My Other Blog

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For the last 2 years, I’ve been doing increasingly more woodcarving, anywhere from spoons and bowls taken from logs to Norwegian forms of carving. In response to my receiving a grant from the North Dakota Council on the Arts, I’ve been specializing in crafting original Norwegian inspired ale bowls. It led Barb and I to rethink our business ventures so we have renamed it Skanderna Wood Works. I’ll continue to make chairs so this blog will continue on furniture making topics.

Please check out https://skandernawoodworks.wordpress.com

My First Joined Chest

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I have some walnut that will become a reproduction of a joined chest from the 1600’s. I have long admired joined chests at historic sites and in museum collections. Building a joined chest gives me an excuse to make a dent in the pile of hardwood lumber that keeps my truck outside in the winter. This year in Eastern North Dakota, winter weather has continued three weeks into spring.

Peter Follansbee has provided photographic and dimensional information about various carved chests in his DVD on Joined Chests available through Lie-Nielsen. I have glued up front and side panels out of basswood, rather than riven oak in the original. I’d love to carve the panels out of riven walnut if it were available to me.

Regarding the carving which involves S curves, the challenge was doing the layout for this newbie to 17th century carved oak furniture. My first attempt on a carved panel involved making a pattern from a photograph for one of the designs. Follansbee can free hand a lot of his carving, but that is where experience really counts. For now I’ll concentrate on mastering the carving of a basic design that was utilized in the 1600s. When I made this pattern it also gave me the opportunity to make some adjustments for variations due to the free hand work on the original. So yesterday I started carving my first panel and now you can see my progress.

Here is the stock I’ve fabricated so far: several stiles (chest legs) and muttins (shorter stiles) using 2″ thick walnut, and I’ll use clear 1″ thick stock on the panels. I am not sure if the carving will involve more than the panels. I also have a top made of three edge glued walnut flat sawn boards that is about 21 inches wide and about 50 inches long. I’ll use secondary woods like pine or popular for the back and bottom. The rails are going to be flat sawn walnut stock that are 1 1/8″thick and they’ll be about 4 1/2″ wide at the top and 3 1/2″ wide at the bottom. The muttins will be approximately 5″ wide. Those thickness dimensions are approximate and allow for trimming and beveling where needed. By limiting the carving to the panels it has the benefit of keeping with an original design and reducing the complexity of my first joined chest.

I am planing to do most of the joinery by hand so it is authentic in appearance. I look forward to using hand planes to cut the ogee sided grooves that are distinctive on the stiles, rails, and muttins.

Popping grain in oak

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The oak I used for the desk box responded well to the 50:50 treatment of linseed oil to turpentine. This is the finish that Peter Follansbee swears by on his 17th Century reproduction pieces. What made my desk box different than Follansbee’s work is that I used some flat sawn stock and I had some issues with moisture content. I did that for obvious reasons, to conserve my supply of riven oak. In that regard, it really helped to use a spray bottle of 50:50 water to isopropyl alcohol when using the moving fillister plane on cross grain and in some carving situations. It also helped when burying the cutoff nail heads that are bent over on the small drawers. The result is that once driven into the grain, they look like staples and better correspond to 17th century drawer construction. The only negative I had to using the alcohol to water mixture was some iron staining that I removed mostly by sanding.

When I have the opportunity to work again with an oak log, it will be great to be thinking about carving 17th century boxes. Besides looking for Windsor chair parts, I will be thinking of stock for carved sides and panels when I’m using wedges to split the log. Thanks to Follansbee, Jennie Alexander, and John Fiske, and others, I have learned a lot about what to look for in designing and building 17th century furniture. I can appreciate the fact that the oak stock can have some variations in thickness and it is part of the charm of 17th century construction. You don’t have to waste as much also. I can definitely appreciate the comment “the eye is very forgiving” after my experiences of grain related variations in my chisel work. So far, I’ve faced more challenges in keeping my carving lines continuous or straight in oak than when working in other woods like basswood. But I am not discouraged, as part of that relates to my getting used to using the mallet along with oak being a harder wood to carve when it is dry.

If you work with 5/8″ stock for the case work, 1.5″ forged nails are all you need to attach the bottom, the cleats, and for the hinges. A shorter nail could be used for the hing you want enough nail to clinch it. I also found that a hand reamer was indispensable for dealing with the taper of the nails. Follansbee uses a reamer quite often in his DVDs. Sizing the pilot hole for the forged nails was quite important, but the reamer was helpful. I couldn’t find a four sided reamer as Follansbee, but I obtained a reamer (General) at a hardware store that worked quite well. I have a bit reamer for a brace, but I can see that a reamer with a T shaped handle is better. FYI, you need 20 nails for the hinges and cleats, and another 9 to attach the bottom. The hinges and nails were made blacksmith Peter Ross.

I may apply the linseed oil mixture on the inside of the box, but I can see why Follansbee doesn’t. It is kind of like not painting the bottom of a Windsor chair seat. It seemed wasteful in the 1700s and still unnecessary now. So as the oil dries it will give me time to think about whether I really want to seal the carved surfaces with shellac or another coating. The challenge of course is to make sure that an addition doesn’t take away from the charm of the carved surfaces. That is why I use spray satin polyurethane when finishing my chip carvings. If I use shellac I’ll make sure it is a lighter cut, probably closer to 1/2 lb.

Slant top oak desk box

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I love the look of this box project. It is amazing how much you can learn by doing a period reproduction piece. I’ve watched the DVD by Peter Follansbee many times on building oak boxes and also utilized his article in February 2018 issue of Popular Woodworking. I’ve benefitted too from the blogs that Follansbee regularly post. Even with great help like that there is still much more to know which only comes from your experience of doing it yourself.

I haven’t put the finish on it, but all the drawers are done and the nails installed. The top is made from flat sawn oak, because I wanted to conserve my riven oak for the carved sides. Because the top is flat sawn stock, I made sure to leave a gap at the hinge line. I learned how the installation of dovetail hinges and the cleats using nails can be trickier than you might expect. I installed the hinges with a gap and a clearance for the cleats so they would not rub on the carved sides. I even used a hand reamer this time to prepare the pilot holes for the nails. What I learned though was how easily some shifting can occur while pounding in the nails. Fortunately, the clearances ended up being sufficient so the top closes without rubbing the carved sides. I’m close on one front corner, but not enough to bother with. I learned that once you start using nails on the hinges they don’t give you much latitude for adjusting. Because the nails are tapered and bite the wood, they are not really removable. I had a couple nails bend on me so they couldn’t be removed no matter what I did. The softness of the nails though is a virtue when clinching them later. Bottom line, I noticed that I couldn’t be very fussy here.

I am considering a couple ways of finishing the oak desk box. When I typically finish a carving, I seal the wood first and then use gel stain to highlight or accentuate the carved areas. The sealing prevents blotching, especially relevant in pine and basswood, and provides good contrast with the darker staining in the carved areas. When Follansbee finishes oak boxes he uses linseed oil cut with turpentine and then he sometimes tints it with various dry pigments like iron oxide and others. I also like the idea of using gel stain to even out the color between the pine bottom and the different grain patterns in the oak. Since I have a good investment of time in this project, I am going to test the different finishes on some scrap oak.

Square Peg Joinery

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I’ve had my first experiences making and driving square wooden pegs or Trenails as they have been called. Previous to this, I’ve gone with round pegs and in part utilized a dowel plate. This time I split some red oak into 1/2″ square pieces with a froe and maul. It gave me an excuse to use some hand split material that I’ve kept for chair parts. Then I worked the blanks down to a smaller size with a framing chisel. I used a bench hook to protect my bench top from the repeated chisel cuts. Final pairing on the pegs was accomplished with one of my Sloyd knives.

I was amazed at how quickly you can process a bunch of pegs that way. Since my carved oak desk box involves 5/8″ thick stock for the carcass, I opted to drill 3/16″ holes for the pegs. Careful sizing of the pegs helped me to avoid splitting even with some wandering of the bit. Just like in furniture from that time period, I didn’t use glue on the pegs or in the peg holes. To drill the holes I used a shell bit in a John Fray Spofford brace. I made sure to hone the outside of the bit like a gouge and the holes came out pretty clean even in end grain.
Now I split pegs with a peg cleaver that was made by blacksmith Tom Latane, of Pepin, Wisconsin, which gives me improved control. It was somewhat awkward to use a large froe to split pegs as I recently did. Tom does beautiful work and the details on the handle are cool. If you haven’t looked at one, they a fairly hefty tool, and weight is a key aspect since they aren’t a cutting tool as Tom mentioned to me. I’ve watched Peter Follansbee use one on a DVD, and like a froe you can drive the cleaver with a club or mallet. You can also split stock by using the weight of the tool itself. I am clearly making the commitment to take on 17th Century furniture projects, probably because the carving really speaks to me.

Resources for 17th Century carving

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I know that I’m one of many in saying this, but I am getting progressively more interested in the carving designs utilized in the 1600s. Perhaps in some way I’m feeling a connection with some of my dad’s Scandinavian family who arrived in Delaware in the 1656 timeframe. They were around English style oak furniture in the colonies and became more and more assimilated into English culture though political changes and intermarriage. Anyway, I finally acquired a copy of Living with Oak: Seventeenth Century English Furniture Then and Now by John Fiske and Lisa Freeman, 2005, and as I flipped the pages I was thrilled to learn more about English oak carving from that period. The Belmont Press out of Belmont, Vermont is the publisher. I’ve clearly got the bug to master this kind of carving. I like it enough to order the more recent book on the same subject, When Oak was New, again by Fiske (2013). I’m looking forward to scouring the many hundreds of photos in it. After looking at other sources, I purchased it through the Fiske and Freeman website and even spoke with John Fiske over the telephone.

Like many woodcarvers, I find it helpful to know the history behind various designs becoming fashionable and then seeing the many examples of various carving motifs applied on, chests, chairs, etc. Peter Follansbee, formerly an artisan at the Plimoth Plantation of Massachusetts, gets much of the credit for this renaissance of interest in 17th Century woodcarving/woodworking tradition. He also worked with Lie-Nielsen tools to provide many instructional DVDs and his wonderful blog also regularly includes instruction.

Woodcarving and woodworking are basically constructive activities in the sense that useful endearing products hopefully are the outcome. Trees are sacrificed for our activities, but responsible management of natural resources can provide for it being renewable. Like many others, I find this creative work with wood to be therapeutic and not a waste of resources. In addition, to the craftsmanship of fashioning wood into useful and attractive objects, I am amazed at the creativity that goes into tool making which corresponds to replicating period furniture as well. For example, I rediscovered that using a scratch stock, or in my case making the filed profile blade, can be quite fun. It just takes a small piece of steel, some files, and a bit of time. In my case, I already had a scratch stock made by Veritas, but never filed my own blades. It’s been in my tool box for awhile. Personally, I am thankful that we have resources in our country to do this and all it takes is some research and willingness to try it. The really cool thing is that outside of some overhead lighting, it didn’t take much electricity to add a decorate edge to my till lids for a carved oak desk project.

If this style of carving peaks your interest, rest assured that there are blacksmiths out there who can supply your needs for hardware and tools, and there are all kinds of sources for chisels and carving tools. You might have to wait for suppliers to fill your orders because of high demand. You might have to wait for them to fill a bunch of orders ahead of you on their order list, but it will be worth it. I now have a greater appreciation for the beauty and quality of hand forged nails and dovetail hinges after obtaining them from blacksmith Peter Ross.

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Likewise, I continue to appreciate watching Follansbee’s DVDs on oak box carving as I learn something new each time. I look forward to posting my assembled carved desk box real soon.

No-nonsense Woodworking

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I’ve heard people say that woodworking is an expensive hobby. Right now, I’d say yes and no to that suggestion as I think most woodworking enthusiasts would. It is expensive if you believe that you require all the very best of equipment, a vast library of books, and a bunch of one week intensive classes. It is expensive if you can’t decide what interests you the most as your starting point. It is expensive if you spend most of your life investigating how to use more refined methods and acquiring more optimum tools. If the latter is your path, then welcome woodworking into your life as something more important and then see how it fits for you not as hobbyist or weekend warrior, but as an artisan woodworker. That is where I’m at in terms of desiring to replicate antiques and yet embracing Woodcarving as a way to individualize my work.

If you do enough research to build a tool box, bookcases, boxes for storage, or opt to build an end table or coffee table you can find it affordable cost wise. The challenge is sorting through the information and finding a plan that works for you. The challenge is to assemble a basic set of tools through a diligent search of new and used equipment and being smart about their cost. It’s a passion where asking the right questions makes the difference. Can a used hand plane with perhaps a new plane iron give satisfactory results when compared with a more expensive new one? It can, if you educate yourself on the old hand planes and take the time to find one in acceptable condition. If you get inspired you can even create a wooden plane that will produce great results, provided you make the investment to learn how. We are truly blessed that the information is out there online and in print.

I’ll be a dinosaur here. During my Junior High and High School years, I learned a lot in what was called industrial arts/woodworking classes. Whatever I learned from my dad who was a handyman at home, I went the next level at school. Back in the late 60’s and early 70’s we weren’t allowed to build anything in school without drawing up a plan. The approved drawing gave us access to the lumber rack of oak, maple, poplar, cherry, walnut, and Honduras mahogany.

You may not have had access to a Woodworking class in school. Over the years litigation concerns drove many public schools to sell off equipment and turn shop classes into technology classes with significantly reduced use of machines. While those changes have occurred, there has been a great interest in antique furniture and reproducing those pieces. Building Shaker tables, chairs, and cabinets, Country furniture, Windsor chairs, and Arts and Crafts furniture have all been taught in through magazines, books, and classes. Woodworking shows have occurred around the country for years that bring together artists, woodworking instructors, and suppliers from around the country. Some suppliers of specialty woodworking tools often have shows or an open house to encourage people to come and check out their products.

Not only that but many famous woodworkers got their start from studying old furniture and doing demonstrations at historic sites. It proves that if you fall in love with furniture from a specific time period and spend enough time in museums, you get a following of those who appreciate reproductions of antique pieces. Part of my path in woodworking was blessed by giving demonstrations at historic sites in Upstate New York, Ohio, and now North Dakota.

There is also another important aspect to woodworking and Woodcarving, community has always been an important part of learning in the arts. I’ve lived in a bunch of places over the years and it is always wonderful to build friendships with other woodworkers. Some may be immensely talented and well paid too, but since there are so many applications it doesn’t matter. You don’t have to travel extensively because interested woodworkers might be in your congregation or in your community. If you do have to drive, it might be just a state away to find a Woodworking club or a Woodworking class. What matters is that woodworking can be either an interest or an occupation depending on the doors it opens in our lives. I continue to be amazed at the commitment clients can have to owning pieces of furniture that are diligent copies of antiques.

But I’m also amazed at how people of different abilities, can still express a sense of wonder at seeing how a simple box can be made of pine boards using hand tools. I get to demonstrate woodworking using hand tools and my audiences include youth and adults at historic sites as well as through an organization that helps the developmentally disadvantaged. They all remind me of the blessings we as woodworkers have in acquiring, tuning, and using old tools. How fortunate to own tools that are 100s of years old and yet see them complete some task in our hands. I don’t know about you, but I find that very neat as an experience and not surprisingly contagious to others.

Blessings on your woodworking and creative endeavors!

Oak Desk Side Carving

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When you don’t carve that often you can easily make more mistakes when you re-emerge yourself into it. I had a super busy week at church, and although I have watched the Follansbee DVD numerous times on oak desk boxes, it didn’t stop me from goofing on my v tool work. According to the original 17th Century oak desk box, the outside lines on the tulips are supposed to stop short of the point on the leaf design. My outside lines were carried too far and are curved somewhat. I was looking at the line drawing and forgetting that the chopped accents are what makes the curvature at the ends of the lines. Oh well, you can’t see both sides at the same time anyway.

I really like the 17th century oak carved look. It is neat when I watch Peter Follansbee on his DVD cut through riven red oak like butter with a v tool. Since I’ve riven red oak from the log, I have a good idea of how much easier and faster it is to shape and carve red oak with greater moisture content.

Since I don’t access to oak logs right now, I am planning to carve subsequent 17th Century designs in clear basswood. It won’t have the characteristic grain pattern of riven red oak, but at least it won’t be as tough on carving tools also. I find this style of carving particularly refreshing in terms of giving some latitude on executing the designs. Carved lines can be irregular and still yield a wonderfully artistic piece of furniture. It is funny too how this style of carving makes you want to fill blank space as if the original carvers were uncomfortable or afraid of empty space. I never felt that way about chip carving. Previously, I actually incorporated empty space into my chip carvings on purpose.

Punch lessons

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As I said in my last post, I’ve been looking at different ways to make steel punches that I can use for carvings. So far my materials include O1 drill rod from Enco, hot rolled and cold rolled stock from Menards, an old screwdriver, and a 3″ cut nail. I feel like I’m either getting closer to the goal or expecting too much.

My first challenge is to make a tool crisp enough in detail for stamping in red oak so I can make a Maltese cross impression or some other design. When you look at sets for punching numbers and letters, ridges are well defined and prominent on those stamps. I have a set and appreciate their ability to make crisp impressions. However, the stamps that Peter Follansbee and others make to decorate the carving on reproductions of 17th Century Furniture are far less detailed. That makes sense when you look at the 17th Century furniture shown on the Marhamchurch Antiques website which illustrates those types of stamped features. So for a newbie on making steel stamps/punches, learning how much detail to incorporate is basically trial and error. My hope is to reach a point where my stamped impressions in wood can truly compliment the chisel work. Somehow those stamped impressions have to look nice enough, but not appear so regular to look manufactured.

So here is my latest attempt using 1/4″ hot rolled steel. I used a knife file, fine milling file, and some needle files to shape the Maltese cross. Here are some impressions. The two impressions on the left were made with the old screwdriver punch that I tweaked some more yesterday. I used a black sharpie on the cross so you could see it better. I also have some 3/16″ cold rolled steel that I can try next. As you can imagine, it is trickier to file a crisp design in smaller stock. So far my efforts to use a cut nail gave me a basic plus shape about 1/8″ wide. Since the maltese cross in Follansbee’s work is about 5/32″ wide or about 4 mm, I’m striving to get the shape and the size of my punches to roughly correspond. That is the second challenge, to make a stamp small enough to make the statement I want for 17th Century furniture reproduction.

Metal stamps for 17th Century Carving

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If you like 17th Century carving on oak boxes then you know about using a steel stamp on the backgrounds. I’m now a dabbler in making punches that can stamp a Maltese cross or add a decorative background on my carvings. So far I’ve made two punches for stamping a Maltese cross using some drill rod. However, those now seem oversized so I used smaller diameter materials to make two more. I also invested in a couple knife shaped files for cutting the rest of my steel stamps. My last two stamps were made using a worn out screwdriver and a large cut nail. It is harder than it looks to carefully file away the metal so it gives you the desired impression when struck with a hammer.

Fortunately, I acquired some steel stamps earlier in my life so I can look at those examples too. I’m kinda surprised that with the popularity of Peter Follansbee’s carvings, his blog, and DVDs with Lie-Nielsen, that someone hasn’t already seized the opportunity to make and sell the steel stamps/punches he routinely uses.

Anyway, it will be cool to make several more stamps/punches and get them correspond to the preferred sizes to reproduce the 17th Century carving designs. Stamping designs into wood goes back pretty far to include stamping names and company names and logos into the ends of wooden planes. It will be interesting to see how these will turn out.

Forgiving Eyes

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Do forgiving eyes help cheer us on when attempting new techniques? I worked on the front of the oak desk box project today. Personally, I will trust that human eyes will be forgiving on this first carved desk box. Thank you Jennie Alexander for reminding us though that our eyes tend to be forgiving of mistakes. Because it matters that we might not recognize artistic value which comes from things planned or unplanned in our furniture work.

Above are a couple pictures of the chisel carving work which is nearly finished on the front. I learned a lot about carving on riven oak that I’ve had for awhile. Even though it was previously kept in a freezer, it proven to be drier and harder than I had hoped. Greener oak would be more fun to work. I’ve got to believe that mallet work in recently split oak would be more forgiving in terms of tool pressure and cause less chipping.

As I said before, I have benefitted greatly from Follansbee’s DVD on oak desk boxes, but something’s you just have to learn by doing. Like spacing a chisel for vertical cuts, it is easy to get them too close when doing 2 or more cuts side by side. I wasn’t sure what chisel widths to use for some of the gouge cut details and I suspect a couple millimeters less in the cuts would enhance the next carved desk box. On the free hand carving of the tulips/leaves, I opted to use chalk and I did pretty well in keeping symmetry and keeping the diagonal line as a guide. Only on one tulip/leaf did I really stray and drift further away from the diagonal line. I also wasn’t sure what chisel width to use for the bird cuts to make on the leaves. I used my #7 sweep Swiss made gouges with 10, 12, and 14 mm widths as I got to the wider part of the features. Personally, I think Follansbee can make his chisels work in narrower and wider cuts by his sheer skill in the holding of the chisels. That seems to be the case especially when he removes background with sometimes 2 cuts of a fairly wide chisel without nicking corners.

Bottomline, I like this style of carving that Peter Follansbee has mastered with 17th century boxes, wainscot chairs, jointed stools, and paneled chests. It would interesting to hear from those of you who got hooked on this style of carving.

Carving Oak Desk Box

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Roy Underhill published a book with the title The Woodwright’s Eclectic Workshop and eclectic as a woodworker fits me also. You see I love to build everything from Windsor chairs to other period furniture, but recently I’ve gotten into building boxes. Part of my reasoning was that after my last two moves, I had to look for woodworking projects to tackle during the chaos of not finding stuff and doing home improvements. The answer was building boxes for candles and making oak boxes like Peter Follansbee of Massachusetts. I’ve had the perfect excuse to build boxes as they don’t take as long to build, can include carving, and are great for doing demos. As a pastor, my shop time is pretty limited, but building boxes seems a good fit for me now. The other shop time has been to set up and organize equipment.

My current project is an oak desk box. Peter Follansbee put out numerous DVDs through Lie Nielsen and the beauty of them is that you can watch them a bunch of times. I haven’t had the opportunity to take a class from Follansbee, but for now his blog, and watching his DVDs on building boxes are refreshing for me. The oak desk box is a design from the 17th century and was originally built from either red or white oak split from logs. I opted to use some red oak that I had split much earlier from a log. Because the pieces are not very wide, I had to edge glue the stock together. I used hide glue to be period correct.

So here are pictures of the desk box that I’m building. I have cut the two sides, the front, and the back. Riven red oak will get used for the sides and front. Flat sawn red oak will be used for the top, lid, and back. White pine was edge glued for the bottom. I’ll use a combination of riven and flat sawn red oak for the compartments and drawers. I use wooden planes and occasionally a metal bodied plane as much as possible. I confess that I also use power tools, when necessary, to expedite the progress.

I’m pretty excited about the project, enough to ask Blacksmith Peter Ross to provide me hand wrought nails and dovetail hinges. I love Peter’s skill in blacksmithing and his hinges and nails will make the project. Barb will claim this desk box, but at least I’ll have some nice pictures for any future clients.

The crazy thing is that red oak won’t be available around here in ND, so I’ll have to use other woods in the future for making carved boxes. But for now, I’m using up oak stock and I love the grain pattern and look forward to carving this design utilized by Follansbee.

