apartment woodworking

One Board Projects

In keeping with the single board project motif, I slapped together a shooting board from a large mahogany off cut that was basically twist free.  Utilizing a wedged fence, the board is about 12 inches long and 9 inches wide.  This version is based very heavily on the plans in The Minimalist Woodworker by Vic Tesolin, just without the cleats.  It’s meant for use on the low occasional workbench so it just buts up against the planing stops.

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How do you make a shooting board if you don’t have a shooting board to make it with?

A shooting board, you may remember, is a jig with a fence at some fixed angle to a reference edge that helps a handtool woodworker true up a sawn edge to that fixed angle.  90 degrees is very common for general, rectilinear work, but a 45 degree fence comes in very handy for precision miter joints.

I find the hardest part about making shooting boards is getting a consistent glue surface between the base and the deck.  My “Biggest Rock is Best Rock” approach to clamping largely grew out of this frustration.  But when your biggest rock isn’t quick big enough, improvise!

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Even with all this weight, I still ended up screwing the boards together from the underside.

The end result is quite nice.  Heavy, flat and (I assume) stable.  And the wedge is dead-square to the deck.  We’ll see if mahogany is tough enough to stand up over time.  I don’t plan on using it for bench-hook purposes (it’s too pretty for that).

Now for that palm!

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The Easy Way Out

A corollary to “Why build it when you can overbuild it?” is “Why do it the easy way when you can do it the hard way?”  The latter seems to be the theme of my latest project, a sitting bench and occasional Roman workbench.

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Cherry, plus Boiled Linseed Oil, plus Sunlight = Beauty

I could have easily glued and nailed a gusset onto each set of legs and called it a day.  That would have been the easy way out.  But I had to go make it all complicated and mortise in a stretcher that’s flush to the underside of the benchtop.  Sure, it looks nicer and will theoretically be stronger, but it’s at least twice as much work.

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This entire article is just a clip show, apparently.

I should note that there are two failure points in this setup.

The first is cross-grain movement.  I assembled the bench in my downstairs, non-HVAC workshop on a humid day.  But the finished piece will live in the HVAC upstairs living area so it should shrink a smidge.  Nonetheless, the quarter inch drawbore pegs are likely not strong enough to resist heavy seasonal movement, even if they had been rived from solid stock instead of storebought dowels.  I have a nagging suspicion that 3/8 would have been more appropriate.

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Clamp pressure was a must, even with the drawbores.

Second, the 10 degree rake on the legs seems a bit aggressive.  There is the slightest bit of flex in the legs when I sit on the bench, although it might just be the slickness of the hardwood floor.  I can imagine that heavy mortising over the legs might loosen the lap joints over time.  We’ll just have to see.

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I added Veritas bench pups to one end.

I used the bench for some basic hand planing last night and have some plans for a special shooting board/bench hook that braces against the bench dogs pictured above.

Once that shooting board is functional, I’ll move onto a Palm that fits over the bench dogs, and maybe a removable crochet/shoulder vise that does the same.  Or maybe just drop the illusion of this being furniture add a whipple hook?

Is it obvious that I’m between major projects right now?

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Nearing Completion

The second mirror for the upstairs bathroom is complete and I’m as pleased as I can be with the result. Everything seems balanced out now.

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Color match is what it is.

In making the second mirror, I took no chances and went straight to a rabbeting bit in the trim router.  There is something to be said for ultra-repeatablility and ease.

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Color match is what it is.

There are a great many power tools I’ve given up since I first started woodworking, but I would rather die than be without my rabbeting bit and flush trim bit (both of which have a place in a hand tool-focused shop).

Or, whatever.

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Working it Out

Once upon a time, I bought a twelve foot long board of 6/4 cherry that was supposed to be the top of the reclaimed cherry console table.  But as fate would have it, there was just enough of the original table to make the full reclaimed version, so this board sat in my workshop for night on a year.  I couldn’t sleep last night, so this board’s time came at about 3am.

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The basic bench takes shape.

The entire bench is made from that one board.  The top consists of two edge-jointed boards and is about 10 3/8″ x 1 1/2″ x 49″.  The legs are 2 1/2″ x 1 1/2″ and angled at 10 degrees.  The overall bench is 19 1/4″ high, which is my preferred height for sitting benches (and saw benches, at that).

The legs are beyond friction fit in their lap joints with the benchtop.  I went through two pine beater blocks with lump hammer persuasion just to get them to seat in a dry fit.  A small part of me wants to make this a knock down bench, but it is compact enough to be portable even when glued together.

