that was rasp like - but they were still flat-ish like a file.

The other side was a little more familiar - like a fairly aggressive single cut file. Another nice feature was both edges were safe - and very well done.
I have had this file for several months now, and when I got it home (it was a gift from a very good friend), there was a rear infill and front bun for a No.4 to fit. I decided to quickly try the unhandled file - just to see what it would do. I was blown away. The toothed side removed wood so fast - I could hardly believe it - but what really got me, was how smooth the surface was. I tried another pass - just to make sure. Same thing - rapid stock removal with a super clean surface. I could hardly contain my excitement. I took of my jacket and kept going. What would have taken 6 rasps and files I was doing with a single tool at twice the speed. Once it was shaped, I flipped over the file and tried the other side. This side was very different. It too cut very quickly, but left an almost polished surface. There was absolutely no clean up after this side. I had both infills fit in record time.
Back to these 7 coffin smoothers. All 7 of them were fit using this single file in conjunction with my Wenzloff saw and small shoulder plane. This process has become much quicker, more accurate and consistent - thanks to this last missing tool being added. The only thing left is to find out where to get a few more of them.
A backyard loss & a surprising new saw
00/00/0000, 00:00 | Sauer & Steiner
When we first moved to our house in Kitchener - the backyard was quite overgrown. It was clear to us that it had not been maintained for some time. We cleared out 75% of the overgrown shrubs and crooked small trees just so we could see what we were dealing with. There was a very large, Norway maple in the middle of the yard, which had clearly been neglected. One side had been butchered, resulting in the main crotch of the tree holding quite a bit of moisture. A few bold plants had even taken root! We knew it was only a matter of time before things started falling - and last summer we lost a very large branch. I was at Westonbirt in England at the time.
With the current trend towards harsh weather - Jill and I were nervously biting our nails watching from the windows with each thunderstorm.
It was time for the tree to come down.

On August 22nd - the chainsaws arrived and the tree was reduced to a pile of firewood length logs. And even more curious - it came down as I was arriving on the grounds of Westonbirt this year. I returned home to a very sunny backyard. There is an old adage that involves lemons and lemonaid... and in that spirit - this tree removal was a good thing. I grew up with a large vegetable garden in the yard - and I have always hoped our kids would be able to experience this as well. Now we can. There is a great sunny spot along a fence that will be perfect.
Some of the limbs were not cut into firewood lengths yet, and as a bit of a lark, I went into the shop to retrieve a recent purchase - a large Japanese saw. I wasn't expecting much to be honest - but boy was I wrong (and in hindsight - I should have known better!).

This is a crosscut timber saw which I am pretty sure is called a Temagori. One of the first things I noticed was the graduated teeth were frightfully sharp and the balance of the saw was very different. It was really heavy in the toe - but as soon as I placed it on the log - it all made sense.
I started the kerf with the smaller teeth (towards the handle). In this position - the weight at the toe held the saw down. All I did was pull - and as the speed quickened - the larger teeth kicked into high gear and removed a tremendous amount of wood. Because of the angle of the handle - the teeth are forced down just by the act of pulling. I did not apply and downward pressure at all. The second stroke was just like the first - but even easier because the kerf was already started. Binding appeared to be a non-issue. I also found myself feeling for the straightest pull - and once I was focusing on that - the saw did all the work. It was effortless to use really - no downward pressure required - the weight of the saw did the cutting. It is a marvel of engineering. So I just started cutting stuff - as Jill peered from the window just shaking her head.

Here are the markings on the blade.

One of the great things about the saw is the teeth are so large, that the complex geometry is very clear.
Oh, and we have already scheduled a new maple tree to be planted in early October. It will be in a new location - so that is shades the house and our patio table in the summer.
And the tree did get the last laugh in the end. Not only were there huge sections of very curly maple - there was quite a bit of birds eye as well. 14" drawer fronts anyone?

Wesonbirt 2008 - still the perfect woodworking show.
00/00/0000, 00:00 | Sauer & SteinerI had the good fortune to attend the Festival of the Tree again this August, and like last year - was not disappointed. The format was the same - camping on the grounds of the Westonbirt Arbouretum, large scale sculptures in a picturesque setting and very fine food prepared by “cheffie” (pictured below drying some tea-towels).

One of the most enjoyable things about traveling is the incredible people - and this year's adventure was no exception. There were many familiar faces to catch up with and just as many new ones. We were set up in the Classic Hand Tools marquee again - situated off to the side of the display area. But judging from the well worn pathways inside - we were certainly not out of sight.

There was a new demonstrator at the show this year - and for all intents and purposes - he stole the show. Steve Woodley specializes in supplying hand hewn timbers for restoration work and provided four days of inspirational demonstration.

He was supplied with 3 oak logs and over the course of the 4 days, managed to square up two of them. I found myself stopping to watch every time I walked by - with several additional deliberate trips to watch his progress. I was struck with the simplicity of the process - and the incredible skill and precision required to execute it properly. Steve taught me two very important lessons about axes. First - he taught me how to sharpen them - and yes - they should look like the backs of your plane irons. Secondly - a mediocre axe is not worth the struggle. He had at least 8 axes with him - all made by Gransfors. These are available in the UK from Classic Handtools or in North America through Lee Valley. Not only is he highly skilled - he is a fantastic guy. His brother lives less than an hour from my house and