I’ll be posting on my progress and the next post will feature the carved panels.

Teaching a Carving Class

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Chip Carving Knives

One of my joys is teaching chip carving to church members and friends.  I have a class coming up in May that will be held at the St. Olaf Retreat Center in Devils Lake, ND.  Our Retreat Center is beautifully situated right along the shoreline of the lake.  The class is being sponsored by the Lake Region Woodcarvers Club and will guide participants through the basics of chip carving.  I have some students who are returning too.  Lately, I’ve been teaching some 3 hour carving sessions at the local senior center and it is cool to see how some students can quickly grasp the carving technique. Part of my interest stems from the connection of chip carving to Scandinavia when it was applied to Viking ships, architectural elements, and household items of that time. I find it fascinating too how Peter Follansbee and others have included chip carving motifs into their fabrication of spoons.  Make no mistake that my interest in woodcarving is not restricted to chip carving, as I’m also striving to progress in figure carving and acanthus carving as well. But for now it is cool to offer chip carving to those affiliated with the Sons of Norway organization and members of my congregation at St. Olaf. It gets one more inspired to carve when others share your enthusiasm and you can encourage each other. I am very grateful to serve at St. Olaf Lutheran Church and to be part of the Devils Lake Community.

Lofty bench

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What do you do with a discarded kitchen base cabinet from long ago. If you are like me you salvage it for your shop!

That is what I did. After moving into our new residence some five months ago, I pulled this cabinet from the wall in the basement and couldn’t wait to repaint it. The bright red paint slopped on it by a previous homeowner didn’t appeal to my shop sense. Once I did that, I immediately discovered that it was handmade. It has a face frame made of yellow pine along with some hardwoods like birch. The drawers were made from popular. Since the craftsman didn’t use particle board and very little plywood, it got me excited. I was further delighted to see some saw marks from a hand saw. The cabinet is solid and sports rabbet joints and nail construction.

To re-purpose it, I attached a solid wood top made from 3 salvaged 2 by 12s, edge glued, and made the width to be flush with the legs. The top of the bench is 27 1/2″ wide. The top once surface planed and sanded is about 1  3/8″ thick, but okay for my purposes. I’ve seen antique benches that sported thinner tops than the 3-5″ tops being advocated nowadays. To reinforce the base, I built two leg assemblies so each side of the cabinet has a solid mounting for the top.  Carriage bolts were used to attach the top to the framing at each end. The cabinets rest on two 2 by 4’s that are half lapped onto the backside of the legs which are doubled 2 by 6’s.  The half lapped joints are bolted together with 5/16- 3/8 diameter carriage bolts. The legs at each end are assembled with upper and lower stretchers (2 by 4’s doubled at top and 2 by 6’s doubled at the base.  The legs and stretchers are held together with mortise and tenon joints that were drawbored.  To stiffen the cabinet assembly I added a piece of 3/4 inch thick plywood that was screwed to the back. I also used steel corner braces inside the cabinet to beef up the structural integrity of the nailed together case work.

For clamping I made a leg vise on the left side of the bench using an antique wooden screw of 2 inch diameter and installed a used Columbia 5″ wide shop vise for the tail vise. I am sure that it will make for a nice bench that is located along the wall. I patterned my leg vise to have a chop of 10″ width at the upper part and then made it progressively narrower toward the base. I used 2″ thick cherry for the chop. This was following the vise chop design that Chris Schwarz sports in his woodworking book on benches.  I still need to carefully fit the wooden vise screw to the leg vise chop, add some trim pieces, and then fabricate and add a thick vise chop to the tail vise. The drawers and knobs will be returned to the casework also.

Admittedly, it looks tall in the picture at 36 1/2″ and it is a few inches taller than my other benches.  It will be less desirable for some hand planing operation too, but I think it will work for me.  In defense of my lofty bench, I’ve noted that some woodworking writers have mentioned bench heights reaching this one or higher, so I though it worth doing.  It is my belief that it will be quite useful for some woodworking operations, possibly chair making and woodcarving operations, and to also serve as a platform for some of my sharpening equipment.  Maybe this will encourage you to build a workbench using your own creativity and by re-purposing some old cabinets too.  If nothing else it will still function as a counter top.

 

Snowy Day in ND

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Ah the challenges that come with moving and setting up shop again.  I guess it took a snowy day in North Dakota for me to realize how much fun and creative juice I experience in preparing a new workplace.  Call me the experiential woodworker, but I like to organize my stuff as I go.   Not surprisingly, I’ve been known to sometimes enjoy reading Soren Kierkegaard, the father of existentialism.   More importantly though, I find it ironic that with all the planning tools available via books and computers, it suits me more to layout my saws, planes, braces, and assorted hand tools based on my gut than to automatically repeat something from the last residence.  Take my set of hand saws,  I can’t settle this time for hanging my go to saws on four Shaker pegs.  No.  This time they’ll reside on a till of some kind.   Even though I don’t have a specific till design in my mind, I find it refreshing somehow.  There are certainly many nice tills featured online as examples.  What I have is a space on the wall next to a cabinet and a desire to store about 10 panel saws efficiently.  So as silly as it might seem, I am really enjoying this experience of how a simple saw till might become part of this wall.  Two basswood corbels, leftover from earlier moves, were my starting point.  I can imagine a till resting on those corbels and that is about it for now.   I know that I will use 3/4″ thick pine or poplar as stock for construction and the rest will be delightfully figured out as I go.  Plain and simple I am imagining what I might view as a low budget saw till.  My Design criteria is to not let it look like a piece of furniture. If you know me you know already I don’t mean it.  Frankly, I like what I’m seeing already and if you have limited shop time, as I do, this approach might appeal to you.  This is certainly a family thing as my dad was more of a carpenter than me, had less woodworking resources at his disposal, and routinely savored his woodworking experiences.   I’ll always remember that.  If you saw my Victorian Scroll Saw in the April 2016 issue of Woodworker’s Journal, I can tell you that I developed the design in the same way.  I enjoyed developing a design through a series of refinements.   This former geologist can say that the design wonderfully evolved.

Blessings,

Jim

Rusty Gimlets

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I confess I’ve never used a gimlet bit in a brace. I acquired these over the years and had planned to ultimately use them in an 18th century demonstration. Today I took a good look at them in their current state. I’ll be careful in cleaning up the original rust. There is quite a range in condition. From the photo you can see that I have a good variety in size also. I’m not sure how to straighten these bits. I tried several braces to test out the bits. My quick trial showed me that these babies will bore quite nicely. The fourth bit from the top has a bend in it and I’m wondering if I should try straightening it. Let me know what you think!

My hope is that I can use them for cutting wedge mortises in molding planes. Larry Williams made a great point of encouraging their use in his DVD on making side escapement planes.

Here is how three of the bits cleaned up this afternoon.

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Setting Up Shop Again

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Dear woodworking friends,
It has been quite awhile since I made a post and I owe you some explanations. Barb and I became North Dakotans in August. I accepted a new call to serve in a Norwegian American Lutheran church community in Eastern North Dakota. It is quite fulfilling work and also exciting to be closer to two of my favorite places: the Milan Village Art School in southwestern Minnesota and also Vesterheim in Decorah, Iowa.  Needless to say, being a pastor and a woodworker has added challenges when it comes to moving 1100 miles north of the Toledo and Bowling Green area.  However, everything worked out great in the big move and we are making strides in passing on the boxes to others who need them.  That will help in housing Barb’s car before the snow falls.   I am grateful for the support of family and friends, and even more excited about living in the upper Midwest. 
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While my progress in setting up the new workspace has been slowed somewhat by some recent surgery, I hope to be working at the bench this winter. I look forward to being active in the local carving club here in Devils Lake and really getting into Norwegian acanthus carving over the next year or so. A recent experience of attending the annual Hostfest in Minot, celebrating all things Scandinavian, was really a hoot!  My dad would have loved it! It was especially great to eat lefse and see numerous woodcarvers there and talk to them about acanthus, flat plane, and ale bowl carving. In particular, my friend Harley Refsal, an internationally known flat plane figure carver, is always a joy to spend time with and he has been wonderfully supportive of my new assignment at St. Olaf.
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Some of my current interests involve eventually making a few side escapement (molding) planes, like hollows and rounds, based on Larry William’s DVD that I watched this week while recuperating from surgery. I also recently enjoyed watching an episode (2015), “hollows and rounds”, on the Woodwright’s shop that featured making a molding plane with Bill Anderson. I look forward to using plane making floats and hopefully filling in the gaps on the partial set of hollows and rounds I’ve acquired over the years. Stay tuned as I eventually post about those plane making adventures using different wood blanks. I’d be happy to make and put to use a few side escapement molding planes. They’ve held my interest since I first got my hands on a couple antique molding planes in the early 80’s that were missing irons. 

Molding Plane Billets yeah!

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Maple Plane BilletMaple Plane Billets 2After carting around some hand split sections of logs that were cut down at a previous ministry assignment, this woodworker now pictures those as billets for molding planes. It isn’t beech or cherry, but none other than figured maple. Truth be told, I’ve had this wood aging in my shop now for six years and it is time to use it somehow. Thank you Caleb James, Larry Williams, Popular Woodworking, and Lie Nielsen Tools for talking up plane making. I have marveled about molding planes for years. I’ve had an appreciation for those planes dating back to my college days in the late 70’s and now I want to make ones to enjoy. Yes I’ve sharpened the irons on antique ones, but now want to take things to the next level.

So here I go. Even though I’ve been planing to do it for years and purchased books on plane making, I finally bought some mild steel just to give float making a try. I ordered the Larry Williams DVD on making side escapement planes and I sense that Lie Nielsen will get some more business from me. But hey I’ll try making floats first and see if I catch the bug to make quite a few of those side escapement planes.

Here are a couple pictures of the billets. Enjoy! My goal is to have more hollows and rounds in the tool kit!

Bench Tweaking

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I don’t build workbenches that often, but I do enjoy optimizing my existing workbenches to get the most out of them. Take my recent bench project, just a couple months ago I acquired a woodworking vise at an antique mall.  It is now reconditioned, attached to my bench, and fully functional.

How cool to have all those dog holes even if it was a pain to machine them with a spiral up cut router bit and finish drilling them with a brad point bit. Let me tell you the plywood top was the challenge with all the glue to gum up the bits. Lowering the speed on the router and frequent cleaning and honing of the bits didn’t help enough. The next bench will definitely have a hardwood top.😀  The good thing is that I can use this bench for now until I save up money for a bigger bench with a solid top.

Even still, to have a rapid release vintage vise that has a 3 inch thick red oak vise chop is an awesome addition to my bench. Now I can hold a Windsor chair seat in the twin screw vise and easily hold chair spindles in the newly installed end vise.  Believe me the twin screw vise is a sweet way to make Windsor chair seats.  By having all the bench dog holes I have every possibility of using 2 or 4 point hold down configurations with the bench dogs in either vise and also have gobs of holes to use for securing stock with holdfasts.  I love the freedom it gives me.  You might like roughing it more with a handful of dog holes.   However, with my bench I can work on either chairs or just about any kind of carving project. There is reason to celebrate here!

Thanks for looking! 

 

 

Tail Vise Tale

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My tale picks up with the vintage vise I recently bought at an antique mall. My purchase of $27, as you’ll soon see, has been rewarded. I am happy to say that the evaporust application, light sanding, and wire brushing made it look like new. I treated the clean metal castings to Rustoleum primer and then a Rustoleum black semi gloss oil enamel coating. I’ll make a new handle out of some scrap walnut. The dog slot will be left empty for now since it made no sense to fabricate a steel one. Perhaps I’ll mill a chunk of wood to fill it for esthetics.

What I opted to do with the vise was to use it on my chairmaker’s bench. This bench is an evolving bench project. In my mind a workbench doesn’t have to be a thing of beauty, but just function well. Practicality and economy kinda dictate that route for me as a woodworker. I still plan to build a nice Roubo bench based on a Chris Schwarz design when time, money, and situation allow. But for now I will tweak the design of this chairmakers bench. The centerpiece of this bench has been the Veritas twin screw vise, but due to the smaller footprint of the bench top, the design didn’t include a tail vise. I admit that I favor having two vises on a bench for a host of reasons. One of which is that I often use my vise for holding spindles so that I can shape them with drawknife and spokeshave for Windsor chairs. So buying this antique vise, and reconditioning it, got me wondering how it might become part of this very stout but smaller bench. By beefing up the dimensions of the undercarriage it showed me that pine/fur stock offers plenty of mass for any hand tool work I’ll do. Bottom line the bench doesn’t move.

With no bench top overhang on the end, I cut a 10 inch by 3/8 inch deep mortise in face of the top stretcher (4 by 4 inch stock) and then mounted the rear jaw flush with the side of the bench. This also required me to cut another mortise about 10 inch by 1 1/8 inch deep on the underside of the stretcher. The only negative that I have with the installation is that the chops have to be fairly wide, 6 inches, to accommodate the installation of the vise. Alternatively, I could have made the chops even wider and passed the vise screw and guide rods through them. The tail vise is mounted at the base of the stretcher versus installing it directly underneath the 3 inch thick top. Judging by the trial fits the rear vise jaw will also include a 3/4 inch thick chop. When I designed the chop for the front vise jaw I realized that it could now include several dog holes in it to give me multi-point hold down capability on the bench from end to end.

My tale of adding a tail vise is to install a vise chop of red oak that is roughly 3 inches thick by 20 inches long. That length gives me 3-4 dog holes for clamping. I would have opted for a shorter length on the vise chop however the installation forced me to mortise the vise dead center on the top stretcher so that the bolts holding down the 3 inch thick bench top were left alone. By using 3 inch stock it eliminates any issues with the depth of the chops.

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Consequently, I rigged my tail vise to have a substantial length of about 20 inches versus the 14 1/2 inch length chosen by Chris Schwarz for a Roubo bench. Comments are welcome!

Hooked on Acanthus

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All it took for me this past week to get hooked on acanthus carving was to learn it through the instruction of Norwegian carver Hans Sandom. Of the ten students at the Milan Village Arts School (MVAS), I was one of two beginners to acanthus carving.  It was humbling to be around all the talent.   It was also great to see progress on their projects and appreciate their commitment to master this form of carving.  It’s contagious I think.  Kinda like finding old woodworking tools, you want to keep searching for them.
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On day one you have to learn the basics and variations of carving acanthus leaves. So after carving practice leaves for about two days, I started on a bread board carving project that looks deceptively simple until you start carving it. You quickly realize how much goes into carving the elements of the acanthus design. During the last day and a half I worked on a small shelf project. I completed half of the carving so I could complete the project at home.

  

  

  

  

  
  

Of all the things to bring, I left my larger V tool at home. If you carve acanthus then you know that the V tool is critically important in helping to define acanthus carving as you work into greater relief. Fortunately for me, Hans provided a V tool for me to use.  Some of the virtues of acanthus carving is that it comes with the challenge of maintaining your concentration, and taking the necessary time to cut smooth continuous bevels on the leaves. It takes patience, and, then when you get into it, you can loose track of time which is a good thing. It offers a needed respite from what many have as occupational stress.  Since I have wanted to take a class in acanthus since 1997, this has been a real treat for me.

You might ask why did I opt to learn acanthus at MVAS?  Aren’t there some other carvers that you’d think of right away?  Well, MVAS is a lesser known jewel in southwestern Minnesota that offers classes in Scandinavian folk arts.  I recommend that you check out those opportunities.  For one thing, Hans Sandom and Bob Yorburg are among the few carvers to recently publish anything on acanthus wood carving.  Get their book Acanthus Carving and Design and you’ll see that not all acanthus is the same. It isn’t all the same even in Norway or Scandinavia.  Having the last name Paulson (it was spelled different ways over the generations), has inspired me to also celebrate some aspects of my Scandinavian heritage.  I have ancestors on my dad’s side that can be traced back to the New Sweden Colonial settlement in Delaware around the 1600’s.

Another great school of Scandinavian folk arts is at the Vesterheim National Norwegian-American Museum and Heritage Center in Decorah, IA.  I have been to Vesterheim and have become a member of the museum, but this was my first time to MVAS. I look forward to pursuing this style of carving with all it challenges including the art of painting those carvings in the Scandinavian tradition.  Like putting on the veins of the leaf, one has to be careful not to ruin the whole piece by rushing the completion. Careful and deliberate effort pays off in accenting and not detracting from the beauty of the piece.

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Plane Healing

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Let me introduce to you a Stanley 10 1/2 carriage maker’s rabbet plane that might have a new life in my shop. Some time ago I purchased this 10 1/2 along with a set of old woodworking tools. It was already broken and the owner had repaired it with a mending plate that was attached with small screws. Perhaps it fell from the bench and hit a concrete floor, I’ll never know. The point is that it sat for many years waiting for someone to restore it to usable condition. Recently, I took it off my plane till and decided to check it out. I enlisted a friend to repair it in a machine shop. I wimped out in trying to go the silver solder route on my own. To my surprise my friend found not one, but several fractures in the plane body that were caused from that earlier fall. You can see the fracture locations based on the repairs. Now that I have the plane repaired I hope to give you a follow up post on how the plane performs after lapping the sole and sides with multiple grits of sandpaper. Remarkably the frog was not damaged in that earlier fall and the plane is complete on parts. I am excited that this repaired carriage maker’s rabbet plane might help me move one more step toward an unplugged shop.

Foot-Powered Shop

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It is fair to say that besides me watching Roy Underhill use old tools on the Woodwright’s shop, what really got me hooked in the early 80’s was his passion for using foot-powered woodworking equipment. In fact, it led me to buy every one of his books as soon as they came out and then to start dreaming of building a treadle lathe. His lathe made of 2 x 4’s and 2 by 6’s got my imagination going about turning on a primitive lathe. Little did I know that I’d eventually build two foot-powered lathes based on his books, I’d pick up a treadle grinding wheel at a flea market in Springfield, Ohio, and that later I’d start to design and build a treadle scroll saw of my own design around 2007. My first foot-powered machine was the treadle lathe that Roy routinely demonstrated turning with on the show, except that on mine I treated the lathe to some chip carving on the sides and front edges of the 2 by 6’s.

Chip carved treadle lathe

On the portable spring pole lathe, featured in Roy’s books, I pretty much followed the Hulot design to the letter so I could use it for demonstrating at re-enactments. Some were held at the Herkimer Home a Revolutionary War Era site in Upstate New York, the Historic Fort Wayne Site (Fort Wayne, Indiana), and at the Fort Meigs War of 1812 Battlefield site in Perrysburg, Ohio. The amazing thing is that since transitioning to seminarian and then ordained ministry in 2004 and several moves later, I managed to retain these primitive machines simply because they have become part of me as a woodworker. As my wife Barb knows, the electric machines go first if I ever have to downsize the shop.

my spring pole lathe

But while I was living in Upstate New York, I also got the bug to build a foot-powered scroll saw. I looked at what others had done and again such things can motivate one to self expression. That proved to be true in my case. My treadle scroll saw design subsequently evolved over 2007-2015. Here is a picture of how it looked until this last year.

Victorian scroll saw 2007

In 2015, I made a bunch of nice refinements on the scroll saw, especially last summer. If you want to see how over the top I got with my refinements on the treadle scroll saw, you can see it in the Shop Talk section in the March/April 2016 issue of Woodworker’s Journal. http://www.rockler.com/woodworkers-journal-march-april-2016
I am delighted that Joanna Werch Takes of the magazine took an interest in my treadle scroll saw. If you know me pretty well you can imagine that I rolled some Victorian scroll saw designs and even some chip carving into the final product. I am also grateful to my machinist friend Bill who came to my rescue and helped me by redesigning the sprocket hub that now has greatly improved the ability to secure the BMX ratcheting freewheel gear. My awesome scroll saw has been dubbed “A Victorian Scroll Saw.” Check it out! Here is a peak at it.

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Who Made It?

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Any ideas who made this woodworking vise?  I purchased it at a local antique mall.  It is heavy duty in construction, has rapid release, and appears to be in decent condition.  The only thing missing is the steel dog.  I’d like to use it as a vise on the next bench project.  The only surprise was the 1/4 inch offset in the cast iron at the top corner between the front and rear vise jaw.  It doesn’t matter since the jaws will have wooden vise chops.  There is no identification on the vise.

Too Many Dog Holes?

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One thing you learn as a woodworker is that what is good for somebody else might not be good for you. Alternately, what works for you might not work for another person. Take my chairmaker’s bench that I built roughly a year ago already, I love the bench. I modified a design from woodworker Drew Langsner and incorporated some other features. After seeing the storage compartment on a Chris Schwarz bench, I added one to mine. I like having a storage compartment underneath. I would have liked to build the whole bench longer with an end vise/tail vise, but I had space constraints. The trick with the hinged storage area underneath is you don’t want to store things on top of it. Dah. In particular, I love having all the dog holes through the bench top. I’ve heard other woodworker’s complain at different times that they don’t like benches with that many dog holes. That’s when you hear that a bench top looks like Swiss cheese, but my response so don’t have them. Having that many dog holes works for me and I like them. My clamping needs and preferences are clearly different than yours if you only need less than 10 dog holes. Even my Ulmia carver’s bench which has two rows of square dog holes has 30. It might not look as esthetic for others to have 30 plus holes, but as a practical woodworker I appreciate the capability. Whether it is making a spoon, fabricating chair parts or holding a woodcarving, I want those clamping options. When I invested in the Veritas twin screw vise, it made all the holes that much more important. Don’t get me wrong, some day I’ll build a thick Roubo bench with dovetailed legs, wooden threaded leg vise, and a nice tail vise, with significantly less dog holes. I don’t plan to do it for awhile though. Other than having a fastener or dust fall through one of the many dog holes on my current chairmaker’s bench, the benefits for me far outweigh the disadvantages.

What is an exciting new addition to my chairmaker bench is that I now have a WoodRiver Patternmaker’s or Gunstock Carving Vise. If you don’t have one, it is sweet for holding anything higher on the bench. I just used it to trim some tenons on some dining table aprons. All it takes to mount the vise is to find a dog hole to attach it anywhere on the bench. Options for changing orientations of stock are there. How cool is that? Like some others, I confess I drooled a little over the elegant Benchcrafted Carver’s vise, but I simply couldn’t afford the cost. Nor could I find the time to build a similar carver’s vise from scratch right now. If you’ve looked you know that there are some nice designs for building a vise for above the bench top clamping. Other than the lower part being cheaped out on the Woodcraft carving vise, by using stamped steel instead of cast iron, I am quite happy with the new vise. Replacing the light weight base with something heavier is one of the upgrades I’ll eventually make.