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As I was making the bench, I had the Saalburg workbench in my mind’s eye.  But looking at it now, I don’t think one could ever mistake the two.  In any event, this bench is more for sitting than for woodworking.  I’m not saying I won’t bore some peg holes.  I just don’t plan do much more than home handiwork on it.

I have some sweet square head lag screws left over from a prior project that would be perfect for reinforcing the glue joint connecting the legs to the bench top.  But I still think there should be some gussets.  I wonder if it’s worth doing drawbored mortise and tenons or just simple lap joints with glue and screws.

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I remembered this time to leave enough extra to make the cutoff easy.

I’ll take some more pictures when I decide what to do.  Until then, I plan to get back to dimensioning the white oak for the lower shelf on the bathroom vanity.

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Gusset (noun)

noun
noun: gusset; plural noun: gussets
A piece of material sewn into a garment to strengthen or enlarge a part of it, such as the collar of a shirt or the crotch of an undergarment.  A bracket strengthening an angle of a structure.
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This is a gusset.

Joining two or more pieces together is an interesting endeavor.  Some joints, like dovetails or mortise and tenon joinery, have tremendous mechanical strength (especially when force would largely be applied in the direction of that mechanical strength).  Other joints, like rabbets and dadoes, offer greater strength than a simple butt joint, but nonetheless require some fasteners to achieve a durable connection.

But what about butt joints?  In theory, a face grain to face grain glue-up using a modern PVA glue with upwards of 3,000 psi in glue strength should do fine on its own.  Prudence dictates adding a metal fastener or two perpendicular to the mating surface to prevent the joint from sliding over time under normal force.  Forces are not uni-directional all the time, however.  And specific woods are not ideal for every application.

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With a 4 sq. inch mating surface, the glue theoretically asserts 12,000 lbs of force at the glue line.

Take, for instance, the above-pictured “saw bench”.  Although patterned somewhat on the Schwarz design (plans are here), it is assuredly not a piece of shop equipment.  Made from Eastern White Pine, it’s instead a portable sitting bench for a buddy who is about have a child.  I like the design, as it’s easy to knock together in a leisurely day.  Plus, it’s so damned comfortable.

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A proper Schwarz saw bench in the background.

Under no circumstances can this bench collapse with a baby in the picture.  So I added some gussets to stabilize the legs laterally.  I might not have done so in another, harder material.  In fact, had this been oak or ash, I might have instead just screwed twice into the face of the joint and put a third screw in from the bottom.  But pine splits with too many fasteners per square inch (even when pre-drilled).

So next time you need to stabilize a joint from forces in a direction other than the mechanical strength of the joint, consider adding a gusset.  It might just save a baby’s life.

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A Valiant Effort

I too read that recent Popular Woodworking online article about Taytools hand planes. I’m not much of a tool collector (I have a spare Stanley No. 5 for my out and about toolbox and a cadaver of an extra Stanley No. 4 to scavenge parts if necessary), but I couldn’t help myself at the Amazon price for a No. 4.  I’ve wasted far more money on other tools, after all.

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The No. 5 was sold out and, besides, I have a No. 5 I love already.

Let me start by saying that, for the price, this seems like a pretty good tool.  I paid US$65 and got something that felt solid in my hand.  Would I recommend it for a new woodworker with limited space to work in?  Very probably.  I think it’s a valiant effort, all told.  But let’s explore a bit further.

I’ve restored between 5-10 antique Stanley planes and setting this thing up for relatively refined work took about an hour.  The most work went into the cap iron (about 20 minutes), which started out a bit rustic.  I also had to grind a bevel onto it, which went slowly and carefully to avoid removing too much material.  The cutting iron was ground hollow and only took about 10 minutes to flatten and another 5 or so to sharpen and introduce the back bevel with the ruler trick.

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I’ve seen worse.  Much worse.

The plane’s sole was also ground pretty hollow, which is fine.  I haven’t fully dressed the sole for smoothing yet, which I plan to do to 220 grit.  The manufacturer seems to have erred on the side of hollow grinding where possible.  For the record, I am 100% okay with this approach.

Three things about the Taytools plane stand out to me, though.

First, the mouth of the plane is cavernous.  On my Type 11 Stanley, the mouth is a smidge under 3/16, and closes up nice and tight with minimal frog advancement.

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The pitting doesn’t affect performance.  Stop complaining.

Compare that to the Taytools version.  The mouth is over 1/4 wide.  Now, 1/6 may not sound like a lot, but it’s noticeable (and a 33% increase!).  If I wanted this plane for general work, it’d do fine.  But as I’ve noted before, smoothing takes a tight mouth.  I had to move the frog significantly forward to close up the mouth.  Will this result in chatter?  Who knows?

