Archive for the ‘Woodworking’ Category

Carving Sampler – early work

Monday, March 9th, 2015

The shop is still too cold for what I want to do next; finish the “words box.”

So, do something else!  There’s been a pile of little practice carvings stacked on a window sill for a few years. All were carved in February to April 2012. The stack made a nice home for spiders, but even they fled the cold. I could toss those carvings, but holding on to them has won out so far.

Let’s see…, if I rearrange them just right, maybe they can be put together as a “sampler,” a lot like cross-stitch samplers.

photo of wood carving sampler; a collage of 15 pieces

Getting them to similar sizes and nesting together was an exercise of time and precision, but work that could be done in a warmer part of the house. A piece of 1/4 inch plywood forms the backing. A rough dab of hide glue holds each. If there is any movement, they might be free to dance around a bit. And Ralph; no mitered corners.  :)  Overall size about 18″ square.

Design sources:

1 “Complete” is completely inaccurate in the title of Koch’s book. It is a collection of 7 carving exercises. Good, but not “complete” in any sense.
2 One of 3 similar books, Wilbur covers a much broader range of architectural carvings than Koch. Very highly recommended.

Affordable Hide Glue Pot

Thursday, March 5th, 2015

The stuff likes to be kept warm … about 140° warm.

One can get a really really nice glue pot at TFWW. Yet, for as often as I use hide glue, something more affordable suits my needs. (Sorry Joel.)

As I walked down the kitchen accessories aisle at Walmart a couple of days ago, this “Roll-Back Special” caught my eye. I don’t know how much Walmart stores across the country standardize their sale items, but in my neighborhood it was priced at $8.86. A slow-cooker glue pot for less than 10 bucks!

It does exactly what I want for the sorts of occasional glue ups I do. I mix glue from TFWW flakes in a small glass jar (pickle relish). That jar fits nicely inside the pot. Fill with enough water to surround, but not overwhelm the jar and set to HIGH for about 30 minutes. That gets the temperature up to near 140. It will go to 180 if you don’t watch it. Then, set to WARM which holds right at 140°. Perfect!

Oh… Keep the lid on the pot while not using the glue. Otherwise the temperature drops off fast.

Photo of pot and bag of glue flakes  thermometer shows 140°

Best Brooms Ever

Wednesday, March 4th, 2015

The shop was almost warm enough to be bearable today, and it needed a good sweeping.

Decades ago, we lived in the middle of Indianapolis, Indiana. A blind man would show up at our house occasionally carrying a dozen or so brooms over his shoulder. He sold brooms made by “Industries for the Blind.” We enthusiastically bought from him because his were really well made brooms of sturdy, thickly padded, broomcorn. They lasted almost forever, more years than I remember. They were the best brooms ever. We left Indianapolis over 30 years ago and there are no blind men walking around selling good brooms where we live now. In that time, the last of the blind-made brooms have worn out.

The last of the real broomcorn brooms I bought at a big-box store was so flimsy, it wouldn’t support its own weight. I’ve witnessed a steady decline in the quality of store bought brooms, seeing broomcorn get thinner and thinner and finally being replaced by plastic bristles, set in plastic heads, attached to plastic handles. They don’t behave like brooms and break too often. Pure junk!

photo of 2 brooms

So, I went on a hunt. The answer to my search was not “handmade,” “blind-made,” “sturdy” or any of the other “durable” words, but “broomcorn!” Two new brooms from Broomcorn Johnny’s now hold my praise for the best brooms ever. Brian Newton is the artisan who operates the broom shop named Broomcorn Johnny’s in Brown County, Indiana. We’ve had two of his brooms long enough to know they’re the new “best.” The flat one is what he calls a “cabin broom.” The round one has about the same amount of broomcorn but is tighter wound and great for heavier work. The flat one stays in the house / cabin. The round one just cleaned up the shop better than any broom I’ve had in the past 15 years and hangs there now. (Cabin brooms are available in plain or in a range of color schemes.)

These brooms seem expensive at $60 – $70 each. Yet, I know they’ll easily outlast the $12 box-store brooms by a factor of 8 -10. That makes them a real bargain, and very attractive too.  Highly recommended, and I have no financial gain from this recommendation.

Kerfing Plane – Done

Monday, October 27th, 2014

photo of completed planeThere are a lot more pictures this time because I read that a lot of people avoid saw making, rehabilitation and sharpening. I want to show that it’s within easy reach of anyone who wants to try and doesn’t care to wait while saws take long trips to the sharpener and back. We can find many sharpening guides and tutorials online. Nearly all are very useful. For this particular saw plate, I followed Paul Seller’s recent tutorial about cutting saw teeth. The method worked wonderfully!

The plate itself is roughly 10″ by 1.5″, recycled from an old Disston that I cut down to make my frame saw a few years ago. Cutting to this shape was simple hack sawing. The tooth edge was smoothed “flat and straight” with a simple single-cut mill file. I decided to cut it to the same pattern I use for other resawing work, 5 TPI, zero rake, no fleam … just a dead simple aggressive rip pattern.

My ever handy Stanley No. 36 1/2 R rule has multiple scales in  8, 10, 12, 16 parts to the inch. The 10 scale made easy work of laying out a guide. The slideshow walks through a number of steps, with notes about each.

The 10 to the inch scale of a Stanley rule is used for marking out 5 TPI.
The little no-name saw was OK for cutting the guide but gave up when it came to the plate.
After making the tooth spacing cuts
Which to use, the one with 6 moving parts and adjustments that can sometimes loosen, or... ?
Saw filing setup. The adjustable lamp is the most important part.
When looking from the edge doesn't show what you expect, look from the side and seek those glints of light from unsharp teeth.
Coarse tool, set for a gentle #8.
Finished plane - toe end
Finished plane - business side - What big teeth you have.
Finished plane - fence side
First cut. The angle is off a bit.
Kerfed all around. The slight angle is noticeable at the corners.
First resawn board. Close enough for government work, but not for me.


photo of first test resultEnd result? A small piece of pine became the test victim. I set the fence to produce a kerf 3/32″ from the edge and went at it with only casual concern. What will this thing do without a lot of fussy attention? Cutting was easy once the initial grabbing was overcome. Hint: start from the far end as one does when planing a molding. You can see in one of the pictures that the kerf is not absolutely square. It’s tilted slightly. Despite that, I ended up with two boards that have less than 1/32″ of roughness left from the cut.

It will be perfect after I make an adjustment to either the face of the fence or to my right elbow.

UPDATE: It was my right elbow that needed adjustment. The plane is perfect when the monkey pushing it holds it correctly.


Kerfing Plane – More carving

Saturday, October 25th, 2014

photo of leaf like carving…and here’s the curvy side.

Next up: cut the saw plate…

Kerfing Plane – a Little Carving

Monday, October 20th, 2014

“Hey, aren’t you done with that thing yet?” You know I can’t make something without a carving decoration.  So…

photo of carving on the fenceHere’s the harder one first. Carving straight lines along the grain line is harder than carving curves. While I’m never satisfied with a carving, this one is done enough to set aside and wait for its partner.

It’s all Shannon’s fault. During his review of a Bontz saw, he mentioned an Art Deco feature in how the saw’s back was shaped. That sparked an old interest and I was off to re-explore the genre and come up with a couple of designs.

The curvy one is next. And yes, I’ll cut a saw plate some day.