Woodcarver's Vise

Woodcarver’s Vise

Woodcarver's Vise

Woodcarver’s Vise

Since woodworking is such a broad application, I am glad for being blessed to do it. Whatever the interest level a person has in woodworking, there are numerous publications out there that can feed you with inspiration, new knowledge, and offer project ideas. To that end I have enjoyed Popular Woodworking Magazine for years and it was Fine Woodworking Magazine before that, but let’s face it our tastes change and publications change. I’m a currently a subscriber to Popular Woodworking, but I find other woodworking magazines also helpful at different times. The fact is that we have many opportunities to share woodworking information through magazines, blogs and websites, to take a class, to buy a DVD, or to watch a video clip on YouTube. What’s growth for me though has been to focus on my experiences of hand tool work in the moment. I find that my just doing the activity of woodworking gives peace, provided the performance goals are kept reasonable. If you read contemporary spiritual leader Thich Nhat Hanh sometime, you’ll get the idea that savoring our experiences is key to finding joy and contentment. Perfectionism can hold some of us back from the enjoyment part and if that is our experience sometimes, then think about using mindfulness as a way to keep the fun in woodworking. I won’t define it here, but suffice it to say that it involves greater appreciation for what you are doing as you do it. If your shop time gets squeezed in with all the other priorities, or you succumb to feeling some pressure to accomplish a lot on a free day, then enjoying the experience in the present tense may help you as well.

My Woodcarving Rantings

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Chip Carving Knives

Chip Carving Knives

It is new for me to contribute features for magazines, but I’ve already learned that it does fire up a person to do new and greater things in woodworking. Truth is that I have more challenging projects in mind now than ever before. First, I am very thankful to the great folks at Fox Chapel Publishing for giving me the opportunity to write about using carving to personalize a tool chest.

You can find a reference to it here http://woodcarvingillustrated.com/blog/woodcarving-illustrated-winter-spring-2016/

Their publication is great for inspiring people of all skill levels to try and excel at woodcarving. It was fun to share about my woodworking/woodcarving experiences in this recent issue. Second, I want to say that I think chip carving really gets a bad rap in woodworking circles and it really puzzles me. It seems there is some thinking out there in the woodworking world that if you don’t use a chisel and mallet to carve something then you haven’t made it into the realm of fine furniture. Frankly, that is crap and this comes from a preacher/woodworker who chooses his words carefully. I for one use carving chisels a lot and while I am not into chip carving plates per se, I’ll argue that there is great skill in using one tool, a sharp knife, (see photo above) to make V shaped cuts in wood. True you are limited to softer hardwoods or pine. But heh when it comes to reproducing country furniture that many of us still love, chip carving has greatly enhanced many pieces over time. Look at how cool it is to add chip carving to a handmade wooden spoon. It definitely personalizes it. Bottomline, think and say what you want, but if it suits me to pick up my chip carving knife and to add some motifs that compliment the piece, then I am going to do it.

Saying all that, in 2016 I am going to learn more and more about acanthus carving, letter carving, and flat carving which all use chisels. It is the challenge of learning something new more than anything else. When it comes to acanthus, I am partial to the Norwegian/Scandinavian approach to it. It is me and I have some Swedish blood in me. I am and have been in love with woodcarving for a long time. I think a real woodcarver has multiple approaches at his or her disposal and that chip carving has its place among them.

Thanks for reading my rantings,
Jim

More Carving Talk

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I begin 2016 by sharing that I have a three page article entitled “Tips for Personalizing a Toolbox” in the Winter/Spring 2016 issue of Woodcarving Illustrated Magazine. As you can see I even made it to the cover.   The article discusses my carved chair maker’s tool chest that I built just before I took my first Windsor chair class in 2007.   It was a class to build the Sack Back chair. Thank you to the editors of Fox Chapel Publishing for giving me this opportunity to be in print. 

Mike Dunbar in Hampton, New Hampshire, has been my teacher for Windsor chair making.   Mike recently announced that he and wife Sue were retiring from teaching Windsor chair making and that the buildings at the Windsor Institute were sold.  I wish them good health and the very best in this transition.  Now whenever I look at the top of that same carved tool chest I will remember all the people, like Mike, who have influenced my woodworking.  

You see I was blessed, like many others, to catch the bug in the mid 80’s to build Windsor chairs simply because we had champions like Mike. They kept up the appreciation for reproducing these fine and classic specimens of American furniture.  But as things change, I look forward to what inspirations in 2016 that I’ll have in exploring my passion for wood carving. My chair work will continue and one reason is that wood carving remains very important in making beautiful reproductions of Windsor chairs. Likewise with wood carving, I am grateful for having been taught and influenced by many outstanding wood carvers who enhanced my carving skills.  Stay tuned as there is a good chance that you’ll hear more carving talk from me.  

Snipes bill postponed

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This sweet little jem just arrived and it will make the more eliptical bead I need to finish stretchers on a couple 18th century tavern table projects.   I can happily wait on making a pair of snipes bill planes now.  I do like the snipes bill planes made by Hackney Tools (http://hackneytools.com/2015/02/making-your-own-moulding-planes/. My jem here is a Sandusky Tool Company 3/8 inch bead molding plane in pretty good condition.  You never know what these babies will look like when you purchase them online, but I’m thrilled with it.

beading plane

Homemade Snipe Bill Plane?

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Do you ever get sticker shock about a possible tool acquisition and say heh I can do that on my own? I can just make one myself.  I’m sure you do.  That is the way I feel right now about possibly making a snipe bill plane.  Then it comes down to whether it would really cost me more in terms of time and money in the end to make something myself. But if you know me, then you know I can build tools when I get the bug. I’ve built planes, saws, and foot powered machinery already myself, but a snipe bill plane looks more demanding in some ways. Yet a challenge can be a good thing for some of us. Suddenly you crave information, right?

Well I have several books on plane making and Todd Herrli’s DVD. A Larry Williams DVD (Lie-Nielsen) may soon be on my wish list too. By the way I have numerous molding planes including hollows and rounds so my interest in a snipe bill is not rash.

As one who comes from more humble means though, I am moving toward making a snipe bill molding plane. Why? Because my love of wooden molding planes goes back to the late 70s and early 80’s. I use them on occasion and love the details they offer.  I especially lean toward making tools that are hard to find, otherwise expensive to buy, and yet useful on projects I would need them for.  Bottom line, I am not content to pass up a chance to preserve a classic detail on a piece of furniture I know will outlast me.

I bet that sounds familiar to some of you. So if you’ve built one please let me know. I’d love to hear about your experiences. I like the idea of having flexibility on making bead details on furniture.

Thanks,
Jim

Shaping Up

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Cherry has always been either my favorite wood or very close to it for much of my woodworking projects. Here I am showing a cherry spoon that I recently carved and to which I added some chip carving on the handle.  Personally, I find that the process of shaping and carving spoons to be conducive to meditation and that it invites reflection and prayer.  Our lives are generally quite busy and this activity has its own pace.  Since you really can’t add the wood back after it’s been carved away, it tends to slow you down to concentrate on what you are doing.  In the doing you also produce something useful that can be used in the kitchen.  

The cherry was cut by one of my parishioners. Since I started carving spoons I’ve been having fun with carving designs that are more free form. Spoons lend themselves to adding free form carving designs. What is appealing to me is that it doesn’t have all the fuss with exacting dimensions on the layout, yet it has the charm of folk carvings from the past. 

What is also happening for me is that I’m getting closer to that idealized “S” shaped spoon profile that is indicative of the Swedish spoon carving style. Even though this stock was dry by the time I carved it, it still came out great in my mind. My goal is carve several about the same size and then build and carve a spoon rack. I hope to do that in the next few months. Stay tuned.

Stem work

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 I think that I’ll stick with carving spoons at least occasionally, but I am preoccupied now with getting the shape of the stem just right. When I look at a Peter Follansbee spoon, I’m drawn to the graceful curves he often leaves on the stem right before the bowl.  The simplicity and appeal of his wooden spoons is definitely there, but the stem is where I am learning to slow down.  After several spoons ending up with straight stems, I’ve seen the light on esthetic appeal of spoon stems with gradual curves. Leaving enough wood on the stem to work in a sweeping curve is my goal now.

Embarking on spoon carving is very appealing for many reasons, but I think the major aspect that I like is that it is eco friendly. If you make spoons you don’t have to discard or burn trimmed tree branches it is prime material for gobs of spoons.  Plus you don’t need to drop a whole tree for stock.  Pretty cool right there, but also sweet in terms of investment cost.  If you pay attention to safety and once you acquire the basic tools,  the  processing time is short.  Great for those woodworkers with limited shop time.  As full time clergy that is one of my challenges to squeeze in my shop time and still see something get done. 

Here is my most recent spoon and this time I made some strides on leaving enough wood on the stem and bowl to incorporate the sweeping gentle curves that are so distinctive on Swedish spoon carvings.  I’ll be paying more attention to incorporating the gentle curve on the profile off the spoons as well. My spoons still seem too bulky, but I’ll be working on aspect as well. 

Card Scrapers Cleanup Spoons

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 I’m getting hooked on carving spoons now and I found card scrapers to be very helpful as a final step.  As a Windsor chairmaker I appreciate how helpful scrapers can be in the final smoothing of oak spindles.  Now as I’ve focused more on the general profile of the Swedish style spoons, I’ve been delighted to successfully employ both straight and curved card scrapers on the final smoothing step on spoons.  Once I had 99% of the spoon carved and the apple wood had dried, scraping proved to work great to achieve the finish I wanted.

I obviously didn’t include chip carving on these two spoons, but that will come later in subsequent spoons. I realize that wooden spoons can come in different shapes, but wow are these puppies strong by design. This dried apple wood gets very smooth in the final knife work, and you may find scrapers to be helpful also. The spoons were oiled with flax oil purchased at Kroger in the refrigerated section.

Thanks for looking!

First Spoons

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Hi everyone,

I am blessed that some nice folks gave me some cherry and apple wood recently so I could carve spoons.  Here are some initial spoons that I carved, but I confess to be humbled that it will take a while to get the right look.

Eventually, I’ll take a class, but for now I welcome any comments. I think the book Swedish Carving Techniques is quite helpful, yet for me you can only glean so much from those resources. Nothing helps more than having an example right in front of me.  

    
   

Awesome New Bench Dog Clamps

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Hi Folks!  Check out these new Armor Tool clamps (auto-adjust in-line dog clamps) that you can get at Woodcraft.  I saw them in action at the Toledo store when one of the staff, Tom, used them in a demonstration for InLace  (I also like InLace, although I realize this might be complete heresy to my fine woodworking colleagues who swear by inlaying ebony or use black dyed wood strips in period pieces.)  I tried a pair of those bench dog clamps just the other day to hold a new carving project and let me tell you that they were truly superb in gripping and holding. I used them on my new bench and they are worth every penny in their utility.  What I especially liked was the ease of adjustment for one thing.  You see I was tempted to buy one or two Veritas bench dog clamps from Lee Valley Tools.  I am a Veritas tool enthusiast and appreciate their quality and excellent design. But I like these Armor Tool clamps and can see myself using them quite often and I don’t regret putting in all the many dog holes in my new bench. I honestly bought these new  

bench dog clamps for spoon making, but heh they’ll work in so many applications and that is cool!

Finding A Couple Handsaws

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Sorry that it has been awhile since my last blog.

I had some fun when I stumbled onto a couple of handsaws while traveling.   Barb and I had the opportunity to do a little antiquing in Michigan this week.  I was attending a continuing education class for my work as a pastor and in our free time we visited some antique shops in the Traverse City area.  When I spotted the Disston D12 with an intact handle and decent blade, I got excited.  You see the distinctive handle on the D12 and the professional quality of these tools continues to have great appeal to many woodworkers, including me.  This one was made after World War II based on some quick research.  One of the characteristics of that saw production is that it sports nickel plated brass saw nuts.  At another shop I found a Disston D8 saw with an intact handle and plenty of steel left in the blade.  As you can see, both saws have five saw nuts holding the handle onto the saw blade or plate and the handles are also made of apple wood.  A great resource on the identification of Disston handsaws can be found here:  http://www.disstonianinstitute.com/quickglance.html

The good part for me is that these saws were affordable and are without condition issues so they can be restored to workable condition.  Here are some pictures of the saws.  One of the saws, the D12, has an etch that is still visible and some wheat carving on the handle.  I’ll make another post when I’ve had the chance to clean the blades, refinish the handles, and sharpen the teeth.  Thanks for looking!

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A Bench with Teeth and Storage

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I finally completed my chairmaker’s bench so I can get back to building Windsor chairs. One of the tasks was to cut a through mortise into the bench top for a planing stop. The planing stop measures 3 by 3 by 6 inches and is red oak. It includes an embedded forged iron stop with a hook and a sharply filed toothed edge. The toothed edge is for gripping and holding furniture parts on the bench top. I’m ashamed to say that over the years I haven’t bothered to use a wooden bench stop, but I have utilized steel bench dogs to provide a similar function. To attach the toothed stop to the oak block, I had to cut a mortise approximately 7/16 inch square by 4 inch deep. I excavated it with a couple brad point bits and a few chisels. I then worked to fit the toothed and oak planing stop into the through mortise in the bench. I used chisels and rasps to clean it up. It proved to be challenging to keep the mortise sides square and 90 degrees vertical in the laminated top. To strengthen the mortise walls in the laminated top, I coated those surfaces and the many dog holes with epoxy from the West System. Based on the recommendation of the folks at West System I opted for the 105 epoxy and the 206 hardener products. It has the consistency of syrup and it slowly hardens the plywood laminations. It worked great! Also, just because it is quite like me to slip and get a cut with edge tools, I followed my wife’s suggestion to install some polyethylene tubing on the toothed edge of the planing stop when the stop is not in use. Yeah Barb!image

Rather than damage tools that might potentially roll off the bench top, I built a tool tray across the long edge out of 3/4 inch stock. It measures 8 inches wide by 48 inches long. I used oak and assembled it with through dovetails. I usually cut the tails first and then measure for the location of the pins. I marked the pins with some very sharp French marking knives I obtained from Garrett Wade some time ago. They offered them with left and right hand blades and I found that I can accurate scribe the pin locations with them and it saves me time in the fitting. The ebony handles are also easy for me to keep track of on the bench. After scribing the pins, I used a couple back saws to cut the tails and pins and a coping saw was used to remove waste between the pins. This time I found that my chopping skills with a sharp chisel made it possible to easily pare to the scribe line on the pin end. I chop from both sides so there is no tearout and it leaves a hollowed area in the middle which aides in making a tight dovetail joint.

At the suggestion of Chris Hedges on Google plus, I also gave dovetail peening a try. Although my gaps were insignificant except for one spot that required doctoring with veneer, the peening turned out to be a great enhancement for my dovetailing skills. The bottom is made of 3/4 inch poplar and fits into a 1/4 inch rabbet. I added a center divider that was installed with several flat head slotted screws. It gives me the option of relocating the divider if it makes sense later. One added benefit of installing the hardwood tool tray was that it helped maintain flatness on the bench top. I used four 5/16 inch dia lag screws to attach the tray.

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As Chris Schwarz found useful on one of his many Roubo bench builds, the area inside the stretchers offers another place for tool storage. Since I continue to use a similar area on my carving bench as shelf storage, I know all too well how things vibrate on that shelf area or get covered with dust and wood shavings. So instead of just using that space as a shelf, I enclosed it with a frame and panel lid. I made the lid components out of red oak and assembled it with draw bored mortise and tenon joints. I installed it with strap hinges from Van Dykes (source provided by Chris Schwarz). To compliment the black strap hinges and lid support hardware, I added a black cast iron shutter pull ring obtained from the House of Antique Hardware that made opening the lid more convenient.

After adding the pull all that’s left is trimming some bench components, sanding/filing away some epoxy in the dog holes, cleaning up some wood filler on the legs, and applying BLO. The good thing is that this “holey” bench, with 27 dog holes, is just the right size for my workshop space.

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Carving Decisions

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Can’t decide yet if this oak frame and panel lid warrants some carving.  It will cover the tool storage area in my chairmaker’s bench.   I fashioned it in a similar way to the lid and compartment Chris Schwarz made for his Roubo bench. My thoughts are to do something minimal like add the date or a word or two in Roman style lettering in the center of the panel.   Cutting the letters/numbers with chisels in the oak is my inclination.  I haven’t tried that before with chisels, but this seems to be my motivation now.  There is something classy about letter carving on flat surfaces.  I’d go minimal because this lid may still get things stored on it.  It really shouldn’t though as then the tools in that compartment are inaccessible. The panel is flush so it doesn’t have the raised edge, but for a tool storage lid it works here.  It was a joy to cut these mortise and tenon joints in oak.  The parts are assembled dry fit so I can work with carving the panel by itself.  I really like the grain.  A few spots are visible that will get cleaned with alcohol or mineral spirits.   Any thoughts?



Windsor Chair Experts

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My first exposure to a Windsor chairmaker was a seminar by Thomas Moser that I attended at the Woodworker’s Store (Rockler) in Denver around 1985. Tom came and spoke for an evening and I was truly wowed by his presence. Here was a professional and accomplished fine woodworker and I got to see him in person. I had already spent a few years pouring over his trailblazing book How to Build Shaker Furniture by Sterling Publishing in 1980, and then I got his autograph. He saw all the worn pages and pencil marks, and then he added his signature. You see I had used his book to build Shaker ladder back chairs for my family and it was enough to give me great results. The picture of Tom’s unique continuous arm Windsor chair that he demonstrated never left my mind from that seminar even though I didn’t venture to build one later his way. Tom’s unique design involved a laminated arm as opposed to using green wood split from a log, steam and a bending form. Afterwards, I can’t tell you how many times I looked at the picture of Tom’s continous arm chair in his book titled Windsor Chairmaking, published by Sterling in 1982. Yes he autographed that book too!

My point is that while I found it quite manageable to build Shaker chairs from a book and I still do, building Windsor chairs on your own is another animal. If you Google Windsor chairmakers you’ll find many many websites and you’ll find many Windsor chairmakers. What means more though is what you hope to get out of it. Are you taken in by the Windsor chair as an art form? Or are you taken in by a style of chair that has continued appeal since the 1700’s when the Sack Back Chair first became popular. Do you hope to make a business out of selling chairs? I say all that because it matters where you come from as a possible student of Windsor chairmaking. My first Windsor chair was purchased at a garage sale in the late 70’s and I confess I didn’t realize then that it was a later variation of a Windsor chair. My first look at a more recognizable Windsor chair form happened in 1986 after I was laid off from my petroleum geologist job and was invited to estimate the cost of repairing not one but a whole set of Windsor chairs. At that time even though I needed the money, I declined the offer. You see I didn’t want to touch something that was so beautiful and a valuable antique without having the full appreciation for the construction and value of a Windsor chair. That is where I come from in valuing antique Windsor chairs.

So what does this post have to do with Windsor Chair Experts? With so many experts available it matters how you see Windsor chairs and whether you appreciate them as full of history, solid design and construction, and as an example of fine craftsmanship. When there are so many teaching opportunities and books available, having answers to such questions will help you decide which expert you want to study under. You can find an expert who has made chairs for years or ones that have made them for several decades. You can find an instructor who can teach you how to turn as part of the class if you need that training. I learned to turn spindles in my High School woodworking shop class back in the early 70’s, but you can acquire such ability through other channels. You can find an expert that builds chairs along with a host of other things or you can find one that builds only Windsor chairs. You can find one who builds and designs chairs with an artistic flair and picks and chooses what to keep from tradition. You can find one that builds chairs in the manner and design that leads you to have a faithful reproduction of a Windsor chair. I have chosen the latter and prefer one who knows what a chair leg from a Windsor looks like from the originals. If you are familiar with the voluminous and well researched publications of Nancy Goyne Evans on the history and evolution of Windsor chairs, then you’ll appreciate my comments.

When I think of Windsor chairs I think of Mike Dunbar. Since 2007, I have been hooked on building Windsor chairs. My training was obtained through Mike Dunbar at the Windsor Institute. I’ve completed six chairmaking classes with Mike and his staff, and I can tell you he is an undisputed expert in Windsor chairmaking. In fact, I’m sure I’ll be back there to tackle another Windsor chair. One of the virtues of studying chairmaking under one master is that you develop a consistent pattern for how you tackle various tasks in chairmaking. That said, I’ve also been blessed by the contributions of other Windsor chairmakers, especially the ones who are blessed to work on chairs for clients every day in their shops. I’m excited now to pour over Peter Galbert’s Chairmaker’s Notes, published by Lost Art Press, so I can glean some nuggets about his approach to building Windsor chairs. Since my primary calling is serving as a Lutheran pastor, my shop time for building Windsor chairs is limited to available free time . If you like the New Hampshire area and have a week available, I encourage you to call the Windsor Institute, talk to Mike about taking the Sack Back class, and then check out Lamie’s for lodging in Hampton. Studying with Mike for 5 days is kinda like being an apprentice in miniature rather than the old days of doing it over several years. Bottomline, if you can it is worth every penny to find a Windsor chairmaker and to study under them. My two cents.

Paring for the Planing Stop

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Months ago I received my iron planing stop that I ordered from Blacksmith Peter Ross. It is very well made and worth the wait. I had planned to install the iron planing stop in a new workbench. Since I opted to build a smaller bench just for fabricating Windsor chair seats based on a design by Drew Langsner http://www.countryworkshops.org/newsletter16/bench.html, I wanted to incorporate the iron planing stop into the new bench. There are a whole lot of ways to make or install a planing stop. I’ve used boards temporarily clamped to the bench top and bench dogs. I’ve seen boards attached to ends of benches or even down the center line of a bench as in a split top Roubo or Nicholson. However, what was appealing about the planing stop made by Peter Ross is that it has teeth meant to be embedded into the end of the stock. Chris Schwarz observed that these toothed iron planing stops were depicted on artwork showing Roubo benches. He also indicated that the teeth on the stop might need some sharpening to grip the stock. See his posts at http://www.popularwoodworking.com/workbenches/schwarz-workbenches/getting-bit-toothed-planing-stop and at http://blog.lostartpress.com/2013/08/13/french-oak-workbench-the-planing-stop/.

Yesterday I got out a sharp chisel and a mallet, and used an extra long 3/8 inch brad point bit in my cordless drill. Before I started drilling holes for the through mortise, I used my chisel to outline the four sides. This led me to excavate down about 3/16 of an inch so that the birch veneer was less damaged on the top. It also helped me to spot the holes in the 3 by 3 inch area. After drilling holes side by side around the edge of the 3 by 3 inch area, I began chopping with a chisel between the holes. Eventually, I removed the block of material from the mortise so I could begin paring the surface of the four sides. The paring is important so that planing stop can be moved up and down with reasonable effort. This means the walls need to be vertical and square to accommodate the fit of block for the stop. The next step will be to glue up the hardwood block, trim it to size and then start fitting it to the through mortise. After that step I’ll fit the iron planing stop to the wooden block. My plan is to take my time by drilling a hole and then paring it to fit the toothed planing stop. Hopefully, I can avoid a force fit that might crack the planing stop block.

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What paring chisel is in your tool chest? Paring chisels aren’t designed for use with a mallet. Instead paring chisels are very sharp and have a lower cutting angle (20 degrees) and are therefore pushed to remove thin shavings. I believe that my paring chisel of choice is a lesser known one. About 16 years ago I bought a couple bent shank (or crank neck) paring chisels from Diefenbacher tools http://www.diefenbacher.com/paring.htm. I bought them to help complete the slant top writing desk I was building for my wife. Back then I obtained the 1/4 and 1/2 inch size chisels. The chisels sold by Diefenbacher are made by Buck Brothers and are no nonsense in appearance and function. The handles are fairly big, even homely, and yet they work well in the hands. I have been thoroughly happy with their performance. They hold an edge period.

In fact, I recently received another two bent shank chisels from Diefenbacher tools as a gift so that I can use them for paring on larger mortises. I can tell you that I’ve used those same bent shank chisels for paring the mortise for my new planing stop.