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Notice the scratch pattern around the edges from testing the flatness.

Second, the frog adjustment mechanism is just garbage.  Novel, but garbage.  The yoke is cast into the frog itself and the tapped hole for the adjustment screw was not parallel to the bed.  This meant the frog kept binding as I turned the screw.  I eventually gave up and removed the frog adjustment screw entirely.

Finally, the plane is longer than a vintage No. 4.  Not by much, but I could see it making an incremental difference over the life of the tool.

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Weird, right?

I would be remiss if I didn’t weigh them both.  I prefer the lighter Stanley No. 4 Bailey pattern plane to the modern Bedrock copies for smoothing tasks.  My current smoother clocks in at a manageable 1615 grams.

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That’s 57 oz or 3 lbs 9 oz for the imperial types.

Surprisingly, the Taytools No. 4 is only 1890 grams (aka, 67 oz or 4 lbs 3 oz).  A bit over half a pound heavier than my Type 11 No. 4.  Not bad – and a far cry from the advertised 5 lbs. of some modern Bedrock copy No. 4’s.

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It lost a couple of grams when I ground the cap iron, in fairness.

So, again, is this I tool I would gift to a beginner woodworker interested in apartment woodworking on a budget?  Yes.  But that “yes” assumes the beginner has basic knowledge of how to prepare and sharpen a plane iron.  I don’t think the rustic cap iron would be much more of a nuisance when shavings got clogged.  And everything else seemed in relatively-good working order (apprentice marks and all).

And setting this tool up would be a hell of a lot less effort than fully restoring a swap meet piece.

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Rapid Fire

It’s been a while since my last blog post, but I’ve been far from idle in terms of woodworking. First off, I finished up the new office desk and it works great. The Eastern White Pine is much easier on the elbows than red oak, and sitting on a stool (rather than an Aeron Chair) has helped my posture immensely.

I have since purchased a drafting stool.  

I’m nearing the end of the the bathroom vanity build, which I’ll post in more detail about later in the week. It’s a complicated project in quartersawn white oak that really does a number on my edge tools. I’ve recently switched to a Lie-Nielsen honing guide (which my sister-in-law bought me for the holidays) and the angles don’t match the cheap-o guide I’ve been using forever. They are, in fact, about 5° difference (e.g., 40° on the old guide roughly corresponds to 35° on the LN). 

Sure, I could have soldiered on doing the math every time.  But thinking is the bane of efficiency in the shop.  So I made a new sharpening jig out of sweet, sweet mahogany.  This jig is less complicated too because planes and chisels register in the same slot in the LN guide (the cheap-o guide has different slots for each).

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I needed a new notation because it’s really about 35.5°.

Interestingly, the LN guide is also wider.  Or, rather, it doesn’t have the extra material in the middle, so on my largest blades (specifically, for my No. 7 plane), it didn’t register fully and introduced additional error.  About 50% wider did the trick.  

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The old guide and the old jig will now live in my toolbox.

Speaking of which, the new tool box is also finished.  It came out really great (if I do say so myself).  It fits a No. 5 jack plane, a tenon saw or half-back saw and all the other accoutrements I may need for on-site work.  And it looks really pretty. 

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Compare it to the old tool tote.

I have two complaints about it, though. First, I haven’t found any lifts that I like yet.  Second, the eye on the transom chain anchor gets in the way sometimes, making it a little finicky to remove the tray.  But that’s the cost of storage, I guess.

So that’s all for now.  

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Alternatives to Fighting

In progressing the standing desk build, I had to make a design choice regarding how to attach the back stretcher. But, more importantly, I had a practical choice to make. The angle of the back leg on each of the two frames is slightly off. Call it half a degree or so. Near the top of the assembly, there is no appreciable difference. 30″ or so down the legs, though, it’s nearly 3/16″ off.

I could, in theory, modify the cheek depth on one of the tenons and cant it very slightly to correct for this discrepancy. Or I could just run the stretcher near the top where the bag legs are, for all practical purposes, parallel. And if I’m doing that, why not in my impatience just lap a dovetail?

Because of course dovetails.

Half-lapped dovetails are an interesting joint. I personally find them aesthetically displeasing, even when executed perfectly. But they provide a mechanical resistance against tensile force that in other joints would require some sort of fastener (dowels, screws or bolts). And, like the comparable joints (mortise and tenon, half lap joint), they have significant long grain to long grain glue surface for maximum strength.

Plus, I find them rather easy to cut once you dial in the compound angle.

Ugly or not, this particular joint is not only on the back of the assembly, so I don’t have to every look at it again. Plus, it will be painted. So I’m happy with the choice.

