There are hundreds of ways to make woodworking joints.  That’s part of the reason I love woodworking so much. Regardless of your skill level, amount of tooling or where you work, you can cut a joint that can far outlive the wood the project is made out of.

That being said, many of the joints to choose from out there are simple variations of a similar  joinery methods.  Pocket screws are simply screws driven from different directions. The Festool Domino is a variation of the venerable mortise and tenon.

One interesting joint that invites a number of variations is the dovetail.  From the basic hand cut through-dovetail, a great number of variations have sprung up over the years.  Half-blind dovetails, machine cut dovetails in a wide and growing variety of flavors - and my most recent discovery, a jig system that creates what is called tapered dovetail splines.

While traditional splines are typically cut with a sled on a router table, that method involves building an extremely precise sled first, then carefully marking and ensuring that the splines line up accurately - especially going from corner to corner. A tolerance of 1/32” is unacceptable because a gap even that small shows up like a pencil line you apply the finish.  And of course you have the tedious and difficult operation of cutting the splines themselves . . .

While doing my interview with John Lucas, I stumbled across the Kehoe Jig, an innovative system that enables you to cut these joints faster, tighter and stronger.

The “system” actually consists of three jigs. The main jig itself, which is used in tandem with a router to cut the spline grooves into the workpiece with a perfect one degree taper, and the Spline-making jig, used on the table saw to cut splines using whatever species of wood you choose. This jig also the matching one degree taper incorporated into it so that the splines will fit tightly into the grooves. The third jig is called the Corner Inlayer. It is also used with your router, and allows you to cut a perfect “mini-dado” of whatever width and depth you choose, but at an angle exactly perpendicular to the corner itself, versus from one of the flat sides of the workpiece. This jig is normally optional, but right now they are running an online special that includes this jig at no additional charge.

The Kehoe Jig was invented by Larry Kehoe out of one part necessity, and one part frustration.  According to Kevin Jaynes, owners of the company, ” . . . . while in the middle of building an oak desk, he was dreading hauling out his dovetail jig to build the drawers because he had never found a dovetail jig that was not slow and cumbersome, and he hated test cuts. As he was walking across the basement shop floor with the traditional dovetail jig in his hands, he had one of those “Flash Of Genius” moments where he actually saw the jig in his minds eye; the jig that would eventually become the Kehoe Dovetail Spline Jig. Larry told me he had seen it ‘in remarkable detail, especially the taper.”

From that first flash of inspiration, Larry perfected it over the first couple of years by tweaking the design. He made dozens of improvements, and even different types of jigs.  In effect, the splines slip in loosely to start with, but quickly tighten as they are tapped home, creating a joint that’s beautiful as well as strong.

While the joint is similar in many ways to traditional dovetails -and creates a strong joint - the beauty of it is that the Kehoe Jig can be used in boxes made of materials such as plywood - since the cutting of the spline grooves doesn’t expose the material’s end grain.

Another strength of the jig - as well as this technique in general  is that you can add splines in contrasting woods that can serve as a design feature.  According to Kevin, “It is not unusual to have your woodworking friends look at the work piece, turning it over and over in their hands and then accuse you of painting them on.”

Kevin is actually the co-owner of the company with his wife Terry.  Mr. Kehoe passed away in 2007,  “I got a call from Elizabeth (Mrs. Kehoe) one cool April day and she gave me the sad news that Larry had passed away. I had expressed an interest in the company a couple of times over the preceding years, in case they ever decided to retire. It was not so much a source of income for them as it was a hobby. Many others had also expressed the same interest over the years, but to make a long story short, she and Larry had decided I would be the best bet to ‘Keep Larry’s baby alive.’ We could never had gotten it back off the ground without Mrs. Kehoe’s knowledge and unselfish help. We consider it a privilege to be the caretakers of this business. ”

Today, the Kehoe Jig continues to be a useful and interesting jig with an even brighter future. Kevin and Terry have already made three prototypes of variations of the jig, and are about a month away from releasing the first one. “It’s along the same lines, but cut’s smaller splines in a pattern closer together. Perfect for the smaller jewelry boxes, small drawers, and small humidors like many of our customers make. The current jig does this as well, but this one will just make it all the faster and easier. We also have a 28” coming right on the heels of that for larger projects.”

This may well be the first time you have heard of the jig, but if Kevin and Terry have their way it won’t be the last. “Larry was a genius tinkerer and inventor, but he hated marketing and selling. He hardly ever advertised it. What he enjoyed most was going to 2 or 3 wood shows a year and just taking orders. He liked meeting people and talking about his jig. We are trying to bring Larry’s ingenious invention to the world, and with the help of happy customers and woodworking sites, we are starting to make a dent.”