As many woodworkers point out in blogs it isn’t how many tools you have, but having the best tools for the job at hand that matters most. As a carver I’ll go one further and say it isn’t how many tools you have, but which ones do you keep sharp that matters. Really though, I think most of us would agree that we have been blessed to have more access to wonderful tools for fine woodworking when compared to 50 years ago. There are many reasons for that too. Most importantly, having a very sharp paring chisel is a must for cleaning out a mortise.

My point is that one of these modestly priced bent shank chisels would make a good addition to your tool chest. The shank of the blade is 6 3/4 inches long which gives you a whole bunch of flexibility for paring tasks. Diefenbacher sells this line of chisels for $25.60 for the 3/8 inch up to $37.30 for the 1 1/2 inch one. They also sell straight shank paring chisels. It has been a blessing for me to own these.

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Installing Iron Planing Stop

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An iron planing stop, obtained from Peter Ross, is also going to be installed on my chairmaker’s bench. Ever since I read about these on Chris Schwarz’s blog a couple years back, I’ve had the bug to try one. Peter is a busy guy and the planing stop is worth waiting for as his workmanship is outstanding. Well this little bench as heavy as it is now will be a good place to try it out. It will have to do until I finally build a big Roubo bench in several years. I hope to cut the hole this weekend using a auger, saber saw and chisel or two as Chris Schwarz had described earlier. Finding a good piece of 3 inch by 3 inch oak will probably be accomplished by gluing up a couple pieces to thickness until I have larger stock available.

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Chairmaker’s Bench Project

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Tongue and grooved pine boards and trim were added for a tool storage area.

Tongue and grooved pine boards and trim were added for a tool storage area.

I don’t know about you, but sometimes distractions have the benefit of energizing me to take on the bigger tasks. I have two tables and a dozen Windsor chairs to make and I was looking for an improved method of holding/securing the thick pine chair seats while I fashion them with hand tools. I was excited when I found a design for a chairmaker’s bench on Drew Langsner’s website for Country Workshops (www.countryworkshops.com).

So here I go with building a modest 2 by 4 foot bench that will comfortably fit in my compact workshop. It features a laminated plywood top that exceeds the thickness of an earlier laminated bench top that involved three layers of 3/4 inch thick plywood. This one involved five layers of plywood that I had available from previous projects. After I laminated the plywood top I squared up the ends, trued the edges, filled voids in the laminations, and then treated the edges with two coats of epoxy. I made some modifications on the Country Workshop’s design by beefing up the size and weight of the legs and stretchers. My goal included a desire to make the bench plenty heavy so it didn’t move when I used a drawknife or spokeshave on the seats or other chair parts. One modification was to include a couple pieces of 1 3/4 inch thick red oak for the rear and front vise jaws. I notched the two front legs, which are roughly 5 5/8- 5 3/4 inch square, for the rear vise jaw.

The front vise jaw is a whopping 30 inches long with 24 inches between the steel screws. This bench features the Veritas Twin Screw Vise which is chain driven so that turning the right screw automatically adjusts the left one. I really like this vise. In the future I may opt to increase the length of the front vise jaw to 36 inches or more in length. With the steel support pins to clear the screws which are greased, the 30 inch vise jaw length limits me on clamping stock on the ends of the jaw like you would with a leg vise. Live and learn I guess. If I make another front vise jaw I think I’ll increase the thickness to 2 1/4 inches so it has more wood especially at the bottom edge. This would seem more optimal when you look at the amount of wood material on the inside bottom edge of the front vise jaw. Based on Veritas recommendations, the inside surface of the front vise jaw should be beveled about 2 degrees which means cutting away a wedge that is 7/32 inch at the base. You notice this more when you drill five 3/4 inch dog holes in the center of the vise jaw and counter bore them to 1 inch diameter for the bottom 2 inches. I’ll try it out the way it is for now. I need to make some chairs.

The legs started with douglas fir 4 by 4s that I laminated up with 2 by 6 and 2 x 4 stock. Needless to say it took a bunch of clamps and numerous glue ups. For the stretchers I used doubled up 2 by 6s and for the top stretchers I used 4 by 4s. With the design change on the front of the bench, it meant that the rear vise jaw became an apron on the bench. While I don’t like aprons on a bench per se, this modification gave me more control on assembling the bench together. Lag screws were used to hold the rear vise jaw and top together. Another piece of 1 3/4 inch thick red oak was used to help flatten the plywood top and to give me 3 1/2 inches of material thickness on the front edge of the bench in case I wanted to use F style clamps. That helped me avoid some otherwise unwanted limitations with an apron on a bench. In this case the rear vise jaw/apron is about 7 3/8 inches wide.

On this project I learned a lot more about using Forstner bits, upcut spiral router bits and brad point bits in a 3 inch thick laminated bench top. For one thing I didn’t realize that the Forstner bits being sold in many stores aren’t all made with HSS, which causes drilling speed to be more important when the bits are made out of carbon steel. Needless to say I lost temper in a couple of them and will now swear by HSS and not complain about the added cost. Nor did I have enough appreciation for the fact that the routing speed would matter as much as it did with HSS spiral upcut bits. It turned out that my standard go to Porter Cable router with 23,000 rpm was too fast for the 3/4 inch diameter Onsrud HSS bit I bought from Woodcraft. I used the spiral upcut bit on my bench top to make bench dog holes. Glen Huey of Popular Woodworking did a feature on using the upcut spiral bit to make dog holes on his benchtop using the same Porter Cable router. One difference was that my bench top is laminated plywood and Glen’s bench was hardwood. If you look at the 5 inch by 5 inch grid of dog holes you’ll see why it mattered to me. After about 5 holes, I discovered that the router bit burnt the wood and needed sharpening.

I am not done with the project. The many holes in the bench top will get an epoxy treatment so that the end grain of the plywood is hardened and durable for use with holdfasts and bench dogs. A West System epoxy with slower hardening time will be used on the dog holes. If I need more holes I’ll definitely use a lower rpm speed on the router bit and will see if my bit sharpening efforts succeeded or if I’ll need to task it to a professional machinist.

A couple things I am planning to do include building a tool tray for along the back side of the bench. I realized I needed this after my 3/4 inch brad point bit went rolling across the bench only to hit the floor. Man was I relieved to see that the spurs and center point were unscathed from the concrete floor. I use rubber mats but they aren’t everywhere. I also am using the area underneath the bench in the stretcher area for a tool storage compartment. I got the idea from Chris Schwarz (blog.lostartpress.com/2010/05/28/another-roubo-bench-fin/) and it entailed adding 1 inch square strips with glue and cut nails along the inside bottom edges of the stretchers. Roy Underhill also featured this idea on one of his episodes of building a Roubo bench on the Woodwright’s shop back in 2007 (French Bench). I then added tongue and grooved boards for a bottom that were attached with 1 1/2 inch long slotted screws. To accommodate some possible movement, I made the holes oblong for the screws and gapped the tongue and groove joints. What is left to do on the storage compartment is to build a lid with a raised panel and attach it with a couple reproduction T shaped hinges. If you like the hinges on Chris Schwarz’s bench storage lid they can be obtained from http://www.vandykes.com. I have an old oak panel that I will salvage for the raised panel and the frame will involve some red oak rails and stiles. I’ll post a follow up article when the bench is completed.

Thanks for looking. Blessings on your furniture making efforts too!

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Drill Press for a Chair maker

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Funny how the addition of a piece of machinery or a new hand tool can get you all fired up to build furniture. For years I’ve looked for any kind of radial drill press to add to my woodworking shop. I’ve had a bench top Delta drill press for years that I bought used back in the mid 80’s, but it has limited capability for drilling holes due to the shallow distance of the spindle to the column/post. Recently, I had the opportunity to acquire a used radial drill press and after some extensive degreasing and replacing the start up capacitor, it is now ready for action. It is the Delta 11-090 model which has a bench top design. Admittedly, it took awhile to clean it up. The previous owner had left the original cosmoline on it(a vaseline type preservative used to prevent rust accumulation) because he stored it in an unheated garage. The cosmoline was really caked on the metal parts and it took some elbow grease and kerosene to remove it. To my surprise the paint and exposed steel surfaces looked like new. Once the cosmoline was gone it was also no problem to adjust the depth and angle of the spindle. To make it suitable for chair making I made a new plywood table that is 16 inches wide by 30 inches long and 3/4 inch thick. The whole purpose for this investment was to perform compound angle drilling in Shaker ladder back and Windsor chair construction.

While I am quite capable in drilling holes using sliding T bevels and sight lines based on my Windsor chair training, I believe that this machine will help me to be more productive as a chair maker. I say that because I have limited shop time and I want to develop some greater efficiency in boring seat, leg and stretcher holes. I will also use it to ream the tapered seat holes for joining the Windsor chair legs with locking tenons. It will also help me to drill all the angled holes required with Shaker ladder back chairs that feature many leg and rung joints that have to be precisely drilled. This will not lessen the accuracy and fit of any legs, spindles or stretchers. Another benefit will be that any jigs I make now for Shaker chairs can be simplified because the drill press has capability to drill angled holes.

A couple critiques of the 11-090 that is worth noting is that the design is lacking for making adjustments for drilling various distances away from the vertical post (throat). Newer radial drill presses feature smoother adjustments through gears for the position of the spindle and the angle of drilling. However, this will not be a problem for me as a chair maker because I won’t be changing the distance between the spindle to vertical post very often. What I will be changing frequently is the drilling angle and that is easy to do with this model.

Likewise the height of the table requires manual adjustment, but that also won’t be a problem for me. Newer models usually feature a cranked adjustment for the height of the table.

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Homemade Frame Saw

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Colonial_at_school_006oppenheimI am a parish pastor whose occasional escape from ministry is working with hand tools.  I also enjoy teaching elementary school kids about 18th century woodworking and giving them a chance to see old tools in action.  In this first photo I was portraying a colonial artisan who told students about a frame saw (veneer saw) that was used to cut thin pieces of wood. Being a fan of Adam Cherubini, I had to make a big frame saw when he did a feature on them in Popular Woodworking several years ago. Being a scrounge and frugal, I also hesitate to buy things that I think I can make myself. Making tools is fun and even more so when I can experience the joy of using them. So here is my story, a parishioner helped me to get an antique frame saw while I lived in Upstate New York.  It was constructed with through mortise and tenon joints which were locked with wooden pegs.Jim's workshop stuff 002 I also studied Adam’s article in Popular Woodworking and the famous Roubo engraving showing frame saws. The result is that I built not one but two frame saws. The first frame saw employed blade holders made from cheap spade bits that I annealed and drilled to accept bolts for attaching the blades. Funny how those spade bits can be re-purposed for all sorts of tool applications. Jim's workshop stuff 012Jim's frame saw On the second saw, which was larger, I designed it to have the classic Roubo design which sported saw buckles as blade holders.  I used flat steel from a home improvement store to make homemade buckles to hold the blade. The buckles were made by forging them into a rough oval shape via my hand cranked track forge and then welding them together at overlap points using a Harbor Freight stick welder.Jim's workshop stuff 007 Once the buckles were welded, I cut slots to accept the blade. Securing the blade to the buckles was accomplished here by using steel cross pins that pierced each end of the saw blade/web and those pins were pulled against the buckle ends through the use of wedges at the intersection of the buckle and the arm.   On my first saw, I copied the original which sported a threaded blade holder which tightened against both of the saw arms. After I annealed the spade bits and shortened them, I cut threads on them to accept a washer and nut. For blades or webs, it wasn’t feasible to buy saw blades for my application at that time so I made a couple to my own specification. It wasn’t hard, I simply purchased some spring steel from McMaster Carr and then used triangular files. I found it enjoyable to make my first blade which sported a 24 inch blade and 4 tpi. The second blade wasn’t as much fun, and sported a 36 inch blade with 2 tpi. I made work for myself by breasting the blade to have 1/2 inch of curvature along the tooth line. You can assemble the saw frame in a lot of ways, my preference was to copy the original design I had which is mortise and tenon joints. By putting mortises in the arms and putting tenons on the ends of the stretchers. Tension on the blade automatically translated to compression on the stretchers. You may notice that the mortise and tenon construction is different between the two saws.  It doesn’t matter which way it is done, both methods of frame construction work.  I like the Roubo design, because the saw can be disassembled when necessary as the mortises are not pinned.  No need.  I appreciate the knowledge of our forebears and simply copied that construction technology.  For the Roubo saw, I made the arms of the frame by using 1.25 inch thick cherry and using 1.25 by 1.5 inch square pine for the stretchers. I am very pleased with the two frame saws that I made and I offer this an alternative to purchasing pre-made saw parts. photo 2 (1)   photo 1

Questions About My Foot Powered Grinder

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I was recently asked about my treadle grinding wheel that I posted on Youtube. There was interest in the substructure that supports the axle and bearings for the grinding wheel.  So before I give some details, I want to give a little introduction to my foot powered grinder.

Back in the late 80’s I had the opportunity to purchase the old grinding wheel at a flea market in Springfield, OH.  I was already 10 years into my passion for hand tools.  I was hooked on regularly watching Roy Underhill and the Woodwright’s Shop on PBS and often hunted for old woodworking and blacksmithing tools at flea markets as an escape from my environmental consulting work.  I still remember the look on my father-in-law’s face and Barb’s too when I tried to load the grinder into the back of their minivan.

The grinder features a big sandstone wheel that was a common item for any homestead in the 1800’s.  Most likely the grinding wheel was mined from the Berea sandstone, a 320 million year old geologic formation (Mississippian Age) that was famous for offering quality grinding stones. Settlers once mined the Berea sandstone in the Cayuhoga Valley for grinding wheels.  Here is a picture of the texture of the stone.

texture of grinding stone

Mine was originally a treadle grinder and it may have either been equipped with a water trough or a funnel above the stone for regular wetting to facilitate grinding edges on tools.  I don’t know.  Years ago I made a funnel and attached a vertical support rod so it would provide a steady drip of water. I have enjoyed using this treadle grinder and one day I might build a new carriage so the base is more stable. So far my modifications include the funnel, forging a connection link, and building a new treadle. I don’t do all my sharpening on it, but it is quite gratifying to grind a new bevel on one of my axes.

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Looking at the pictures you can tell that the front and the rear legs look different.  The legs near the tool rest are clearly the original ones and the other square shaped legs were added later by a previous owner.

grinding wheel bearings

If someone knows more about the company, McD, that made these  I’d love to hear about it.

Thanks.

My Carving Axe

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I’ve been admiring the work of Peter Follansbee lately, especially his carving of riven oak panels and spoons. My Christmas gifts this year included some instructional DVDs and a couple hook knives.  All of this has motivated me to find and restore an old axe so that it functions as a carving axe.

I took an old Blombach axe, made in Germany, and retrofitted it with a new handle in the style of the Granfors Bruks carving axes.

axe disassembledaxe head before restoration

Here is a picture of the axe right after I removed the handle which you can see featured a metal sleeve.   I believe that my axe was probably originally setup to be the carpenters model.

The restoration began with me purchasing some hickory from a local source. My selection criteria included finding stock that had curved grain not straight. I wanted curved grain so the grain pattern would run parallel to the handle curvature I wanted. I designed the handle to exaggerate the curvature of the Gransfors Bruks axe. I started with 1 3/8″ thick stock and worked it with a drawknife, coarse rasp, spokeshave, and then finally I used a cabinet scraper. After frequently testing the fit of the handle fit to axe head as I reduced down the stock, I got to a point where I was happy with the fit of the handle in the eye and could then invest more time in shaping the handle. The outcome is that I made a handle that nicely fits my hand. This is the first time that I’ve made my own handle and it was a good experience. I might eventually invest in a Gransfors Bruk carving axe, but right now I’m satisfied that this retrofitted axe has a good edge and will be suitable for attempting to carve a wooden spoon in the Swedish tradition.

hickory and axe handle

 

 

handle cutout

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axe with rough handle fit

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axe with new handle

Here is a picture of the completed axe restoration.  I ground and honed the bevel on one side and then oiled the handle with boiled linseed oil.

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Working the Spring Pole Lathe

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Last Saturday and Sunday, I was doing Windsor chair making demonstrations at the Historic Fort Meigs War of 1812 site located in Perrysburg, OH. Specifically, I was demonstrating how early chair makers would have used a lathe that was foot powered. I was there along with many other costumed re-enactors for the Early Life in Ohio event which is an annual event at the fort. I enjoy using the lathe and particularly the fascination folks have in seeing it and pondering how that technology supplied quality turnings. That wasn’t because my turnings were poor quality, but that it took a bit longer to remove unneeded wood. My lathe was a reproduction of the Hulot lathe of 1775 vintage that I built using Roy Underhill’s books. I was blessed to see several of my parishioners from St. Paul, to talk with visitors to the fort and to mingle with the rest of the re-enactors.

On Sunday morning the site was visited by Alexis Means of Channel 13 abcnews of Toledo. If you click on the “Living History on display at Fort Meigs” shown below you’ll see me on a news clip using a froe and a splitting maul to rive a chair leg part before using it on the lathe. It took more effort in the news clip to split the white oak because the wood was getting dry. Usually, with wet oak it splits much easier.

Living History on display at Fort Meigs
rough shaping a windsor leg

Windsor Chair at Colonial Fort Michilimackinac

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Did the British use this chair?

Did the British use this chair?

Recently, my wife and I got up to Mackinaw City, MI, and we visited Colonial Fort Michilimackinac. I hadn’t seen the fort since the 60’s when my parents stopped there as part of a camping trip. At that time the archaeological excavations had spanned several years (began in 1959), and they were reconstructing most of the buildings. The Fort has its origins with the French fur trade in 1715 and after the French and Indian War, the British occupied the fort from 1761-1781. Later the fort was torn down by the British, and the buildings moved to Mackinac Island where a new and more secure fort was built (Fort Mackinac). Excavations at Fort Michilimackinac has since revealed many artifacts due to the long period of occupation.

During my recent visit to Fort Michilimackinac, I was surprised to see a bow-back Windsor side chair among the furnishings depicted in the Officers Quarters building. Immediately, I started wondering if the British would have had such a chair in their officer’s quarters since they became popular in the 1780’s. If so, this would suppose that the British military acquired one of the earliest versions of the stylish bow-back Windsor chair, and one that was made by Colonial craftsman in the eastern U.S. According to Charles Santore, The Windsor Style in America, the origins of the bow-back chair is that it was first inspired by a oriental design that was popular in England and when it was introduced in Philadelphia in the 1780’s it featured bamboo turnings.

Being a Windsor Chair Maker who has studied with Mike Dunbar in New Hampshire, and someone who loves Windsor chairs, it isn’t a surprise that I wonder these things.

My blog has recently been added to Woodworking Blogs, which is part of one of the largest networks of blog directories on the Web. Please visit my blog’s personal page to vote for my blog and comment to other blog users.

Back to Windsor Chair Making

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Hi,
We moved our home and Windsor chair making shop in January 2013. I serve as a full-time pastor at St. Paul Lutheran Church in Bowling Green(Haskins), Ohio. I’m still setting up the Windsor chair making shop in Haskins, but here are a couple pictures of a Handmade Windsor chair that I just finished. This one is a gift to my Mom. It is a Philadelphia High Back Windsor chair. It reflects my training several years ago with Mike Dunbar at The Windsor Institute in Hampton, NH. The chair was finished by first applying a medium walnut dye, then coatings of red then black milk paint, distressing the milk paint to reveal the underlying red paint, sealing it with blonde dewaxed shellac, and finally applying a finish of Minwax wipe on polyurethane. I borrowed the idea of using shellac as a base coat before applying wipe on polyurethane from Peter Galbert another respected and well published Windsor chair maker. I had to rub out the finishes several times including the application of milk paint and the shellac base coat. Hope you enjoy the pictures of this black Windsor chair made in the Philadelphia style. I never cease to marvel at how nice these chairs look and the beauty of the design.

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My blog has recently been added to Woodworking Blogs, which is part of one of the largest networks of blog directories on the Web. Please visit my blog’s personal page to vote for my blog and comment to other blog users.

Rescue Me

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Recently, I stumbled into a real find at a garage sale. Barb and I were out looking at people’s junk and there it was a ugly painted saw that was done for the owner. I might like landscapes, but what I observed was a nice saw handle and saw plate with almost no wear. So for $3 I took it home and it sat on my drafting table as a painted saw for months.

A couple months later I had gotten sufficiently tired of the oil painting on it and it found itself in the garage being subjected to paint stripper. The stripper took off the painted scene and I soon noticed an etch from the manufacturer on the blade, HSB and Co. and it got more exciting. The painter had the blade sandblasted to remove rust, but the etch was still visible and the blade looked great. Some of the sandblasting work had damaged the handle too, but it wasn’t severe. I felt very fortunate here.

So here is the good news, I rescued from the painters brush a perfectly good saw that had very little use from its owner. The previous owner liked this premium Chicago made saw so much that his name H.M. Simpson was stamped all over the handle, but fortunately for me there is much life left in the saw plate.

After I removed the fall landscape scene and the flat black paint on the back side, I knew I was on the right track. I carefully removed the sandblasting texture from the plate with 220 sandpaper attached to a sanding block. The sanding block helped keep me above the etch and so I could preserve it for some future treatments to darken it. The apple handle was cleaned up of stray paint and then lightly sanded. To even out the color I applied a maple dye, gave it a good coat of boiled linseed oil, added 2 coats of garnet shellac, and then applied wax.

The saw nuts were originally nickel plated and most of that was lost in cleaning it up. I was able to preserve the nickel plating on the medalion.

I am thrilled with the condition of this handsaw, the way it cleaned up, and I can’t wait to sharpen this up and use it.

Thanks for looking!
Jim


New Life for a Stanley 8 Plane

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Sometime ago, I added a stanley bailey #8 plane to my arsenal of furniture making tools. I took a risk and purchased it on ebay and then I opted to do a total restoration of the plane. After checking the 24″ long sole with a straight edge, I discovered that the plane had unacceptable concavity between the toe and the heel. Once that was discovered I embarked on the tedious job of flattening a 24″ long sole. My friends, this is not for the faint of heart and it turned out to be a real pain. I used 6 inch wide 80 grit self adhesive backed sandpaper on a 3 foot long piece of float glass that is 3/8 inch thick. As suggested my others, I regularly changed the sandpaper whenever it lost the effective cutting capability. This helped to keep things manageable. Once the bottom of the plate reached sufficient flatness (within a couple thousands of an inch) I switched to the 120 and 220 grits. It probably cost me $40 in sandpaper alone, but heh when you compare the cost of purchasing a brand new one it was worth it. Before this I had flattened a #4 1/2 and a Bedrock 605 and found that to be a lot of work. Now I was a glutton for punishment.

The plane casting was in pretty good shape in terms of having only minor oxidation, but the original paint was beyond hope. Between someone having scratched a large initial and there being a lot of small bare and rusty spots all over, I decided to strip the paint and make it look like new. I applied several coats of satin black Rust-oleum to recreate the look of the original finish. This is not what collectors do because it reduces the value. I obviously did this for my own use and without concern about preserving original paint.

Here is the before and what the plane looks like afterward. I cut a few curls on it and it brought smiles after all the effort of repainting, cleaning the parts of rust, polishing the brass, and the equipping the plane with a new IBC A2 steel plane blade. Thanks for looking.