Now I just have to make the top.

Have I mentioned that Eastern White Pine is just the best? Because it is.

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Palate Cleanser

With the bathroom renovation fully underway, I couldn’t put off building the vanity any longer. Almost two years ago, I selected the design to generally rip off. Shortly thereafter, I purchased who knows how many board feet of 8/4 quartersawn white oak, which then sat in my workshop to acclimate for many months before dimensioning.

It’s been so long, my new workbench was still in big room..

White Oak can be very beautiful and (being both waterproof and tough) it is perfect for applications like bathroom vanities. Hard Maple works well too. But unless it’s air dried, White Oak is just too damned hard to work with hand tools alone. Based on how tough it is (and the way it warped when acclimating in the shop), I assume this stock is kiln dried. So I didn’t even bother trying to chop the mortises by hand. Instead, I utilized the drill press like a mortising machine and pared each mortise to width with a chisel. I also squared the corners, because effort.

Before and after.

The tenons were no peach either. I typically saw tenon shoulders and then split the tenons cheeks (rather than saw them). A router plane then pares down the cheeks to get a piston fit. This approach works pretty well, even in kiln dried White Oak, as long as I don’t take too much of a bite with the router plane. But fine-tuning the tenon shoulders (i.e., end grain) with a shoulder plane is basically impossible. If I don’t saw perfectly to the line, it’s chisel paring or bust.

So after getting through the joinery on both end frames, I was ready for a change. Back to the Eastern White Pine standing desk I’m leisurely making for my home office! If you’ve been reading for any amount of time, you know that I prefer to torture myself with angled back legs and this desk build is no exception.

Fluffy and delightful.

Why Eastern White Pine for desk, you may ask? Well, it’s my experience that a softer wood with a bit of flex is better in the long run for hands and elbows. I’ve been working on a quartersawn red oak desk for about five years now and I’m pretty sure I have arthritis in one elbow because of it. I’ve taken to using gel rests for both keyboard and mouse, but they don’t do anything to make up for the lack of flex.

It’s always a boon to make it through an assembly with no broken pegs.

These frames are only 34″ high overall (and will likely be down to 33.5″ when the feet are leveled). Add in two inches of bearer and two more inches of tabletop, and perhaps 3/8 of felt furniture pad, it’s still only about 38″ high. At just a bit over 5’10”, a perfect standing desk for me is about 40″ high. So where am I getting the rest of the height? From my ventilated laptop stand, of course!

The final desk won’t be quite as long or as wide as my current desk. I don’t work from home nearly as much as I used to, so there is just no good reason for a 76″ x 30″ desk. It takes up too much space. Something more like 60″ x 20″ will be plenty of real estate and will free up a fair amount of floor space.

But this new standing desk will make my current office chair pretty useless, so I need to find a decent 30″ stool with a backrest.

Find or make, I guess.

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The Treasure was with Me All Along

I think every woodworker has at least some hoarding tendencies. But I tend to loan or gift away my old tools to family or friends (mostly so I have something functional on hand when they ask me to help with a project). And I freely distribute completed projects long before they clutter start to clutter up my living space. Neither do I hoard scraps, having but a single bin for useful longer boards and another box for smaller (mostly quartersawn) off-cuts, with the rest going in the fire. What I hoard, though, is uncommon boards. Whenever I’m at the lumber yard and I see a particularly tantalizing (which, for me, usually means “wide”) board , there is a good chance I’ll buy it.

For example, I’ve had for about two years now an eight foot long, 17 inch wide, 8/4 board of white ash, which I swear one day will become something. I also have four foot long, 6 inch wide, 16/4 slab of soft maple, which seems to have been cut diagonally along the length of the tree so both faces are entirely end grain like a miter (and, therefore, probably perfectly stable).

But my most prized board right now is probably the least flashy. A ten foot long, 17 inch wide, perfectly clear piece of 5/4 eastern white pine. Not a single knot in the 18 or whatever board feet this thing represents.

That’s the big off-cut bin in the background.

I have absolutely no idea when I purchased it, and I only just rediscovered it stashed behind a sheet of plywood in storage. In theory, you could get the entire carcase of a blanket chest out of the single board. But I already have a blanket chest, so there is nothing to do but let it sit until something else comes along.

Nearly 17 inches at the good end.

There is a little bit of punk near the middle of the board (it may have been dropped on a rail or something at some point), and one end has a bit of wain, taking it down to a paltry 16 inches wide. But I could cut around those minor defects.

The circular blade on the lumber mill must only have been 13.5″ at max height.

But it just goes to show: sometimes, the treasure was with you all along.

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