Besides looking like an interesting jig to cut dovetails with, the story of Kevin and Terry has captured my attention.  “We’re one of those rare American mom-n-pop shop manufacturers that are still making a go at it. We are making some dramatic improvements in the jig kit, and are also committed to keeping the manufacturing 100% within our borders. We are woodworkers ourselves and have dealt with many online suppliers over the years. It has been our experience overall, that most woodworking supply and tool companies have excellent customer satisfaction. Customer satisfaction is our first priority as well, because we believe that’s the foundation of any business.”

I think I’m going to have to give this jig a shot and tell you my impressions…

Woodworking can be tough on your clothes.  I can’t tell you how many times I have reached across a glue up to only to discover later the telltale streak of glue over a favorite tee shirt.  Ruined forever!  Or, after routing a series of dovetails, find that I have sawdust in ‘uncomfortable places’ in my clothing.

To overcome these challenges, some woodworkers turn to shop aprons.  Many are dirt cheap, made of light canvas and given away to advertise some lumberyard or hardware store.  Others are from the other side of the spectrum, custom made of top-grain leather, expertly tailored to fit comfortably and keep a selection of tools close at hand.

So, what are your thoughts about shop aprons?  Essential comfort and safety clothing or something for woodworkers who care about the designer clothes they wear to the shop?

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Woodturning Online

If you are a woodworker and find yourself with your head spinning, this might be a good place to check out.  Woodturning Online is a great place to start if you want to get into wood turning - or discover new tips and tricks.

The site offers articles for woodturners from complete novice to seasoned pro.  Tool selection, technique and a fascinating look at turning materials - including metal spinning - are covered here.

Of course, tool buying advice and reviews are offered as well - leading turners from their basic tool kit to the most exotic gouges and chisels.

What may be the most helpful features of this site are the links to woodturning associations and vendors that can supply the know how and materials to make your journey into woodturning a memorable and exciting one.

Whether you turn bowls, spindles, pens, platters, knobs or just want to get started, this is a great place to bookmark.

The Fujiwhara Chest

• June, 2008

For those who follow along at the Wood Whisperer Blog, Marc Spagnuolo has featured one of my latest projects as his featured Project of the Week.

This is a Krenov-inspired chest on stand I built mostly out of offcuts I purchased at Weiss Hardwoods in Largo, Florida.  I wanted the base to have a little movement and grace, so I cut the rails and stretchers with a curve in them. Both the front and back curves have identical arcs - as do the two sides.

The chest is made of maple and is dovetailed with my Keller Journeyman jig.  I was able to use variable spacing by following the simple instructions Dave Keller wrote up in the manual.

The top rails of the doors echo the identical arcs in the aprons and rails, and the panels are veneered sapele wood I got from Veneer Supplies dot com.

The write up I put on Marc’s blog goes into great detail about the construction.  But, what I loved most about this project was the number of firsts.  My first veneered project (Loved it).  My first attempt at a Krenov Cabinet.  My first variably spaced dovetails.

The Fujiwhara Chest was recently dropped off at the county’s personnel office - the coordinating office for the annual art show sponsored by the  National Arts Program.  I will find out at a reception late on October 1 how the piece fared.  With any luck, the judges might see some merit in honoring the piece.

Just as an FYI - I have also put the piece up for sale for $1,000.  I’ll be donating a portion of the proceeds to my county’s Christmas Bikes program which allows employees to contribute to purchase bikes for underprivelidged kids.

I’m sure there are one hundred ways to build a work bench, and all of them are correct if they meet your needs.

…………………….- Danny Proulx, Building Woodshop Workstations

You wanna brew up an instant argument? Find a group of woodworkers and ask them their opinions about brands of pick up trucks.

For the record, I drive a Toyota Corolla. I chose this car because it gets me from point A to point B with a modicum of comfort while using as little gas as possible. It has a reputation for reliability. The fact that it also happens to be able to hold my entire family is a bonus. Other than that, I really couldn’t care what make the car is.

But, when you drag Ford, Chevy, Dodge, Nissan, Toyota and other manufacturers into the mix, people become defensive about their trucks. Boastful. Arrogant. “My Ford will tow your Chevy to the junk yard when it dies.” “My Dodge is a beast and will out perform both of your toy trucks.” This conversation can drag on for hours while people go back and forth essentially over what is a utility vehicle designed to carry a load of items.

In much the same way, woodworkers have a tendency to look at their workbenches and compare how they stack up to others. Whether a woodworker believes a huge steamed beech bench modeled after some European standard is the only way or a solid door on sawhorses is their preference, a great deal of personality is invested in the decision.

I have been looking at my workbench recently. Sure, Big Ugly still answers the call without a whine or whimper each time I go into the shop. She serves me well. But, I’m thinking it might be time to do some upgrading.  Some extra features.  A little more heft.

That’s where I’m getting stuck.

At the recommendation of many woodworkers, I recently picked up Workbenches, the first book written by Popular Woodworking Editor Chris Schwarz. The book has been touted as a seminal work, required reading for woodworkers of all levels of experience.