My Other Blog

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For the last 2 years, I’ve been doing increasingly more woodcarving, anywhere from spoons and bowls taken from logs to Norwegian forms of carving. In response to my receiving a grant from the North Dakota Council on the Arts, I’ve been specializing in crafting original Norwegian inspired ale bowls. It led Barb and I to rethink our business ventures so we have renamed it Skanderna Wood Works. I’ll continue to make chairs so this blog will continue on furniture making topics.

Please check out https://skandernawoodworks.wordpress.com

My First Joined Chest

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I have some walnut that will become a reproduction of a joined chest from the 1600’s. I have long admired joined chests at historic sites and in museum collections. Building a joined chest gives me an excuse to make a dent in the pile of hardwood lumber that keeps my truck outside in the winter. This year in Eastern North Dakota, winter weather has continued three weeks into spring.

Peter Follansbee has provided photographic and dimensional information about various carved chests in his DVD on Joined Chests available through Lie-Nielsen. I have glued up front and side panels out of basswood, rather than riven oak in the original. I’d love to carve the panels out of riven walnut if it were available to me.

Regarding the carving which involves S curves, the challenge was doing the layout for this newbie to 17th century carved oak furniture. My first attempt on a carved panel involved making a pattern from a photograph for one of the designs. Follansbee can free hand a lot of his carving, but that is where experience really counts. For now I’ll concentrate on mastering the carving of a basic design that was utilized in the 1600s. When I made this pattern it also gave me the opportunity to make some adjustments for variations due to the free hand work on the original. So yesterday I started carving my first panel and now you can see my progress.

Here is the stock I’ve fabricated so far: several stiles (chest legs) and muttins (shorter stiles) using 2″ thick walnut, and I’ll use clear 1″ thick stock on the panels. I am not sure if the carving will involve more than the panels. I also have a top made of three edge glued walnut flat sawn boards that is about 21 inches wide and about 50 inches long. I’ll use secondary woods like pine or popular for the back and bottom. The rails are going to be flat sawn walnut stock that are 1 1/8″thick and they’ll be about 4 1/2″ wide at the top and 3 1/2″ wide at the bottom. The muttins will be approximately 5″ wide. Those thickness dimensions are approximate and allow for trimming and beveling where needed. By limiting the carving to the panels it has the benefit of keeping with an original design and reducing the complexity of my first joined chest.

I am planing to do most of the joinery by hand so it is authentic in appearance. I look forward to using hand planes to cut the ogee sided grooves that are distinctive on the stiles, rails, and muttins.

Popping grain in oak

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The oak I used for the desk box responded well to the 50:50 treatment of linseed oil to turpentine. This is the finish that Peter Follansbee swears by on his 17th Century reproduction pieces. What made my desk box different than Follansbee’s work is that I used some flat sawn stock and I had some issues with moisture content. I did that for obvious reasons, to conserve my supply of riven oak. In that regard, it really helped to use a spray bottle of 50:50 water to isopropyl alcohol when using the moving fillister plane on cross grain and in some carving situations. It also helped when burying the cutoff nail heads that are bent over on the small drawers. The result is that once driven into the grain, they look like staples and better correspond to 17th century drawer construction. The only negative I had to using the alcohol to water mixture was some iron staining that I removed mostly by sanding.

When I have the opportunity to work again with an oak log, it will be great to be thinking about carving 17th century boxes. Besides looking for Windsor chair parts, I will be thinking of stock for carved sides and panels when I’m using wedges to split the log. Thanks to Follansbee, Jennie Alexander, and John Fiske, and others, I have learned a lot about what to look for in designing and building 17th century furniture. I can appreciate the fact that the oak stock can have some variations in thickness and it is part of the charm of 17th century construction. You don’t have to waste as much also. I can definitely appreciate the comment “the eye is very forgiving” after my experiences of grain related variations in my chisel work. So far, I’ve faced more challenges in keeping my carving lines continuous or straight in oak than when working in other woods like basswood. But I am not discouraged, as part of that relates to my getting used to using the mallet along with oak being a harder wood to carve when it is dry.

If you work with 5/8″ stock for the case work, 1.5″ forged nails are all you need to attach the bottom, the cleats, and for the hinges. A shorter nail could be used for the hing you want enough nail to clinch it. I also found that a hand reamer was indispensable for dealing with the taper of the nails. Follansbee uses a reamer quite often in his DVDs. Sizing the pilot hole for the forged nails was quite important, but the reamer was helpful. I couldn’t find a four sided reamer as Follansbee, but I obtained a reamer (General) at a hardware store that worked quite well. I have a bit reamer for a brace, but I can see that a reamer with a T shaped handle is better. FYI, you need 20 nails for the hinges and cleats, and another 9 to attach the bottom. The hinges and nails were made blacksmith Peter Ross.

I may apply the linseed oil mixture on the inside of the box, but I can see why Follansbee doesn’t. It is kind of like not painting the bottom of a Windsor chair seat. It seemed wasteful in the 1700s and still unnecessary now. So as the oil dries it will give me time to think about whether I really want to seal the carved surfaces with shellac or another coating. The challenge of course is to make sure that an addition doesn’t take away from the charm of the carved surfaces. That is why I use spray satin polyurethane when finishing my chip carvings. If I use shellac I’ll make sure it is a lighter cut, probably closer to 1/2 lb.

Slant top oak desk box

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I love the look of this box project. It is amazing how much you can learn by doing a period reproduction piece. I’ve watched the DVD by Peter Follansbee many times on building oak boxes and also utilized his article in February 2018 issue of Popular Woodworking. I’ve benefitted too from the blogs that Follansbee regularly post. Even with great help like that there is still much more to know which only comes from your experience of doing it yourself.

I haven’t put the finish on it, but all the drawers are done and the nails installed. The top is made from flat sawn oak, because I wanted to conserve my riven oak for the carved sides. Because the top is flat sawn stock, I made sure to leave a gap at the hinge line. I learned how the installation of dovetail hinges and the cleats using nails can be trickier than you might expect. I installed the hinges with a gap and a clearance for the cleats so they would not rub on the carved sides. I even used a hand reamer this time to prepare the pilot holes for the nails. What I learned though was how easily some shifting can occur while pounding in the nails. Fortunately, the clearances ended up being sufficient so the top closes without rubbing the carved sides. I’m close on one front corner, but not enough to bother with. I learned that once you start using nails on the hinges they don’t give you much latitude for adjusting. Because the nails are tapered and bite the wood, they are not really removable. I had a couple nails bend on me so they couldn’t be removed no matter what I did. The softness of the nails though is a virtue when clinching them later. Bottom line, I noticed that I couldn’t be very fussy here.

I am considering a couple ways of finishing the oak desk box. When I typically finish a carving, I seal the wood first and then use gel stain to highlight or accentuate the carved areas. The sealing prevents blotching, especially relevant in pine and basswood, and provides good contrast with the darker staining in the carved areas. When Follansbee finishes oak boxes he uses linseed oil cut with turpentine and then he sometimes tints it with various dry pigments like iron oxide and others. I also like the idea of using gel stain to even out the color between the pine bottom and the different grain patterns in the oak. Since I have a good investment of time in this project, I am going to test the different finishes on some scrap oak.

Square Peg Joinery

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I’ve had my first experiences making and driving square wooden pegs or Trenails as they have been called. Previous to this, I’ve gone with round pegs and in part utilized a dowel plate. This time I split some red oak into 1/2″ square pieces with a froe and maul. It gave me an excuse to use some hand split material that I’ve kept for chair parts. Then I worked the blanks down to a smaller size with a framing chisel. I used a bench hook to protect my bench top from the repeated chisel cuts. Final pairing on the pegs was accomplished with one of my Sloyd knives.

I was amazed at how quickly you can process a bunch of pegs that way. Since my carved oak desk box involves 5/8″ thick stock for the carcass, I opted to drill 3/16″ holes for the pegs. Careful sizing of the pegs helped me to avoid splitting even with some wandering of the bit. Just like in furniture from that time period, I didn’t use glue on the pegs or in the peg holes. To drill the holes I used a shell bit in a John Fray Spofford brace. I made sure to hone the outside of the bit like a gouge and the holes came out pretty clean even in end grain.
Now I split pegs with a peg cleaver that was made by blacksmith Tom Latane, of Pepin, Wisconsin, which gives me improved control. It was somewhat awkward to use a large froe to split pegs as I recently did. Tom does beautiful work and the details on the handle are cool. If you haven’t looked at one, they a fairly hefty tool, and weight is a key aspect since they aren’t a cutting tool as Tom mentioned to me. I’ve watched Peter Follansbee use one on a DVD, and like a froe you can drive the cleaver with a club or mallet. You can also split stock by using the weight of the tool itself. I am clearly making the commitment to take on 17th Century furniture projects, probably because the carving really speaks to me.

Resources for 17th Century carving

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I know that I’m one of many in saying this, but I am getting progressively more interested in the carving designs utilized in the 1600s. Perhaps in some way I’m feeling a connection with some of my dad’s Scandinavian family who arrived in Delaware in the 1656 timeframe. They were around English style oak furniture in the colonies and became more and more assimilated into English culture though political changes and intermarriage. Anyway, I finally acquired a copy of Living with Oak: Seventeenth Century English Furniture Then and Now by John Fiske and Lisa Freeman, 2005, and as I flipped the pages I was thrilled to learn more about English oak carving from that period. The Belmont Press out of Belmont, Vermont is the publisher. I’ve clearly got the bug to master this kind of carving. I like it enough to order the more recent book on the same subject, When Oak was New, again by Fiske (2013). I’m looking forward to scouring the many hundreds of photos in it. After looking at other sources, I purchased it through the Fiske and Freeman website and even spoke with John Fiske over the telephone.

Like many woodcarvers, I find it helpful to know the history behind various designs becoming fashionable and then seeing the many examples of various carving motifs applied on, chests, chairs, etc. Peter Follansbee, formerly an artisan at the Plimoth Plantation of Massachusetts, gets much of the credit for this renaissance of interest in 17th Century woodcarving/woodworking tradition. He also worked with Lie-Nielsen tools to provide many instructional DVDs and his wonderful blog also regularly includes instruction.

Woodcarving and woodworking are basically constructive activities in the sense that useful endearing products hopefully are the outcome. Trees are sacrificed for our activities, but responsible management of natural resources can provide for it being renewable. Like many others, I find this creative work with wood to be therapeutic and not a waste of resources. In addition, to the craftsmanship of fashioning wood into useful and attractive objects, I am amazed at the creativity that goes into tool making which corresponds to replicating period furniture as well. For example, I rediscovered that using a scratch stock, or in my case making the filed profile blade, can be quite fun. It just takes a small piece of steel, some files, and a bit of time. In my case, I already had a scratch stock made by Veritas, but never filed my own blades. It’s been in my tool box for awhile. Personally, I am thankful that we have resources in our country to do this and all it takes is some research and willingness to try it. The really cool thing is that outside of some overhead lighting, it didn’t take much electricity to add a decorate edge to my till lids for a carved oak desk project.

If this style of carving peaks your interest, rest assured that there are blacksmiths out there who can supply your needs for hardware and tools, and there are all kinds of sources for chisels and carving tools. You might have to wait for suppliers to fill your orders because of high demand. You might have to wait for them to fill a bunch of orders ahead of you on their order list, but it will be worth it. I now have a greater appreciation for the beauty and quality of hand forged nails and dovetail hinges after obtaining them from blacksmith Peter Ross.

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Likewise, I continue to appreciate watching Follansbee’s DVDs on oak box carving as I learn something new each time. I look forward to posting my assembled carved desk box real soon.

No-nonsense Woodworking

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I’ve heard people say that woodworking is an expensive hobby. Right now, I’d say yes and no to that suggestion as I think most woodworking enthusiasts would. It is expensive if you believe that you require all the very best of equipment, a vast library of books, and a bunch of one week intensive classes. It is expensive if you can’t decide what interests you the most as your starting point. It is expensive if you spend most of your life investigating how to use more refined methods and acquiring more optimum tools. If the latter is your path, then welcome woodworking into your life as something more important and then see how it fits for you not as hobbyist or weekend warrior, but as an artisan woodworker. That is where I’m at in terms of desiring to replicate antiques and yet embracing Woodcarving as a way to individualize my work.

If you do enough research to build a tool box, bookcases, boxes for storage, or opt to build an end table or coffee table you can find it affordable cost wise. The challenge is sorting through the information and finding a plan that works for you. The challenge is to assemble a basic set of tools through a diligent search of new and used equipment and being smart about their cost. It’s a passion where asking the right questions makes the difference. Can a used hand plane with perhaps a new plane iron give satisfactory results when compared with a more expensive new one? It can, if you educate yourself on the old hand planes and take the time to find one in acceptable condition. If you get inspired you can even create a wooden plane that will produce great results, provided you make the investment to learn how. We are truly blessed that the information is out there online and in print.

I’ll be a dinosaur here. During my Junior High and High School years, I learned a lot in what was called industrial arts/woodworking classes. Whatever I learned from my dad who was a handyman at home, I went the next level at school. Back in the late 60’s and early 70’s we weren’t allowed to build anything in school without drawing up a plan. The approved drawing gave us access to the lumber rack of oak, maple, poplar, cherry, walnut, and Honduras mahogany.

You may not have had access to a Woodworking class in school. Over the years litigation concerns drove many public schools to sell off equipment and turn shop classes into technology classes with significantly reduced use of machines. While those changes have occurred, there has been a great interest in antique furniture and reproducing those pieces. Building Shaker tables, chairs, and cabinets, Country furniture, Windsor chairs, and Arts and Crafts furniture have all been taught in through magazines, books, and classes. Woodworking shows have occurred around the country for years that bring together artists, woodworking instructors, and suppliers from around the country. Some suppliers of specialty woodworking tools often have shows or an open house to encourage people to come and check out their products.

Not only that but many famous woodworkers got their start from studying old furniture and doing demonstrations at historic sites. It proves that if you fall in love with furniture from a specific time period and spend enough time in museums, you get a following of those who appreciate reproductions of antique pieces. Part of my path in woodworking was blessed by giving demonstrations at historic sites in Upstate New York, Ohio, and now North Dakota.

There is also another important aspect to woodworking and Woodcarving, community has always been an important part of learning in the arts. I’ve lived in a bunch of places over the years and it is always wonderful to build friendships with other woodworkers. Some may be immensely talented and well paid too, but since there are so many applications it doesn’t matter. You don’t have to travel extensively because interested woodworkers might be in your congregation or in your community. If you do have to drive, it might be just a state away to find a Woodworking club or a Woodworking class. What matters is that woodworking can be either an interest or an occupation depending on the doors it opens in our lives. I continue to be amazed at the commitment clients can have to owning pieces of furniture that are diligent copies of antiques.

But I’m also amazed at how people of different abilities, can still express a sense of wonder at seeing how a simple box can be made of pine boards using hand tools. I get to demonstrate woodworking using hand tools and my audiences include youth and adults at historic sites as well as through an organization that helps the developmentally disadvantaged. They all remind me of the blessings we as woodworkers have in acquiring, tuning, and using old tools. How fortunate to own tools that are 100s of years old and yet see them complete some task in our hands. I don’t know about you, but I find that very neat as an experience and not surprisingly contagious to others.

Blessings on your woodworking and creative endeavors!

Oak Desk Side Carving

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When you don’t carve that often you can easily make more mistakes when you re-emerge yourself into it. I had a super busy week at church, and although I have watched the Follansbee DVD numerous times on oak desk boxes, it didn’t stop me from goofing on my v tool work. According to the original 17th Century oak desk box, the outside lines on the tulips are supposed to stop short of the point on the leaf design. My outside lines were carried too far and are curved somewhat. I was looking at the line drawing and forgetting that the chopped accents are what makes the curvature at the ends of the lines. Oh well, you can’t see both sides at the same time anyway.

I really like the 17th century oak carved look. It is neat when I watch Peter Follansbee on his DVD cut through riven red oak like butter with a v tool. Since I’ve riven red oak from the log, I have a good idea of how much easier and faster it is to shape and carve red oak with greater moisture content.

Since I don’t access to oak logs right now, I am planning to carve subsequent 17th Century designs in clear basswood. It won’t have the characteristic grain pattern of riven red oak, but at least it won’t be as tough on carving tools also. I find this style of carving particularly refreshing in terms of giving some latitude on executing the designs. Carved lines can be irregular and still yield a wonderfully artistic piece of furniture. It is funny too how this style of carving makes you want to fill blank space as if the original carvers were uncomfortable or afraid of empty space. I never felt that way about chip carving. Previously, I actually incorporated empty space into my chip carvings on purpose.

Punch lessons

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As I said in my last post, I’ve been looking at different ways to make steel punches that I can use for carvings. So far my materials include O1 drill rod from Enco, hot rolled and cold rolled stock from Menards, an old screwdriver, and a 3″ cut nail. I feel like I’m either getting closer to the goal or expecting too much.

My first challenge is to make a tool crisp enough in detail for stamping in red oak so I can make a Maltese cross impression or some other design. When you look at sets for punching numbers and letters, ridges are well defined and prominent on those stamps. I have a set and appreciate their ability to make crisp impressions. However, the stamps that Peter Follansbee and others make to decorate the carving on reproductions of 17th Century Furniture are far less detailed. That makes sense when you look at the 17th Century furniture shown on the Marhamchurch Antiques website which illustrates those types of stamped features. So for a newbie on making steel stamps/punches, learning how much detail to incorporate is basically trial and error. My hope is to reach a point where my stamped impressions in wood can truly compliment the chisel work. Somehow those stamped impressions have to look nice enough, but not appear so regular to look manufactured.

So here is my latest attempt using 1/4″ hot rolled steel. I used a knife file, fine milling file, and some needle files to shape the Maltese cross. Here are some impressions. The two impressions on the left were made with the old screwdriver punch that I tweaked some more yesterday. I used a black sharpie on the cross so you could see it better. I also have some 3/16″ cold rolled steel that I can try next. As you can imagine, it is trickier to file a crisp design in smaller stock. So far my efforts to use a cut nail gave me a basic plus shape about 1/8″ wide. Since the maltese cross in Follansbee’s work is about 5/32″ wide or about 4 mm, I’m striving to get the shape and the size of my punches to roughly correspond. That is the second challenge, to make a stamp small enough to make the statement I want for 17th Century furniture reproduction.

Metal stamps for 17th Century Carving

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If you like 17th Century carving on oak boxes then you know about using a steel stamp on the backgrounds. I’m now a dabbler in making punches that can stamp a Maltese cross or add a decorative background on my carvings. So far I’ve made two punches for stamping a Maltese cross using some drill rod. However, those now seem oversized so I used smaller diameter materials to make two more. I also invested in a couple knife shaped files for cutting the rest of my steel stamps. My last two stamps were made using a worn out screwdriver and a large cut nail. It is harder than it looks to carefully file away the metal so it gives you the desired impression when struck with a hammer.

Fortunately, I acquired some steel stamps earlier in my life so I can look at those examples too. I’m kinda surprised that with the popularity of Peter Follansbee’s carvings, his blog, and DVDs with Lie-Nielsen, that someone hasn’t already seized the opportunity to make and sell the steel stamps/punches he routinely uses.

Anyway, it will be cool to make several more stamps/punches and get them correspond to the preferred sizes to reproduce the 17th Century carving designs. Stamping designs into wood goes back pretty far to include stamping names and company names and logos into the ends of wooden planes. It will be interesting to see how these will turn out.

Forgiving Eyes

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Do forgiving eyes help cheer us on when attempting new techniques? I worked on the front of the oak desk box project today. Personally, I will trust that human eyes will be forgiving on this first carved desk box. Thank you Jennie Alexander for reminding us though that our eyes tend to be forgiving of mistakes. Because it matters that we might not recognize artistic value which comes from things planned or unplanned in our furniture work.

Above are a couple pictures of the chisel carving work which is nearly finished on the front. I learned a lot about carving on riven oak that I’ve had for awhile. Even though it was previously kept in a freezer, it proven to be drier and harder than I had hoped. Greener oak would be more fun to work. I’ve got to believe that mallet work in recently split oak would be more forgiving in terms of tool pressure and cause less chipping.

As I said before, I have benefitted greatly from Follansbee’s DVD on oak desk boxes, but something’s you just have to learn by doing. Like spacing a chisel for vertical cuts, it is easy to get them too close when doing 2 or more cuts side by side. I wasn’t sure what chisel widths to use for some of the gouge cut details and I suspect a couple millimeters less in the cuts would enhance the next carved desk box. On the free hand carving of the tulips/leaves, I opted to use chalk and I did pretty well in keeping symmetry and keeping the diagonal line as a guide. Only on one tulip/leaf did I really stray and drift further away from the diagonal line. I also wasn’t sure what chisel width to use for the bird cuts to make on the leaves. I used my #7 sweep Swiss made gouges with 10, 12, and 14 mm widths as I got to the wider part of the features. Personally, I think Follansbee can make his chisels work in narrower and wider cuts by his sheer skill in the holding of the chisels. That seems to be the case especially when he removes background with sometimes 2 cuts of a fairly wide chisel without nicking corners.

Bottomline, I like this style of carving that Peter Follansbee has mastered with 17th century boxes, wainscot chairs, jointed stools, and paneled chests. It would interesting to hear from those of you who got hooked on this style of carving.

Carving Oak Desk Box

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Roy Underhill published a book with the title The Woodwright’s Eclectic Workshop and eclectic as a woodworker fits me also. You see I love to build everything from Windsor chairs to other period furniture, but recently I’ve gotten into building boxes. Part of my reasoning was that after my last two moves, I had to look for woodworking projects to tackle during the chaos of not finding stuff and doing home improvements. The answer was building boxes for candles and making oak boxes like Peter Follansbee of Massachusetts. I’ve had the perfect excuse to build boxes as they don’t take as long to build, can include carving, and are great for doing demos. As a pastor, my shop time is pretty limited, but building boxes seems a good fit for me now. The other shop time has been to set up and organize equipment.

My current project is an oak desk box. Peter Follansbee put out numerous DVDs through Lie Nielsen and the beauty of them is that you can watch them a bunch of times. I haven’t had the opportunity to take a class from Follansbee, but for now his blog, and watching his DVDs on building boxes are refreshing for me. The oak desk box is a design from the 17th century and was originally built from either red or white oak split from logs. I opted to use some red oak that I had split much earlier from a log. Because the pieces are not very wide, I had to edge glue the stock together. I used hide glue to be period correct.

So here are pictures of the desk box that I’m building. I have cut the two sides, the front, and the back. Riven red oak will get used for the sides and front. Flat sawn red oak will be used for the top, lid, and back. White pine was edge glued for the bottom. I’ll use a combination of riven and flat sawn red oak for the compartments and drawers. I use wooden planes and occasionally a metal bodied plane as much as possible. I confess that I also use power tools, when necessary, to expedite the progress.

I’m pretty excited about the project, enough to ask Blacksmith Peter Ross to provide me hand wrought nails and dovetail hinges. I love Peter’s skill in blacksmithing and his hinges and nails will make the project. Barb will claim this desk box, but at least I’ll have some nice pictures for any future clients.

The crazy thing is that red oak won’t be available around here in ND, so I’ll have to use other woods in the future for making carved boxes. But for now, I’m using up oak stock and I love the grain pattern and look forward to carving this design utilized by Follansbee.

I’ll be posting on my progress and the next post will feature the carved panels.

Teaching a Carving Class

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Chip Carving Knives

One of my joys is teaching chip carving to church members and friends.  I have a class coming up in May that will be held at the St. Olaf Retreat Center in Devils Lake, ND.  Our Retreat Center is beautifully situated right along the shoreline of the lake.  The class is being sponsored by the Lake Region Woodcarvers Club and will guide participants through the basics of chip carving.  I have some students who are returning too.  Lately, I’ve been teaching some 3 hour carving sessions at the local senior center and it is cool to see how some students can quickly grasp the carving technique. Part of my interest stems from the connection of chip carving to Scandinavia when it was applied to Viking ships, architectural elements, and household items of that time. I find it fascinating too how Peter Follansbee and others have included chip carving motifs into their fabrication of spoons.  Make no mistake that my interest in woodcarving is not restricted to chip carving, as I’m also striving to progress in figure carving and acanthus carving as well. But for now it is cool to offer chip carving to those affiliated with the Sons of Norway organization and members of my congregation at St. Olaf. It gets one more inspired to carve when others share your enthusiasm and you can encourage each other. I am very grateful to serve at St. Olaf Lutheran Church and to be part of the Devils Lake Community.

Lofty bench

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What do you do with a discarded kitchen base cabinet from long ago. If you are like me you salvage it for your shop!

That is what I did. After moving into our new residence some five months ago, I pulled this cabinet from the wall in the basement and couldn’t wait to repaint it. The bright red paint slopped on it by a previous homeowner didn’t appeal to my shop sense. Once I did that, I immediately discovered that it was handmade. It has a face frame made of yellow pine along with some hardwoods like birch. The drawers were made from popular. Since the craftsman didn’t use particle board and very little plywood, it got me excited. I was further delighted to see some saw marks from a hand saw. The cabinet is solid and sports rabbet joints and nail construction.

To re-purpose it, I attached a solid wood top made from 3 salvaged 2 by 12s, edge glued, and made the width to be flush with the legs. The top of the bench is 27 1/2″ wide. The top once surface planed and sanded is about 1  3/8″ thick, but okay for my purposes. I’ve seen antique benches that sported thinner tops than the 3-5″ tops being advocated nowadays. To reinforce the base, I built two leg assemblies so each side of the cabinet has a solid mounting for the top.  Carriage bolts were used to attach the top to the framing at each end. The cabinets rest on two 2 by 4’s that are half lapped onto the backside of the legs which are doubled 2 by 6’s.  The half lapped joints are bolted together with 5/16- 3/8 diameter carriage bolts. The legs at each end are assembled with upper and lower stretchers (2 by 4’s doubled at top and 2 by 6’s doubled at the base.  The legs and stretchers are held together with mortise and tenon joints that were drawbored.  To stiffen the cabinet assembly I added a piece of 3/4 inch thick plywood that was screwed to the back. I also used steel corner braces inside the cabinet to beef up the structural integrity of the nailed together case work.

For clamping I made a leg vise on the left side of the bench using an antique wooden screw of 2 inch diameter and installed a used Columbia 5″ wide shop vise for the tail vise. I am sure that it will make for a nice bench that is located along the wall. I patterned my leg vise to have a chop of 10″ width at the upper part and then made it progressively narrower toward the base. I used 2″ thick cherry for the chop. This was following the vise chop design that Chris Schwarz sports in his woodworking book on benches.  I still need to carefully fit the wooden vise screw to the leg vise chop, add some trim pieces, and then fabricate and add a thick vise chop to the tail vise. The drawers and knobs will be returned to the casework also.

Admittedly, it looks tall in the picture at 36 1/2″ and it is a few inches taller than my other benches.  It will be less desirable for some hand planing operation too, but I think it will work for me.  In defense of my lofty bench, I’ve noted that some woodworking writers have mentioned bench heights reaching this one or higher, so I though it worth doing.  It is my belief that it will be quite useful for some woodworking operations, possibly chair making and woodcarving operations, and to also serve as a platform for some of my sharpening equipment.  Maybe this will encourage you to build a workbench using your own creativity and by re-purposing some old cabinets too.  If nothing else it will still function as a counter top.

 

Snowy Day in ND

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Ah the challenges that come with moving and setting up shop again.  I guess it took a snowy day in North Dakota for me to realize how much fun and creative juice I experience in preparing a new workplace.  Call me the experiential woodworker, but I like to organize my stuff as I go.   Not surprisingly, I’ve been known to sometimes enjoy reading Soren Kierkegaard, the father of existentialism.   More importantly though, I find it ironic that with all the planning tools available via books and computers, it suits me more to layout my saws, planes, braces, and assorted hand tools based on my gut than to automatically repeat something from the last residence.  Take my set of hand saws,  I can’t settle this time for hanging my go to saws on four Shaker pegs.  No.  This time they’ll reside on a till of some kind.   Even though I don’t have a specific till design in my mind, I find it refreshing somehow.  There are certainly many nice tills featured online as examples.  What I have is a space on the wall next to a cabinet and a desire to store about 10 panel saws efficiently.  So as silly as it might seem, I am really enjoying this experience of how a simple saw till might become part of this wall.  Two basswood corbels, leftover from earlier moves, were my starting point.  I can imagine a till resting on those corbels and that is about it for now.   I know that I will use 3/4″ thick pine or poplar as stock for construction and the rest will be delightfully figured out as I go.  Plain and simple I am imagining what I might view as a low budget saw till.  My Design criteria is to not let it look like a piece of furniture. If you know me you know already I don’t mean it.  Frankly, I like what I’m seeing already and if you have limited shop time, as I do, this approach might appeal to you.  This is certainly a family thing as my dad was more of a carpenter than me, had less woodworking resources at his disposal, and routinely savored his woodworking experiences.   I’ll always remember that.  If you saw my Victorian Scroll Saw in the April 2016 issue of Woodworker’s Journal, I can tell you that I developed the design in the same way.  I enjoyed developing a design through a series of refinements.   This former geologist can say that the design wonderfully evolved.

Blessings,

Jim

Rusty Gimlets

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I confess I’ve never used a gimlet bit in a brace. I acquired these over the years and had planned to ultimately use them in an 18th century demonstration. Today I took a good look at them in their current state. I’ll be careful in cleaning up the original rust. There is quite a range in condition. From the photo you can see that I have a good variety in size also. I’m not sure how to straighten these bits. I tried several braces to test out the bits. My quick trial showed me that these babies will bore quite nicely. The fourth bit from the top has a bend in it and I’m wondering if I should try straightening it. Let me know what you think!

My hope is that I can use them for cutting wedge mortises in molding planes. Larry Williams made a great point of encouraging their use in his DVD on making side escapement planes.

Here is how three of the bits cleaned up this afternoon.

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Setting Up Shop Again

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Dear woodworking friends,
It has been quite awhile since I made a post and I owe you some explanations. Barb and I became North Dakotans in August. I accepted a new call to serve in a Norwegian American Lutheran church community in Eastern North Dakota. It is quite fulfilling work and also exciting to be closer to two of my favorite places: the Milan Village Art School in southwestern Minnesota and also Vesterheim in Decorah, Iowa.  Needless to say, being a pastor and a woodworker has added challenges when it comes to moving 1100 miles north of the Toledo and Bowling Green area.  However, everything worked out great in the big move and we are making strides in passing on the boxes to others who need them.  That will help in housing Barb’s car before the snow falls.   I am grateful for the support of family and friends, and even more excited about living in the upper Midwest. 
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While my progress in setting up the new workspace has been slowed somewhat by some recent surgery, I hope to be working at the bench this winter. I look forward to being active in the local carving club here in Devils Lake and really getting into Norwegian acanthus carving over the next year or so. A recent experience of attending the annual Hostfest in Minot, celebrating all things Scandinavian, was really a hoot!  My dad would have loved it! It was especially great to eat lefse and see numerous woodcarvers there and talk to them about acanthus, flat plane, and ale bowl carving. In particular, my friend Harley Refsal, an internationally known flat plane figure carver, is always a joy to spend time with and he has been wonderfully supportive of my new assignment at St. Olaf.
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Some of my current interests involve eventually making a few side escapement (molding) planes, like hollows and rounds, based on Larry William’s DVD that I watched this week while recuperating from surgery. I also recently enjoyed watching an episode (2015), “hollows and rounds”, on the Woodwright’s shop that featured making a molding plane with Bill Anderson. I look forward to using plane making floats and hopefully filling in the gaps on the partial set of hollows and rounds I’ve acquired over the years. Stay tuned as I eventually post about those plane making adventures using different wood blanks. I’d be happy to make and put to use a few side escapement molding planes. They’ve held my interest since I first got my hands on a couple antique molding planes in the early 80’s that were missing irons. 

Molding Plane Billets yeah!

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Maple Plane BilletMaple Plane Billets 2After carting around some hand split sections of logs that were cut down at a previous ministry assignment, this woodworker now pictures those as billets for molding planes. It isn’t beech or cherry, but none other than figured maple. Truth be told, I’ve had this wood aging in my shop now for six years and it is time to use it somehow. Thank you Caleb James, Larry Williams, Popular Woodworking, and Lie Nielsen Tools for talking up plane making. I have marveled about molding planes for years. I’ve had an appreciation for those planes dating back to my college days in the late 70’s and now I want to make ones to enjoy. Yes I’ve sharpened the irons on antique ones, but now want to take things to the next level.

So here I go. Even though I’ve been planing to do it for years and purchased books on plane making, I finally bought some mild steel just to give float making a try. I ordered the Larry Williams DVD on making side escapement planes and I sense that Lie Nielsen will get some more business from me. But hey I’ll try making floats first and see if I catch the bug to make quite a few of those side escapement planes.

Here are a couple pictures of the billets. Enjoy! My goal is to have more hollows and rounds in the tool kit!

Bench Tweaking

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I don’t build workbenches that often, but I do enjoy optimizing my existing workbenches to get the most out of them. Take my recent bench project, just a couple months ago I acquired a woodworking vise at an antique mall.  It is now reconditioned, attached to my bench, and fully functional.

How cool to have all those dog holes even if it was a pain to machine them with a spiral up cut router bit and finish drilling them with a brad point bit. Let me tell you the plywood top was the challenge with all the glue to gum up the bits. Lowering the speed on the router and frequent cleaning and honing of the bits didn’t help enough. The next bench will definitely have a hardwood top.😀  The good thing is that I can use this bench for now until I save up money for a bigger bench with a solid top.

Even still, to have a rapid release vintage vise that has a 3 inch thick red oak vise chop is an awesome addition to my bench. Now I can hold a Windsor chair seat in the twin screw vise and easily hold chair spindles in the newly installed end vise.  Believe me the twin screw vise is a sweet way to make Windsor chair seats.  By having all the bench dog holes I have every possibility of using 2 or 4 point hold down configurations with the bench dogs in either vise and also have gobs of holes to use for securing stock with holdfasts.  I love the freedom it gives me.  You might like roughing it more with a handful of dog holes.   However, with my bench I can work on either chairs or just about any kind of carving project. There is reason to celebrate here!

Thanks for looking! 

 

 

Tail Vise Tale

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My tale picks up with the vintage vise I recently bought at an antique mall. My purchase of $27, as you’ll soon see, has been rewarded. I am happy to say that the evaporust application, light sanding, and wire brushing made it look like new. I treated the clean metal castings to Rustoleum primer and then a Rustoleum black semi gloss oil enamel coating. I’ll make a new handle out of some scrap walnut. The dog slot will be left empty for now since it made no sense to fabricate a steel one. Perhaps I’ll mill a chunk of wood to fill it for esthetics.

What I opted to do with the vise was to use it on my chairmaker’s bench. This bench is an evolving bench project. In my mind a workbench doesn’t have to be a thing of beauty, but just function well. Practicality and economy kinda dictate that route for me as a woodworker. I still plan to build a nice Roubo bench based on a Chris Schwarz design when time, money, and situation allow. But for now I will tweak the design of this chairmakers bench. The centerpiece of this bench has been the Veritas twin screw vise, but due to the smaller footprint of the bench top, the design didn’t include a tail vise. I admit that I favor having two vises on a bench for a host of reasons. One of which is that I often use my vise for holding spindles so that I can shape them with drawknife and spokeshave for Windsor chairs. So buying this antique vise, and reconditioning it, got me wondering how it might become part of this very stout but smaller bench. By beefing up the dimensions of the undercarriage it showed me that pine/fur stock offers plenty of mass for any hand tool work I’ll do. Bottom line the bench doesn’t move.

With no bench top overhang on the end, I cut a 10 inch by 3/8 inch deep mortise in face of the top stretcher (4 by 4 inch stock) and then mounted the rear jaw flush with the side of the bench. This also required me to cut another mortise about 10 inch by 1 1/8 inch deep on the underside of the stretcher. The only negative that I have with the installation is that the chops have to be fairly wide, 6 inches, to accommodate the installation of the vise. Alternatively, I could have made the chops even wider and passed the vise screw and guide rods through them. The tail vise is mounted at the base of the stretcher versus installing it directly underneath the 3 inch thick top. Judging by the trial fits the rear vise jaw will also include a 3/4 inch thick chop. When I designed the chop for the front vise jaw I realized that it could now include several dog holes in it to give me multi-point hold down capability on the bench from end to end.

My tale of adding a tail vise is to install a vise chop of red oak that is roughly 3 inches thick by 20 inches long. That length gives me 3-4 dog holes for clamping. I would have opted for a shorter length on the vise chop however the installation forced me to mortise the vise dead center on the top stretcher so that the bolts holding down the 3 inch thick bench top were left alone. By using 3 inch stock it eliminates any issues with the depth of the chops.

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Consequently, I rigged my tail vise to have a substantial length of about 20 inches versus the 14 1/2 inch length chosen by Chris Schwarz for a Roubo bench. Comments are welcome!

Hooked on Acanthus

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All it took for me this past week to get hooked on acanthus carving was to learn it through the instruction of Norwegian carver Hans Sandom. Of the ten students at the Milan Village Arts School (MVAS), I was one of two beginners to acanthus carving.  It was humbling to be around all the talent.   It was also great to see progress on their projects and appreciate their commitment to master this form of carving.  It’s contagious I think.  Kinda like finding old woodworking tools, you want to keep searching for them.
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On day one you have to learn the basics and variations of carving acanthus leaves. So after carving practice leaves for about two days, I started on a bread board carving project that looks deceptively simple until you start carving it. You quickly realize how much goes into carving the elements of the acanthus design. During the last day and a half I worked on a small shelf project. I completed half of the carving so I could complete the project at home.

  

  

  

  

  
  

Of all the things to bring, I left my larger V tool at home. If you carve acanthus then you know that the V tool is critically important in helping to define acanthus carving as you work into greater relief. Fortunately for me, Hans provided a V tool for me to use.  Some of the virtues of acanthus carving is that it comes with the challenge of maintaining your concentration, and taking the necessary time to cut smooth continuous bevels on the leaves. It takes patience, and, then when you get into it, you can loose track of time which is a good thing. It offers a needed respite from what many have as occupational stress.  Since I have wanted to take a class in acanthus since 1997, this has been a real treat for me.

You might ask why did I opt to learn acanthus at MVAS?  Aren’t there some other carvers that you’d think of right away?  Well, MVAS is a lesser known jewel in southwestern Minnesota that offers classes in Scandinavian folk arts.  I recommend that you check out those opportunities.  For one thing, Hans Sandom and Bob Yorburg are among the few carvers to recently publish anything on acanthus wood carving.  Get their book Acanthus Carving and Design and you’ll see that not all acanthus is the same. It isn’t all the same even in Norway or Scandinavia.  Having the last name Paulson (it was spelled different ways over the generations), has inspired me to also celebrate some aspects of my Scandinavian heritage.  I have ancestors on my dad’s side that can be traced back to the New Sweden Colonial settlement in Delaware around the 1600’s.

Another great school of Scandinavian folk arts is at the Vesterheim National Norwegian-American Museum and Heritage Center in Decorah, IA.  I have been to Vesterheim and have become a member of the museum, but this was my first time to MVAS. I look forward to pursuing this style of carving with all it challenges including the art of painting those carvings in the Scandinavian tradition.  Like putting on the veins of the leaf, one has to be careful not to ruin the whole piece by rushing the completion. Careful and deliberate effort pays off in accenting and not detracting from the beauty of the piece.

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Plane Healing

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Let me introduce to you a Stanley 10 1/2 carriage maker’s rabbet plane that might have a new life in my shop. Some time ago I purchased this 10 1/2 along with a set of old woodworking tools. It was already broken and the owner had repaired it with a mending plate that was attached with small screws. Perhaps it fell from the bench and hit a concrete floor, I’ll never know. The point is that it sat for many years waiting for someone to restore it to usable condition. Recently, I took it off my plane till and decided to check it out. I enlisted a friend to repair it in a machine shop. I wimped out in trying to go the silver solder route on my own. To my surprise my friend found not one, but several fractures in the plane body that were caused from that earlier fall. You can see the fracture locations based on the repairs. Now that I have the plane repaired I hope to give you a follow up post on how the plane performs after lapping the sole and sides with multiple grits of sandpaper. Remarkably the frog was not damaged in that earlier fall and the plane is complete on parts. I am excited that this repaired carriage maker’s rabbet plane might help me move one more step toward an unplugged shop.

Foot-Powered Shop

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It is fair to say that besides me watching Roy Underhill use old tools on the Woodwright’s shop, what really got me hooked in the early 80’s was his passion for using foot-powered woodworking equipment. In fact, it led me to buy every one of his books as soon as they came out and then to start dreaming of building a treadle lathe. His lathe made of 2 x 4’s and 2 by 6’s got my imagination going about turning on a primitive lathe. Little did I know that I’d eventually build two foot-powered lathes based on his books, I’d pick up a treadle grinding wheel at a flea market in Springfield, Ohio, and that later I’d start to design and build a treadle scroll saw of my own design around 2007. My first foot-powered machine was the treadle lathe that Roy routinely demonstrated turning with on the show, except that on mine I treated the lathe to some chip carving on the sides and front edges of the 2 by 6’s.

Chip carved treadle lathe

On the portable spring pole lathe, featured in Roy’s books, I pretty much followed the Hulot design to the letter so I could use it for demonstrating at re-enactments. Some were held at the Herkimer Home a Revolutionary War Era site in Upstate New York, the Historic Fort Wayne Site (Fort Wayne, Indiana), and at the Fort Meigs War of 1812 Battlefield site in Perrysburg, Ohio. The amazing thing is that since transitioning to seminarian and then ordained ministry in 2004 and several moves later, I managed to retain these primitive machines simply because they have become part of me as a woodworker. As my wife Barb knows, the electric machines go first if I ever have to downsize the shop.

my spring pole lathe

But while I was living in Upstate New York, I also got the bug to build a foot-powered scroll saw. I looked at what others had done and again such things can motivate one to self expression. That proved to be true in my case. My treadle scroll saw design subsequently evolved over 2007-2015. Here is a picture of how it looked until this last year.

Victorian scroll saw 2007

In 2015, I made a bunch of nice refinements on the scroll saw, especially last summer. If you want to see how over the top I got with my refinements on the treadle scroll saw, you can see it in the Shop Talk section in the March/April 2016 issue of Woodworker’s Journal. http://www.rockler.com/woodworkers-journal-march-april-2016
I am delighted that Joanna Werch Takes of the magazine took an interest in my treadle scroll saw. If you know me pretty well you can imagine that I rolled some Victorian scroll saw designs and even some chip carving into the final product. I am also grateful to my machinist friend Bill who came to my rescue and helped me by redesigning the sprocket hub that now has greatly improved the ability to secure the BMX ratcheting freewheel gear. My awesome scroll saw has been dubbed “A Victorian Scroll Saw.” Check it out! Here is a peak at it.

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Who Made It?

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Any ideas who made this woodworking vise?  I purchased it at a local antique mall.  It is heavy duty in construction, has rapid release, and appears to be in decent condition.  The only thing missing is the steel dog.  I’d like to use it as a vise on the next bench project.  The only surprise was the 1/4 inch offset in the cast iron at the top corner between the front and rear vise jaw.  It doesn’t matter since the jaws will have wooden vise chops.  There is no identification on the vise.

Too Many Dog Holes?

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One thing you learn as a woodworker is that what is good for somebody else might not be good for you. Alternately, what works for you might not work for another person. Take my chairmaker’s bench that I built roughly a year ago already, I love the bench. I modified a design from woodworker Drew Langsner and incorporated some other features. After seeing the storage compartment on a Chris Schwarz bench, I added one to mine. I like having a storage compartment underneath. I would have liked to build the whole bench longer with an end vise/tail vise, but I had space constraints. The trick with the hinged storage area underneath is you don’t want to store things on top of it. Dah. In particular, I love having all the dog holes through the bench top. I’ve heard other woodworker’s complain at different times that they don’t like benches with that many dog holes. That’s when you hear that a bench top looks like Swiss cheese, but my response so don’t have them. Having that many dog holes works for me and I like them. My clamping needs and preferences are clearly different than yours if you only need less than 10 dog holes. Even my Ulmia carver’s bench which has two rows of square dog holes has 30. It might not look as esthetic for others to have 30 plus holes, but as a practical woodworker I appreciate the capability. Whether it is making a spoon, fabricating chair parts or holding a woodcarving, I want those clamping options. When I invested in the Veritas twin screw vise, it made all the holes that much more important. Don’t get me wrong, some day I’ll build a thick Roubo bench with dovetailed legs, wooden threaded leg vise, and a nice tail vise, with significantly less dog holes. I don’t plan to do it for awhile though. Other than having a fastener or dust fall through one of the many dog holes on my current chairmaker’s bench, the benefits for me far outweigh the disadvantages.

What is an exciting new addition to my chairmaker bench is that I now have a WoodRiver Patternmaker’s or Gunstock Carving Vise. If you don’t have one, it is sweet for holding anything higher on the bench. I just used it to trim some tenons on some dining table aprons. All it takes to mount the vise is to find a dog hole to attach it anywhere on the bench. Options for changing orientations of stock are there. How cool is that? Like some others, I confess I drooled a little over the elegant Benchcrafted Carver’s vise, but I simply couldn’t afford the cost. Nor could I find the time to build a similar carver’s vise from scratch right now. If you’ve looked you know that there are some nice designs for building a vise for above the bench top clamping. Other than the lower part being cheaped out on the Woodcraft carving vise, by using stamped steel instead of cast iron, I am quite happy with the new vise. Replacing the light weight base with something heavier is one of the upgrades I’ll eventually make.