I’ve got to hand it to him. I think Chris has written a very well researched book on the topic of workbenches. Besides old photos of woodworkers actually using their benches from bygone ages, his book is replete with drawings, block prints and ads from tool and bench manufacturers from years gone by. This really helped me get an idea of just how these specialized shop tools has evolved from the first flat rock to today’s high-tech offerings.

Chris offers outstanding plans with measured drawings and step-by-step instructions in exacting detail. Chapters devoted to stock selection, bench accessories and the best methods to accomplish certain tasks make this book an invaluable reference for any shop. It’s written in a style where – yes – I didn’t want to put it down.

But, I do have a quibble with the author on a few points.

No doubt Chris is imminently more qualified than I to write about all things woodworking. He’s worked with the best. He’s held some of the most expensive tools ever manufactured in his own hands. He’s perched in an enviable position from where he can monitor the latest developments in the craft. When he speaks, his voice carries with it a great deal of authority.

For some reason, his book hit me the wrong way. Chris makes excellent points about the shortcomings of many bench designs. He validly points out that many benches today are glorified kitchen counters – with no access to clamp materials from below – or overgrown dining room tables. However, the way he belabors the point seemed to set uneasily with me.

He speaks about other designs – some of which he designed for Popular Woodworking – as if they are somehow beneath a serious woodworker. “Build it like that, and you’ll be terribly disappointed,” is a common refrain. Perfectly serviceable benches such as the 24 hour bench and the $175 bench are dismissed as ’starter’ benches, perfect for customizing as you would an old Volkswagen Beetle.

What iced me from the book was when he pointed out the shortcomings of the benches found in the shops of Tage Frid, James Krenov and Frank Klausz. There is no question that these men have built incredible works of craft – and art – from their modest benches. While maybe not the ‘perfect’ forms, the quality these men have produced speaks volumes for their ability to use these benches effectively.

And, that’s without saying a word about the Japanese masters such as Toshio Odate who create their masterworks without even touching a western-style bench.

Chris describes his first exposure to the French-inspired Roubo workbench as a near religious experience – divine inspiration into the perfect form and function of what a bench could become. In some ways, I wish he would position himself as less of a Zealot when considering bench forms. Unfortunately, there will be many starting woodworkers who will walk away from this book thinking that any workbench – other than those recommended by Chris – would be a waste of time. Indeed, I can see many up-and-coming woodworkers stymied by the impression that they MUST build a Roubo before they dare touch a tool.

Listen; there are dozens – closer to hundreds – of published plans out there to help you build a workbench. From ultra-quick, ultra-cheap weekend benches knocked out a few 2 x 4’s and some plywood all the way to the could-double-as-an-altar-in-some-minor-woodworking-religion uber-benches – there’s something out there for everyone.

Before you go out and build your bench – consider doing what I’m doing. Look at plans. Lots of ‘em. Ask yourself some questions. What am I going to use this bench for? What’s my budget? What skill level do I have? How much space is there in my shop?

Sure, you can’t plan for any eventuality. I could hit the lottery next week, quit my day job and woodwork full time. Of course, my kids could need glasses, braces and piano lessons too…

What kind of bench you work on is a personal decision you will have to make. Ask around. Take all of this input with a grain of salt, understanding that everyone will offer his or her opinion based on what works for them.

Then, go boldly, build your bench – and get back to the fun stuff – woodworking!

By the way, here are some resources I’ve already checked out:

• 24 Hour Bench - Popular Woodworking
• $175 Bench - Popular Woodworking
• Build A Workbench - Popular Mechanics
• A Traditional Workbench
• A Heavy Duty Workbench - The Woodworker’s Website Association

Since its invention by Raymond DeWalt back in 1923, the radial arm saw has had quite an interesting history.  Once held as the ultimate home woodworking machine, the saw could crosscut, rip, dado, cut joints and do other tasks with specialized attachments.

While the saw was enjoying its reputation, questions about its accuracy, space utilization and - most importantly - safety were being raised.

With the invention of the power miter saw in the 1970’s, radial arm saw use declined precipitously. While radial arm saws are still produced today, table saws far outsell these machines.

Where do you stand when it comes to these tools?

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The Reluctant Gourmet:  Wood or Plastic?

As woodworkers, when it comes to cutting boards, if it’s not made out of wood, it’s not worth using.

While that’s our first go-to-ground instinct, the recipient may have lots of questions about wood being a safe material for the purpose.   After all, for many years, wood was seen as a material that harbored dangerous microbes and other nasties while plastic was seen as a more sanitary substitute.

This article goes into great detail and links to laboratory analysis about the nature of both materials and shows how wood actually fares very well when compared to its synthetic counterpart.

Armed with this information, you can explain how the block maple end grain wooden cutting board you built for Aunt Sally this holiday season is safe for her use in her kitchen - and back it up with sound reasearch.