Woodcarver's Vise

Woodcarver’s Vise

Woodcarver's Vise

Woodcarver’s Vise

Since woodworking is such a broad application, I am glad for being blessed to do it. Whatever the interest level a person has in woodworking, there are numerous publications out there that can feed you with inspiration, new knowledge, and offer project ideas. To that end I have enjoyed Popular Woodworking Magazine for years and it was Fine Woodworking Magazine before that, but let’s face it our tastes change and publications change. I’m a currently a subscriber to Popular Woodworking, but I find other woodworking magazines also helpful at different times. The fact is that we have many opportunities to share woodworking information through magazines, blogs and websites, to take a class, to buy a DVD, or to watch a video clip on YouTube. What’s growth for me though has been to focus on my experiences of hand tool work in the moment. I find that my just doing the activity of woodworking gives peace, provided the performance goals are kept reasonable. If you read contemporary spiritual leader Thich Nhat Hanh sometime, you’ll get the idea that savoring our experiences is key to finding joy and contentment. Perfectionism can hold some of us back from the enjoyment part and if that is our experience sometimes, then think about using mindfulness as a way to keep the fun in woodworking. I won’t define it here, but suffice it to say that it involves greater appreciation for what you are doing as you do it. If your shop time gets squeezed in with all the other priorities, or you succumb to feeling some pressure to accomplish a lot on a free day, then enjoying the experience in the present tense may help you as well.

My Woodcarving Rantings

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Chip Carving Knives

Chip Carving Knives

It is new for me to contribute features for magazines, but I’ve already learned that it does fire up a person to do new and greater things in woodworking. Truth is that I have more challenging projects in mind now than ever before. First, I am very thankful to the great folks at Fox Chapel Publishing for giving me the opportunity to write about using carving to personalize a tool chest.

You can find a reference to it here http://woodcarvingillustrated.com/blog/woodcarving-illustrated-winter-spring-2016/

Their publication is great for inspiring people of all skill levels to try and excel at woodcarving. It was fun to share about my woodworking/woodcarving experiences in this recent issue. Second, I want to say that I think chip carving really gets a bad rap in woodworking circles and it really puzzles me. It seems there is some thinking out there in the woodworking world that if you don’t use a chisel and mallet to carve something then you haven’t made it into the realm of fine furniture. Frankly, that is crap and this comes from a preacher/woodworker who chooses his words carefully. I for one use carving chisels a lot and while I am not into chip carving plates per se, I’ll argue that there is great skill in using one tool, a sharp knife, (see photo above) to make V shaped cuts in wood. True you are limited to softer hardwoods or pine. But heh when it comes to reproducing country furniture that many of us still love, chip carving has greatly enhanced many pieces over time. Look at how cool it is to add chip carving to a handmade wooden spoon. It definitely personalizes it. Bottomline, think and say what you want, but if it suits me to pick up my chip carving knife and to add some motifs that compliment the piece, then I am going to do it.

Saying all that, in 2016 I am going to learn more and more about acanthus carving, letter carving, and flat carving which all use chisels. It is the challenge of learning something new more than anything else. When it comes to acanthus, I am partial to the Norwegian/Scandinavian approach to it. It is me and I have some Swedish blood in me. I am and have been in love with woodcarving for a long time. I think a real woodcarver has multiple approaches at his or her disposal and that chip carving has its place among them.

Thanks for reading my rantings,
Jim

More Carving Talk

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I begin 2016 by sharing that I have a three page article entitled “Tips for Personalizing a Toolbox” in the Winter/Spring 2016 issue of Woodcarving Illustrated Magazine. As you can see I even made it to the cover.   The article discusses my carved chair maker’s tool chest that I built just before I took my first Windsor chair class in 2007.   It was a class to build the Sack Back chair. Thank you to the editors of Fox Chapel Publishing for giving me this opportunity to be in print. 

Mike Dunbar in Hampton, New Hampshire, has been my teacher for Windsor chair making.   Mike recently announced that he and wife Sue were retiring from teaching Windsor chair making and that the buildings at the Windsor Institute were sold.  I wish them good health and the very best in this transition.  Now whenever I look at the top of that same carved tool chest I will remember all the people, like Mike, who have influenced my woodworking.  

You see I was blessed, like many others, to catch the bug in the mid 80’s to build Windsor chairs simply because we had champions like Mike. They kept up the appreciation for reproducing these fine and classic specimens of American furniture.  But as things change, I look forward to what inspirations in 2016 that I’ll have in exploring my passion for wood carving. My chair work will continue and one reason is that wood carving remains very important in making beautiful reproductions of Windsor chairs. Likewise with wood carving, I am grateful for having been taught and influenced by many outstanding wood carvers who enhanced my carving skills.  Stay tuned as there is a good chance that you’ll hear more carving talk from me.  

Snipes bill postponed

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This sweet little jem just arrived and it will make the more eliptical bead I need to finish stretchers on a couple 18th century tavern table projects.   I can happily wait on making a pair of snipes bill planes now.  I do like the snipes bill planes made by Hackney Tools (http://hackneytools.com/2015/02/making-your-own-moulding-planes/. My jem here is a Sandusky Tool Company 3/8 inch bead molding plane in pretty good condition.  You never know what these babies will look like when you purchase them online, but I’m thrilled with it.

beading plane

Homemade Snipe Bill Plane?

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Do you ever get sticker shock about a possible tool acquisition and say heh I can do that on my own? I can just make one myself.  I’m sure you do.  That is the way I feel right now about possibly making a snipe bill plane.  Then it comes down to whether it would really cost me more in terms of time and money in the end to make something myself. But if you know me, then you know I can build tools when I get the bug. I’ve built planes, saws, and foot powered machinery already myself, but a snipe bill plane looks more demanding in some ways. Yet a challenge can be a good thing for some of us. Suddenly you crave information, right?

Well I have several books on plane making and Todd Herrli’s DVD. A Larry Williams DVD (Lie-Nielsen) may soon be on my wish list too. By the way I have numerous molding planes including hollows and rounds so my interest in a snipe bill is not rash.

As one who comes from more humble means though, I am moving toward making a snipe bill molding plane. Why? Because my love of wooden molding planes goes back to the late 70s and early 80’s. I use them on occasion and love the details they offer.  I especially lean toward making tools that are hard to find, otherwise expensive to buy, and yet useful on projects I would need them for.  Bottom line, I am not content to pass up a chance to preserve a classic detail on a piece of furniture I know will outlast me.

I bet that sounds familiar to some of you. So if you’ve built one please let me know. I’d love to hear about your experiences. I like the idea of having flexibility on making bead details on furniture.

Thanks,
Jim

Shaping Up

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Cherry has always been either my favorite wood or very close to it for much of my woodworking projects. Here I am showing a cherry spoon that I recently carved and to which I added some chip carving on the handle.  Personally, I find that the process of shaping and carving spoons to be conducive to meditation and that it invites reflection and prayer.  Our lives are generally quite busy and this activity has its own pace.  Since you really can’t add the wood back after it’s been carved away, it tends to slow you down to concentrate on what you are doing.  In the doing you also produce something useful that can be used in the kitchen.  

The cherry was cut by one of my parishioners. Since I started carving spoons I’ve been having fun with carving designs that are more free form. Spoons lend themselves to adding free form carving designs. What is appealing to me is that it doesn’t have all the fuss with exacting dimensions on the layout, yet it has the charm of folk carvings from the past. 

What is also happening for me is that I’m getting closer to that idealized “S” shaped spoon profile that is indicative of the Swedish spoon carving style. Even though this stock was dry by the time I carved it, it still came out great in my mind. My goal is carve several about the same size and then build and carve a spoon rack. I hope to do that in the next few months. Stay tuned.

Stem work

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 I think that I’ll stick with carving spoons at least occasionally, but I am preoccupied now with getting the shape of the stem just right. When I look at a Peter Follansbee spoon, I’m drawn to the graceful curves he often leaves on the stem right before the bowl.  The simplicity and appeal of his wooden spoons is definitely there, but the stem is where I am learning to slow down.  After several spoons ending up with straight stems, I’ve seen the light on esthetic appeal of spoon stems with gradual curves. Leaving enough wood on the stem to work in a sweeping curve is my goal now.

Embarking on spoon carving is very appealing for many reasons, but I think the major aspect that I like is that it is eco friendly. If you make spoons you don’t have to discard or burn trimmed tree branches it is prime material for gobs of spoons.  Plus you don’t need to drop a whole tree for stock.  Pretty cool right there, but also sweet in terms of investment cost.  If you pay attention to safety and once you acquire the basic tools,  the  processing time is short.  Great for those woodworkers with limited shop time.  As full time clergy that is one of my challenges to squeeze in my shop time and still see something get done. 

Here is my most recent spoon and this time I made some strides on leaving enough wood on the stem and bowl to incorporate the sweeping gentle curves that are so distinctive on Swedish spoon carvings.  I’ll be paying more attention to incorporating the gentle curve on the profile off the spoons as well. My spoons still seem too bulky, but I’ll be working on aspect as well. 

Card Scrapers Cleanup Spoons

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 I’m getting hooked on carving spoons now and I found card scrapers to be very helpful as a final step.  As a Windsor chairmaker I appreciate how helpful scrapers can be in the final smoothing of oak spindles.  Now as I’ve focused more on the general profile of the Swedish style spoons, I’ve been delighted to successfully employ both straight and curved card scrapers on the final smoothing step on spoons.  Once I had 99% of the spoon carved and the apple wood had dried, scraping proved to work great to achieve the finish I wanted.

I obviously didn’t include chip carving on these two spoons, but that will come later in subsequent spoons. I realize that wooden spoons can come in different shapes, but wow are these puppies strong by design. This dried apple wood gets very smooth in the final knife work, and you may find scrapers to be helpful also. The spoons were oiled with flax oil purchased at Kroger in the refrigerated section.

Thanks for looking!

First Spoons

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Hi everyone,

I am blessed that some nice folks gave me some cherry and apple wood recently so I could carve spoons.  Here are some initial spoons that I carved, but I confess to be humbled that it will take a while to get the right look.

Eventually, I’ll take a class, but for now I welcome any comments. I think the book Swedish Carving Techniques is quite helpful, yet for me you can only glean so much from those resources. Nothing helps more than having an example right in front of me.  

    
   

Awesome New Bench Dog Clamps

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Hi Folks!  Check out these new Armor Tool clamps (auto-adjust in-line dog clamps) that you can get at Woodcraft.  I saw them in action at the Toledo store when one of the staff, Tom, used them in a demonstration for InLace  (I also like InLace, although I realize this might be complete heresy to my fine woodworking colleagues who swear by inlaying ebony or use black dyed wood strips in period pieces.)  I tried a pair of those bench dog clamps just the other day to hold a new carving project and let me tell you that they were truly superb in gripping and holding. I used them on my new bench and they are worth every penny in their utility.  What I especially liked was the ease of adjustment for one thing.  You see I was tempted to buy one or two Veritas bench dog clamps from Lee Valley Tools.  I am a Veritas tool enthusiast and appreciate their quality and excellent design. But I like these Armor Tool clamps and can see myself using them quite often and I don’t regret putting in all the many dog holes in my new bench. I honestly bought these new  

bench dog clamps for spoon making, but heh they’ll work in so many applications and that is cool!

Finding A Couple Handsaws

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Sorry that it has been awhile since my last blog.

I had some fun when I stumbled onto a couple of handsaws while traveling.   Barb and I had the opportunity to do a little antiquing in Michigan this week.  I was attending a continuing education class for my work as a pastor and in our free time we visited some antique shops in the Traverse City area.  When I spotted the Disston D12 with an intact handle and decent blade, I got excited.  You see the distinctive handle on the D12 and the professional quality of these tools continues to have great appeal to many woodworkers, including me.  This one was made after World War II based on some quick research.  One of the characteristics of that saw production is that it sports nickel plated brass saw nuts.  At another shop I found a Disston D8 saw with an intact handle and plenty of steel left in the blade.  As you can see, both saws have five saw nuts holding the handle onto the saw blade or plate and the handles are also made of apple wood.  A great resource on the identification of Disston handsaws can be found here:  http://www.disstonianinstitute.com/quickglance.html

The good part for me is that these saws were affordable and are without condition issues so they can be restored to workable condition.  Here are some pictures of the saws.  One of the saws, the D12, has an etch that is still visible and some wheat carving on the handle.  I’ll make another post when I’ve had the chance to clean the blades, refinish the handles, and sharpen the teeth.  Thanks for looking!

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A Bench with Teeth and Storage

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I finally completed my chairmaker’s bench so I can get back to building Windsor chairs. One of the tasks was to cut a through mortise into the bench top for a planing stop. The planing stop measures 3 by 3 by 6 inches and is red oak. It includes an embedded forged iron stop with a hook and a sharply filed toothed edge. The toothed edge is for gripping and holding furniture parts on the bench top. I’m ashamed to say that over the years I haven’t bothered to use a wooden bench stop, but I have utilized steel bench dogs to provide a similar function. To attach the toothed stop to the oak block, I had to cut a mortise approximately 7/16 inch square by 4 inch deep. I excavated it with a couple brad point bits and a few chisels. I then worked to fit the toothed and oak planing stop into the through mortise in the bench. I used chisels and rasps to clean it up. It proved to be challenging to keep the mortise sides square and 90 degrees vertical in the laminated top. To strengthen the mortise walls in the laminated top, I coated those surfaces and the many dog holes with epoxy from the West System. Based on the recommendation of the folks at West System I opted for the 105 epoxy and the 206 hardener products. It has the consistency of syrup and it slowly hardens the plywood laminations. It worked great! Also, just because it is quite like me to slip and get a cut with edge tools, I followed my wife’s suggestion to install some polyethylene tubing on the toothed edge of the planing stop when the stop is not in use. Yeah Barb!image

Rather than damage tools that might potentially roll off the bench top, I built a tool tray across the long edge out of 3/4 inch stock. It measures 8 inches wide by 48 inches long. I used oak and assembled it with through dovetails. I usually cut the tails first and then measure for the location of the pins. I marked the pins with some very sharp French marking knives I obtained from Garrett Wade some time ago. They offered them with left and right hand blades and I found that I can accurate scribe the pin locations with them and it saves me time in the fitting. The ebony handles are also easy for me to keep track of on the bench. After scribing the pins, I used a couple back saws to cut the tails and pins and a coping saw was used to remove waste between the pins. This time I found that my chopping skills with a sharp chisel made it possible to easily pare to the scribe line on the pin end. I chop from both sides so there is no tearout and it leaves a hollowed area in the middle which aides in making a tight dovetail joint.

At the suggestion of Chris Hedges on Google plus, I also gave dovetail peening a try. Although my gaps were insignificant except for one spot that required doctoring with veneer, the peening turned out to be a great enhancement for my dovetailing skills. The bottom is made of 3/4 inch poplar and fits into a 1/4 inch rabbet. I added a center divider that was installed with several flat head slotted screws. It gives me the option of relocating the divider if it makes sense later. One added benefit of installing the hardwood tool tray was that it helped maintain flatness on the bench top. I used four 5/16 inch dia lag screws to attach the tray.

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As Chris Schwarz found useful on one of his many Roubo bench builds, the area inside the stretchers offers another place for tool storage. Since I continue to use a similar area on my carving bench as shelf storage, I know all too well how things vibrate on that shelf area or get covered with dust and wood shavings. So instead of just using that space as a shelf, I enclosed it with a frame and panel lid. I made the lid components out of red oak and assembled it with draw bored mortise and tenon joints. I installed it with strap hinges from Van Dykes (source provided by Chris Schwarz). To compliment the black strap hinges and lid support hardware, I added a black cast iron shutter pull ring obtained from the House of Antique Hardware that made opening the lid more convenient.

After adding the pull all that’s left is trimming some bench components, sanding/filing away some epoxy in the dog holes, cleaning up some wood filler on the legs, and applying BLO. The good thing is that this “holey” bench, with 27 dog holes, is just the right size for my workshop space.

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Carving Decisions

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Can’t decide yet if this oak frame and panel lid warrants some carving.  It will cover the tool storage area in my chairmaker’s bench.   I fashioned it in a similar way to the lid and compartment Chris Schwarz made for his Roubo bench. My thoughts are to do something minimal like add the date or a word or two in Roman style lettering in the center of the panel.   Cutting the letters/numbers with chisels in the oak is my inclination.  I haven’t tried that before with chisels, but this seems to be my motivation now.  There is something classy about letter carving on flat surfaces.  I’d go minimal because this lid may still get things stored on it.  It really shouldn’t though as then the tools in that compartment are inaccessible. The panel is flush so it doesn’t have the raised edge, but for a tool storage lid it works here.  It was a joy to cut these mortise and tenon joints in oak.  The parts are assembled dry fit so I can work with carving the panel by itself.  I really like the grain.  A few spots are visible that will get cleaned with alcohol or mineral spirits.   Any thoughts?



Windsor Chair Experts

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hand carved arm detail

My first exposure to a Windsor chairmaker was a seminar by Thomas Moser that I attended at the Woodworker’s Store (Rockler) in Denver around 1985. Tom came and spoke for an evening and I was truly wowed by his presence. Here was a professional and accomplished fine woodworker and I got to see him in person. I had already spent a few years pouring over his trailblazing book How to Build Shaker Furniture by Sterling Publishing in 1980, and then I got his autograph. He saw all the worn pages and pencil marks, and then he added his signature. You see I had used his book to build Shaker ladder back chairs for my family and it was enough to give me great results. The picture of Tom’s unique continuous arm Windsor chair that he demonstrated never left my mind from that seminar even though I didn’t venture to build one later his way. Tom’s unique design involved a laminated arm as opposed to using green wood split from a log, steam and a bending form. Afterwards, I can’t tell you how many times I looked at the picture of Tom’s continous arm chair in his book titled Windsor Chairmaking, published by Sterling in 1982. Yes he autographed that book too!

My point is that while I found it quite manageable to build Shaker chairs from a book and I still do, building Windsor chairs on your own is another animal. If you Google Windsor chairmakers you’ll find many many websites and you’ll find many Windsor chairmakers. What means more though is what you hope to get out of it. Are you taken in by the Windsor chair as an art form? Or are you taken in by a style of chair that has continued appeal since the 1700’s when the Sack Back Chair first became popular. Do you hope to make a business out of selling chairs? I say all that because it matters where you come from as a possible student of Windsor chairmaking. My first Windsor chair was purchased at a garage sale in the late 70’s and I confess I didn’t realize then that it was a later variation of a Windsor chair. My first look at a more recognizable Windsor chair form happened in 1986 after I was laid off from my petroleum geologist job and was invited to estimate the cost of repairing not one but a whole set of Windsor chairs. At that time even though I needed the money, I declined the offer. You see I didn’t want to touch something that was so beautiful and a valuable antique without having the full appreciation for the construction and value of a Windsor chair. That is where I come from in valuing antique Windsor chairs.

So what does this post have to do with Windsor Chair Experts? With so many experts available it matters how you see Windsor chairs and whether you appreciate them as full of history, solid design and construction, and as an example of fine craftsmanship. When there are so many teaching opportunities and books available, having answers to such questions will help you decide which expert you want to study under. You can find an expert who has made chairs for years or ones that have made them for several decades. You can find an instructor who can teach you how to turn as part of the class if you need that training. I learned to turn spindles in my High School woodworking shop class back in the early 70’s, but you can acquire such ability through other channels. You can find an expert that builds chairs along with a host of other things or you can find one that builds only Windsor chairs. You can find one who builds and designs chairs with an artistic flair and picks and chooses what to keep from tradition. You can find one that builds chairs in the manner and design that leads you to have a faithful reproduction of a Windsor chair. I have chosen the latter and prefer one who knows what a chair leg from a Windsor looks like from the originals. If you are familiar with the voluminous and well researched publications of Nancy Goyne Evans on the history and evolution of Windsor chairs, then you’ll appreciate my comments.

When I think of Windsor chairs I think of Mike Dunbar. Since 2007, I have been hooked on building Windsor chairs. My training was obtained through Mike Dunbar at the Windsor Institute. I’ve completed six chairmaking classes with Mike and his staff, and I can tell you he is an undisputed expert in Windsor chairmaking. In fact, I’m sure I’ll be back there to tackle another Windsor chair. One of the virtues of studying chairmaking under one master is that you develop a consistent pattern for how you tackle various tasks in chairmaking. That said, I’ve also been blessed by the contributions of other Windsor chairmakers, especially the ones who are blessed to work on chairs for clients every day in their shops. I’m excited now to pour over Peter Galbert’s Chairmaker’s Notes, published by Lost Art Press, so I can glean some nuggets about his approach to building Windsor chairs. Since my primary calling is serving as a Lutheran pastor, my shop time for building Windsor chairs is limited to available free time . If you like the New Hampshire area and have a week available, I encourage you to call the Windsor Institute, talk to Mike about taking the Sack Back class, and then check out Lamie’s for lodging in Hampton. Studying with Mike for 5 days is kinda like being an apprentice in miniature rather than the old days of doing it over several years. Bottomline, if you can it is worth every penny to find a Windsor chairmaker and to study under them. My two cents.

Paring for the Planing Stop

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Months ago I received my iron planing stop that I ordered from Blacksmith Peter Ross. It is very well made and worth the wait. I had planned to install the iron planing stop in a new workbench. Since I opted to build a smaller bench just for fabricating Windsor chair seats based on a design by Drew Langsner http://www.countryworkshops.org/newsletter16/bench.html, I wanted to incorporate the iron planing stop into the new bench. There are a whole lot of ways to make or install a planing stop. I’ve used boards temporarily clamped to the bench top and bench dogs. I’ve seen boards attached to ends of benches or even down the center line of a bench as in a split top Roubo or Nicholson. However, what was appealing about the planing stop made by Peter Ross is that it has teeth meant to be embedded into the end of the stock. Chris Schwarz observed that these toothed iron planing stops were depicted on artwork showing Roubo benches. He also indicated that the teeth on the stop might need some sharpening to grip the stock. See his posts at http://www.popularwoodworking.com/workbenches/schwarz-workbenches/getting-bit-toothed-planing-stop and at http://blog.lostartpress.com/2013/08/13/french-oak-workbench-the-planing-stop/.

Yesterday I got out a sharp chisel and a mallet, and used an extra long 3/8 inch brad point bit in my cordless drill. Before I started drilling holes for the through mortise, I used my chisel to outline the four sides. This led me to excavate down about 3/16 of an inch so that the birch veneer was less damaged on the top. It also helped me to spot the holes in the 3 by 3 inch area. After drilling holes side by side around the edge of the 3 by 3 inch area, I began chopping with a chisel between the holes. Eventually, I removed the block of material from the mortise so I could begin paring the surface of the four sides. The paring is important so that planing stop can be moved up and down with reasonable effort. This means the walls need to be vertical and square to accommodate the fit of block for the stop. The next step will be to glue up the hardwood block, trim it to size and then start fitting it to the through mortise. After that step I’ll fit the iron planing stop to the wooden block. My plan is to take my time by drilling a hole and then paring it to fit the toothed planing stop. Hopefully, I can avoid a force fit that might crack the planing stop block.

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What paring chisel is in your tool chest? Paring chisels aren’t designed for use with a mallet. Instead paring chisels are very sharp and have a lower cutting angle (20 degrees) and are therefore pushed to remove thin shavings. I believe that my paring chisel of choice is a lesser known one. About 16 years ago I bought a couple bent shank (or crank neck) paring chisels from Diefenbacher tools http://www.diefenbacher.com/paring.htm. I bought them to help complete the slant top writing desk I was building for my wife. Back then I obtained the 1/4 and 1/2 inch size chisels. The chisels sold by Diefenbacher are made by Buck Brothers and are no nonsense in appearance and function. The handles are fairly big, even homely, and yet they work well in the hands. I have been thoroughly happy with their performance. They hold an edge period.

In fact, I recently received another two bent shank chisels from Diefenbacher tools as a gift so that I can use them for paring on larger mortises. I can tell you that I’ve used those same bent shank chisels for paring the mortise for my new planing stop.

As many woodworkers point out in blogs it isn’t how many tools you have, but having the best tools for the job at hand that matters most. As a carver I’ll go one further and say it isn’t how many tools you have, but which ones do you keep sharp that matters. Really though, I think most of us would agree that we have been blessed to have more access to wonderful tools for fine woodworking when compared to 50 years ago. There are many reasons for that too. Most importantly, having a very sharp paring chisel is a must for cleaning out a mortise.

My point is that one of these modestly priced bent shank chisels would make a good addition to your tool chest. The shank of the blade is 6 3/4 inches long which gives you a whole bunch of flexibility for paring tasks. Diefenbacher sells this line of chisels for $25.60 for the 3/8 inch up to $37.30 for the 1 1/2 inch one. They also sell straight shank paring chisels. It has been a blessing for me to own these.

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Installing Iron Planing Stop

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An iron planing stop, obtained from Peter Ross, is also going to be installed on my chairmaker’s bench. Ever since I read about these on Chris Schwarz’s blog a couple years back, I’ve had the bug to try one. Peter is a busy guy and the planing stop is worth waiting for as his workmanship is outstanding. Well this little bench as heavy as it is now will be a good place to try it out. It will have to do until I finally build a big Roubo bench in several years. I hope to cut the hole this weekend using a auger, saber saw and chisel or two as Chris Schwarz had described earlier. Finding a good piece of 3 inch by 3 inch oak will probably be accomplished by gluing up a couple pieces to thickness until I have larger stock available.

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Chairmaker’s Bench Project

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Tongue and grooved pine boards and trim were added for a tool storage area.

Tongue and grooved pine boards and trim were added for a tool storage area.

I don’t know about you, but sometimes distractions have the benefit of energizing me to take on the bigger tasks. I have two tables and a dozen Windsor chairs to make and I was looking for an improved method of holding/securing the thick pine chair seats while I fashion them with hand tools. I was excited when I found a design for a chairmaker’s bench on Drew Langsner’s website for Country Workshops (www.countryworkshops.com).

So here I go with building a modest 2 by 4 foot bench that will comfortably fit in my compact workshop. It features a laminated plywood top that exceeds the thickness of an earlier laminated bench top that involved three layers of 3/4 inch thick plywood. This one involved five layers of plywood that I had available from previous projects. After I laminated the plywood top I squared up the ends, trued the edges, filled voids in the laminations, and then treated the edges with two coats of epoxy. I made some modifications on the Country Workshop’s design by beefing up the size and weight of the legs and stretchers. My goal included a desire to make the bench plenty heavy so it didn’t move when I used a drawknife or spokeshave on the seats or other chair parts. One modification was to include a couple pieces of 1 3/4 inch thick red oak for the rear and front vise jaws. I notched the two front legs, which are roughly 5 5/8- 5 3/4 inch square, for the rear vise jaw.

The front vise jaw is a whopping 30 inches long with 24 inches between the steel screws. This bench features the Veritas Twin Screw Vise which is chain driven so that turning the right screw automatically adjusts the left one. I really like this vise. In the future I may opt to increase the length of the front vise jaw to 36 inches or more in length. With the steel support pins to clear the screws which are greased, the 30 inch vise jaw length limits me on clamping stock on the ends of the jaw like you would with a leg vise. Live and learn I guess. If I make another front vise jaw I think I’ll increase the thickness to 2 1/4 inches so it has more wood especially at the bottom edge. This would seem more optimal when you look at the amount of wood material on the inside bottom edge of the front vise jaw. Based on Veritas recommendations, the inside surface of the front vise jaw should be beveled about 2 degrees which means cutting away a wedge that is 7/32 inch at the base. You notice this more when you drill five 3/4 inch dog holes in the center of the vise jaw and counter bore them to 1 inch diameter for the bottom 2 inches. I’ll try it out the way it is for now. I need to make some chairs.

The legs started with douglas fir 4 by 4s that I laminated up with 2 by 6 and 2 x 4 stock. Needless to say it took a bunch of clamps and numerous glue ups. For the stretchers I used doubled up 2 by 6s and for the top stretchers I used 4 by 4s. With the design change on the front of the bench, it meant that the rear vise jaw became an apron on the bench. While I don’t like aprons on a bench per se, this modification gave me more control on assembling the bench together. Lag screws were used to hold the rear vise jaw and top together. Another piece of 1 3/4 inch thick red oak was used to help flatten the plywood top and to give me 3 1/2 inches of material thickness on the front edge of the bench in case I wanted to use F style clamps. That helped me avoid some otherwise unwanted limitations with an apron on a bench. In this case the rear vise jaw/apron is about 7 3/8 inches wide.

On this project I learned a lot more about using Forstner bits, upcut spiral router bits and brad point bits in a 3 inch thick laminated bench top. For one thing I didn’t realize that the Forstner bits being sold in many stores aren’t all made with HSS, which causes drilling speed to be more important when the bits are made out of carbon steel. Needless to say I lost temper in a couple of them and will now swear by HSS and not complain about the added cost. Nor did I have enough appreciation for the fact that the routing speed would matter as much as it did with HSS spiral upcut bits. It turned out that my standard go to Porter Cable router with 23,000 rpm was too fast for the 3/4 inch diameter Onsrud HSS bit I bought from Woodcraft. I used the spiral upcut bit on my bench top to make bench dog holes. Glen Huey of Popular Woodworking did a feature on using the upcut spiral bit to make dog holes on his benchtop using the same Porter Cable router. One difference was that my bench top is laminated plywood and Glen’s bench was hardwood. If you look at the 5 inch by 5 inch grid of dog holes you’ll see why it mattered to me. After about 5 holes, I discovered that the router bit burnt the wood and needed sharpening.

I am not done with the project. The many holes in the bench top will get an epoxy treatment so that the end grain of the plywood is hardened and durable for use with holdfasts and bench dogs. A West System epoxy with slower hardening time will be used on the dog holes. If I need more holes I’ll definitely use a lower rpm speed on the router bit and will see if my bit sharpening efforts succeeded or if I’ll need to task it to a professional machinist.

A couple things I am planning to do include building a tool tray for along the back side of the bench. I realized I needed this after my 3/4 inch brad point bit went rolling across the bench only to hit the floor. Man was I relieved to see that the spurs and center point were unscathed from the concrete floor. I use rubber mats but they aren’t everywhere. I also am using the area underneath the bench in the stretcher area for a tool storage compartment. I got the idea from Chris Schwarz (blog.lostartpress.com/2010/05/28/another-roubo-bench-fin/) and it entailed adding 1 inch square strips with glue and cut nails along the inside bottom edges of the stretchers. Roy Underhill also featured this idea on one of his episodes of building a Roubo bench on the Woodwright’s shop back in 2007 (French Bench). I then added tongue and grooved boards for a bottom that were attached with 1 1/2 inch long slotted screws. To accommodate some possible movement, I made the holes oblong for the screws and gapped the tongue and groove joints. What is left to do on the storage compartment is to build a lid with a raised panel and attach it with a couple reproduction T shaped hinges. If you like the hinges on Chris Schwarz’s bench storage lid they can be obtained from http://www.vandykes.com. I have an old oak panel that I will salvage for the raised panel and the frame will involve some red oak rails and stiles. I’ll post a follow up article when the bench is completed.

Thanks for looking. Blessings on your furniture making efforts too!

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Drill Press for a Chair maker

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Funny how the addition of a piece of machinery or a new hand tool can get you all fired up to build furniture. For years I’ve looked for any kind of radial drill press to add to my woodworking shop. I’ve had a bench top Delta drill press for years that I bought used back in the mid 80’s, but it has limited capability for drilling holes due to the shallow distance of the spindle to the column/post. Recently, I had the opportunity to acquire a used radial drill press and after some extensive degreasing and replacing the start up capacitor, it is now ready for action. It is the Delta 11-090 model which has a bench top design. Admittedly, it took awhile to clean it up. The previous owner had left the original cosmoline on it(a vaseline type preservative used to prevent rust accumulation) because he stored it in an unheated garage. The cosmoline was really caked on the metal parts and it took some elbow grease and kerosene to remove it. To my surprise the paint and exposed steel surfaces looked like new. Once the cosmoline was gone it was also no problem to adjust the depth and angle of the spindle. To make it suitable for chair making I made a new plywood table that is 16 inches wide by 30 inches long and 3/4 inch thick. The whole purpose for this investment was to perform compound angle drilling in Shaker ladder back and Windsor chair construction.

While I am quite capable in drilling holes using sliding T bevels and sight lines based on my Windsor chair training, I believe that this machine will help me to be more productive as a chair maker. I say that because I have limited shop time and I want to develop some greater efficiency in boring seat, leg and stretcher holes. I will also use it to ream the tapered seat holes for joining the Windsor chair legs with locking tenons. It will also help me to drill all the angled holes required with Shaker ladder back chairs that feature many leg and rung joints that have to be precisely drilled. This will not lessen the accuracy and fit of any legs, spindles or stretchers. Another benefit will be that any jigs I make now for Shaker chairs can be simplified because the drill press has capability to drill angled holes.

A couple critiques of the 11-090 that is worth noting is that the design is lacking for making adjustments for drilling various distances away from the vertical post (throat). Newer radial drill presses feature smoother adjustments through gears for the position of the spindle and the angle of drilling. However, this will not be a problem for me as a chair maker because I won’t be changing the distance between the spindle to vertical post very often. What I will be changing frequently is the drilling angle and that is easy to do with this model.

Likewise the height of the table requires manual adjustment, but that also won’t be a problem for me. Newer models usually feature a cranked adjustment for the height of the table.

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Homemade Frame Saw

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Colonial_at_school_006oppenheimI am a parish pastor whose occasional escape from ministry is working with hand tools.  I also enjoy teaching elementary school kids about 18th century woodworking and giving them a chance to see old tools in action.  In this first photo I was portraying a colonial artisan who told students about a frame saw (veneer saw) that was used to cut thin pieces of wood. Being a fan of Adam Cherubini, I had to make a big frame saw when he did a feature on them in Popular Woodworking several years ago. Being a scrounge and frugal, I also hesitate to buy things that I think I can make myself. Making tools is fun and even more so when I can experience the joy of using them. So here is my story, a parishioner helped me to get an antique frame saw while I lived in Upstate New York.  It was constructed with through mortise and tenon joints which were locked with wooden pegs.Jim's workshop stuff 002 I also studied Adam’s article in Popular Woodworking and the famous Roubo engraving showing frame saws. The result is that I built not one but two frame saws. The first frame saw employed blade holders made from cheap spade bits that I annealed and drilled to accept bolts for attaching the blades. Funny how those spade bits can be re-purposed for all sorts of tool applications. Jim's workshop stuff 012Jim's frame saw On the second saw, which was larger, I designed it to have the classic Roubo design which sported saw buckles as blade holders.  I used flat steel from a home improvement store to make homemade buckles to hold the blade. The buckles were made by forging them into a rough oval shape via my hand cranked track forge and then welding them together at overlap points using a Harbor Freight stick welder.Jim's workshop stuff 007 Once the buckles were welded, I cut slots to accept the blade. Securing the blade to the buckles was accomplished here by using steel cross pins that pierced each end of the saw blade/web and those pins were pulled against the buckle ends through the use of wedges at the intersection of the buckle and the arm.   On my first saw, I copied the original which sported a threaded blade holder which tightened against both of the saw arms. After I annealed the spade bits and shortened them, I cut threads on them to accept a washer and nut. For blades or webs, it wasn’t feasible to buy saw blades for my application at that time so I made a couple to my own specification. It wasn’t hard, I simply purchased some spring steel from McMaster Carr and then used triangular files. I found it enjoyable to make my first blade which sported a 24 inch blade and 4 tpi. The second blade wasn’t as much fun, and sported a 36 inch blade with 2 tpi. I made work for myself by breasting the blade to have 1/2 inch of curvature along the tooth line. You can assemble the saw frame in a lot of ways, my preference was to copy the original design I had which is mortise and tenon joints. By putting mortises in the arms and putting tenons on the ends of the stretchers. Tension on the blade automatically translated to compression on the stretchers. You may notice that the mortise and tenon construction is different between the two saws.  It doesn’t matter which way it is done, both methods of frame construction work.  I like the Roubo design, because the saw can be disassembled when necessary as the mortises are not pinned.  No need.  I appreciate the knowledge of our forebears and simply copied that construction technology.  For the Roubo saw, I made the arms of the frame by using 1.25 inch thick cherry and using 1.25 by 1.5 inch square pine for the stretchers. I am very pleased with the two frame saws that I made and I offer this an alternative to purchasing pre-made saw parts. photo 2 (1)   photo 1

Questions About My Foot Powered Grinder

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I was recently asked about my treadle grinding wheel that I posted on Youtube. There was interest in the substructure that supports the axle and bearings for the grinding wheel.  So before I give some details, I want to give a little introduction to my foot powered grinder.

Back in the late 80’s I had the opportunity to purchase the old grinding wheel at a flea market in Springfield, OH.  I was already 10 years into my passion for hand tools.  I was hooked on regularly watching Roy Underhill and the Woodwright’s Shop on PBS and often hunted for old woodworking and blacksmithing tools at flea markets as an escape from my environmental consulting work.  I still remember the look on my father-in-law’s face and Barb’s too when I tried to load the grinder into the back of their minivan.

The grinder features a big sandstone wheel that was a common item for any homestead in the 1800’s.  Most likely the grinding wheel was mined from the Berea sandstone, a 320 million year old geologic formation (Mississippian Age) that was famous for offering quality grinding stones. Settlers once mined the Berea sandstone in the Cayuhoga Valley for grinding wheels.  Here is a picture of the texture of the stone.

texture of grinding stone

Mine was originally a treadle grinder and it may have either been equipped with a water trough or a funnel above the stone for regular wetting to facilitate grinding edges on tools.  I don’t know.  Years ago I made a funnel and attached a vertical support rod so it would provide a steady drip of water. I have enjoyed using this treadle grinder and one day I might build a new carriage so the base is more stable. So far my modifications include the funnel, forging a connection link, and building a new treadle. I don’t do all my sharpening on it, but it is quite gratifying to grind a new bevel on one of my axes.

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Looking at the pictures you can tell that the front and the rear legs look different.  The legs near the tool rest are clearly the original ones and the other square shaped legs were added later by a previous owner.

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If someone knows more about the company, McD, that made these  I’d love to hear about it.

Thanks.

My Carving Axe

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I’ve been admiring the work of Peter Follansbee lately, especially his carving of riven oak panels and spoons. My Christmas gifts this year included some instructional DVDs and a couple hook knives.  All of this has motivated me to find and restore an old axe so that it functions as a carving axe.

I took an old Blombach axe, made in Germany, and retrofitted it with a new handle in the style of the Granfors Bruks carving axes.

axe disassembledaxe head before restoration

Here is a picture of the axe right after I removed the handle which you can see featured a metal sleeve.   I believe that my axe was probably originally setup to be the carpenters model.

The restoration began with me purchasing some hickory from a local source. My selection criteria included finding stock that had curved grain not straight. I wanted curved grain so the grain pattern would run parallel to the handle curvature I wanted. I designed the handle to exaggerate the curvature of the Gransfors Bruks axe. I started with 1 3/8″ thick stock and worked it with a drawknife, coarse rasp, spokeshave, and then finally I used a cabinet scraper. After frequently testing the fit of the handle fit to axe head as I reduced down the stock, I got to a point where I was happy with the fit of the handle in the eye and could then invest more time in shaping the handle. The outcome is that I made a handle that nicely fits my hand. This is the first time that I’ve made my own handle and it was a good experience. I might eventually invest in a Gransfors Bruk carving axe, but right now I’m satisfied that this retrofitted axe has a good edge and will be suitable for attempting to carve a wooden spoon in the Swedish tradition.

hickory and axe handle

 

 

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axe with rough handle fit

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axe with new handle

Here is a picture of the completed axe restoration.  I ground and honed the bevel on one side and then oiled the handle with boiled linseed oil.

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Working the Spring Pole Lathe

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Last Saturday and Sunday, I was doing Windsor chair making demonstrations at the Historic Fort Meigs War of 1812 site located in Perrysburg, OH. Specifically, I was demonstrating how early chair makers would have used a lathe that was foot powered. I was there along with many other costumed re-enactors for the Early Life in Ohio event which is an annual event at the fort. I enjoy using the lathe and particularly the fascination folks have in seeing it and pondering how that technology supplied quality turnings. That wasn’t because my turnings were poor quality, but that it took a bit longer to remove unneeded wood. My lathe was a reproduction of the Hulot lathe of 1775 vintage that I built using Roy Underhill’s books. I was blessed to see several of my parishioners from St. Paul, to talk with visitors to the fort and to mingle with the rest of the re-enactors.

On Sunday morning the site was visited by Alexis Means of Channel 13 abcnews of Toledo. If you click on the “Living History on display at Fort Meigs” shown below you’ll see me on a news clip using a froe and a splitting maul to rive a chair leg part before using it on the lathe. It took more effort in the news clip to split the white oak because the wood was getting dry. Usually, with wet oak it splits much easier.

Living History on display at Fort Meigs
rough shaping a windsor leg

Windsor Chair at Colonial Fort Michilimackinac

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Did the British use this chair?

Did the British use this chair?

Recently, my wife and I got up to Mackinaw City, MI, and we visited Colonial Fort Michilimackinac. I hadn’t seen the fort since the 60’s when my parents stopped there as part of a camping trip. At that time the archaeological excavations had spanned several years (began in 1959), and they were reconstructing most of the buildings. The Fort has its origins with the French fur trade in 1715 and after the French and Indian War, the British occupied the fort from 1761-1781. Later the fort was torn down by the British, and the buildings moved to Mackinac Island where a new and more secure fort was built (Fort Mackinac). Excavations at Fort Michilimackinac has since revealed many artifacts due to the long period of occupation.

During my recent visit to Fort Michilimackinac, I was surprised to see a bow-back Windsor side chair among the furnishings depicted in the Officers Quarters building. Immediately, I started wondering if the British would have had such a chair in their officer’s quarters since they became popular in the 1780’s. If so, this would suppose that the British military acquired one of the earliest versions of the stylish bow-back Windsor chair, and one that was made by Colonial craftsman in the eastern U.S. According to Charles Santore, The Windsor Style in America, the origins of the bow-back chair is that it was first inspired by a oriental design that was popular in England and when it was introduced in Philadelphia in the 1780’s it featured bamboo turnings.

Being a Windsor Chair Maker who has studied with Mike Dunbar in New Hampshire, and someone who loves Windsor chairs, it isn’t a surprise that I wonder these things.

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Back to Windsor Chair Making

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Hi,
We moved our home and Windsor chair making shop in January 2013. I serve as a full-time pastor at St. Paul Lutheran Church in Bowling Green(Haskins), Ohio. I’m still setting up the Windsor chair making shop in Haskins, but here are a couple pictures of a Handmade Windsor chair that I just finished. This one is a gift to my Mom. It is a Philadelphia High Back Windsor chair. It reflects my training several years ago with Mike Dunbar at The Windsor Institute in Hampton, NH. The chair was finished by first applying a medium walnut dye, then coatings of red then black milk paint, distressing the milk paint to reveal the underlying red paint, sealing it with blonde dewaxed shellac, and finally applying a finish of Minwax wipe on polyurethane. I borrowed the idea of using shellac as a base coat before applying wipe on polyurethane from Peter Galbert another respected and well published Windsor chair maker. I had to rub out the finishes several times including the application of milk paint and the shellac base coat. Hope you enjoy the pictures of this black Windsor chair made in the Philadelphia style. I never cease to marvel at how nice these chairs look and the beauty of the design.

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My blog has recently been added to Woodworking Blogs, which is part of one of the largest networks of blog directories on the Web. Please visit my blog’s personal page to vote for my blog and comment to other blog users.

Rescue Me

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Recently, I stumbled into a real find at a garage sale. Barb and I were out looking at people’s junk and there it was a ugly painted saw that was done for the owner. I might like landscapes, but what I observed was a nice saw handle and saw plate with almost no wear. So for $3 I took it home and it sat on my drafting table as a painted saw for months.

A couple months later I had gotten sufficiently tired of the oil painting on it and it found itself in the garage being subjected to paint stripper. The stripper took off the painted scene and I soon noticed an etch from the manufacturer on the blade, HSB and Co. and it got more exciting. The painter had the blade sandblasted to remove rust, but the etch was still visible and the blade looked great. Some of the sandblasting work had damaged the handle too, but it wasn’t severe. I felt very fortunate here.

So here is the good news, I rescued from the painters brush a perfectly good saw that had very little use from its owner. The previous owner liked this premium Chicago made saw so much that his name H.M. Simpson was stamped all over the handle, but fortunately for me there is much life left in the saw plate.

After I removed the fall landscape scene and the flat black paint on the back side, I knew I was on the right track. I carefully removed the sandblasting texture from the plate with 220 sandpaper attached to a sanding block. The sanding block helped keep me above the etch and so I could preserve it for some future treatments to darken it. The apple handle was cleaned up of stray paint and then lightly sanded. To even out the color I applied a maple dye, gave it a good coat of boiled linseed oil, added 2 coats of garnet shellac, and then applied wax.

The saw nuts were originally nickel plated and most of that was lost in cleaning it up. I was able to preserve the nickel plating on the medalion.

I am thrilled with the condition of this handsaw, the way it cleaned up, and I can’t wait to sharpen this up and use it.

Thanks for looking!
Jim


New Life for a Stanley 8 Plane

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Sometime ago, I added a stanley bailey #8 plane to my arsenal of furniture making tools. I took a risk and purchased it on ebay and then I opted to do a total restoration of the plane. After checking the 24″ long sole with a straight edge, I discovered that the plane had unacceptable concavity between the toe and the heel. Once that was discovered I embarked on the tedious job of flattening a 24″ long sole. My friends, this is not for the faint of heart and it turned out to be a real pain. I used 6 inch wide 80 grit self adhesive backed sandpaper on a 3 foot long piece of float glass that is 3/8 inch thick. As suggested my others, I regularly changed the sandpaper whenever it lost the effective cutting capability. This helped to keep things manageable. Once the bottom of the plate reached sufficient flatness (within a couple thousands of an inch) I switched to the 120 and 220 grits. It probably cost me $40 in sandpaper alone, but heh when you compare the cost of purchasing a brand new one it was worth it. Before this I had flattened a #4 1/2 and a Bedrock 605 and found that to be a lot of work. Now I was a glutton for punishment.

The plane casting was in pretty good shape in terms of having only minor oxidation, but the original paint was beyond hope. Between someone having scratched a large initial and there being a lot of small bare and rusty spots all over, I decided to strip the paint and make it look like new. I applied several coats of satin black Rust-oleum to recreate the look of the original finish. This is not what collectors do because it reduces the value. I obviously did this for my own use and without concern about preserving original paint.

Here is the before and what the plane looks like afterward. I cut a few curls on it and it brought smiles after all the effort of repainting, cleaning the parts of rust, polishing the brass, and the equipping the plane with a new IBC A2 steel plane blade. Thanks for looking.