All posts by Tom

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Link of the Week

Build Cabinets with Pocket Screws

Building with pocket screws.The pocket screw has proven to be a fast and convenient way to build case construction.  From face frames to box assembly, this system gives very good results in short order.

This article, published by Readers Digest:  The Home Handyman, not only demonstrates the proper way to build with pocket screws, but also provides a materials list for the reader to build their own ‘coat locker’ cabinet.

Clear step-by-step instructions show how the project can be planned and built – all the way down to the drawers, face frames an trim pieces.

If you are undecided as to whether or not to buy a pocket hole joinery system, or you have one but have yet to give it a real workout, this article is a good orientation to the method and a valuable read, even though it is ten years old.

Places I shop – Tools for Working Wood

New York CityNew York City is known as the City that Never Sleeps. The incessant lights, activity and electronic chatter could lead one to believe that NYC is constantly on the move, flying away from tradition at warp speed.

If you think that’s all that’s at the heart of the Big Apple, you would be terribly mistaken. Find a good deli that makes its own pastrami the old-fashioned way. A green grocer sacking tomatoes and other fresh veggies on a street corner. And, after seeing the sights, be sure to stop in at Tools for Working Wood.

“What’s that?” you ask. Well, Joel Moskowitz, the owner of the tool shop in Brooklyn, owns and operates a company that’s moving forward by looking back. Back on April 1, 1999 – no, it wasn’t an April Fool’s joke – Joel opened the shop and started offering some classic tool designs for sale to the regular woodworker. Today, the company he founded is closing in on its tenth anniversary.

Tools for Working Wood's LogoThe company’s world headquarters is located in the Bush Terminal Market – a giant warehouse facility built in 1907 to service the Brooklyn docks. Now also known as Industry City, it is home to lots of warehouses and a fair number of woodworking shops. The surrounding area is known as Sunset Park and is also on the edge of Green Wood Cemetery – which is considered one of the most beautiful historic cemetery parks in the nation. Joel even gives direction from the local subway line. Just take the D, M, N or R line. And, don’t come too late. “The freight elevator stops running for the lunch hour and at 5 p.m. If you are still in the shop, you’ll have to walk down the stairs to get out.

Tools for Working Wood focuses on offering a core of high-quality tools for sale to woodworkers far and wide. “Sure, we stock the Festool line and some other power tools, but we love to carry the hand tools. We are very happy to be in the hand tool revival movement.”

Gramercy Bow SawFor a guy who started woodworking at the local ‘Y’ back when he was seven, Joel has a keen eye toward the history, design and function of classic hand tools. In 1996, he and a partner founded the online Museum of Woodworking Tools, an online showcase of old woodworking tools from shops across the country and the world. “I love the way these old tools look, feel in the hand and function. In many ways, they can work just as fast – or even faster – than power tools and give the user more connection with the wood.”

This love and appreciation for hand tools – honed through the museum and the countless books he has read and antique tools he has handled – helped spur the development of the Gramercy Tool line. For those of you not from the Big Apple, the tools are named after the Gramercy neighborhood, a quaint, historic residential district just down the street from the Empire State Building on the island of Manhattan.

In these tools, the true art of the tool makers is brought to life. Whether in the hand-forged heads of the hold downs, the sinuous curves of the bow saw or the gleaming blades of the dovetail saws, every detail is carefully considered before it gets added to the final tool. “We make the tools here in the USA, and in New York City as much as possible. Our recently-added line of high-quality finish brushes is made entirely within the city.”

While these works of art are appreciated by such notable woodworkers as Frank Klausz, the clientele doesn’t just contain the luminaries of the woodworking world. “You might be surprised with the range of woodworkers we work with. Sure, we have the masters who need a specific tool, but we also get lots of beginners just starting out and some average professionals who need high-quality tools to get stuff done fast.”

New York City is one of the oldest and most storied cities in the United States – craftsmen have plied their trade in the city for the past 400 years. When asked what working in this historically and culturally significant city, Joel answered, “It’s great! There is a core of high end professional shops that help support our efforts, museums and libraries to help with research and there is a wonderful pool of skilled labor. Also I think NYC has the best overall customer service on the planet so it’s easy to learn how to do customer service. OK, we may be far from perfect, but at least we have good local role models to try to copy.”

And, that kind of historic thinking and return to the roots of the craft is what keeps Tools for Working Wood surging ahead into their second decade

Swinging into hinges

Think about the shelving and storage projects you have built.  How many were built to remain as open shelves?  Sure, lots of bookcases are open.  And some curio shelves.

an old hingeHowever, when you get into entertainment centers, kitchen cabinets and other projects, doors become important design elements.  I was terrified when I had to build my first doors, but that was the easy part.  Selecting the hinge hardware was actually one of the tougher decisions I had to make.

Hinges have been around since the earliest structures were built.  Tired of having to push and drag a cover to protect an entryway, early builders struck on the idea of attaching the door to one side of the entryway and having it pivot.  Some stone pivot hinges can still be found – fully operational – in ancient stone structures.

European cup hingeAs building techniques progressed, more sophisticated hinge designs came into play.  The technology to forge bronze, then iron, gave builders a wider selection from which to choose.  The hinges forged by these smiths were both beautiful and durable, and can serve archaeologists well in helping to identify the date a particular structure was built.

Today, forged and stamped hinges come in a bewildering number of styles for many applications.  And, while there are thousands – or tens of thousands – of different looks, they break down into three broad families:

  • Mortised:  These hinges require that part of the hinge body be mortised into the project to get better support.  Butt hinges and European cup hinges are two of the more popular varieties of this style hinge.  Regardless of what tool is required to cut the mortise – chisel, router, hollow-chisel mortiser, biscuit joiner… they all fit in this family.
  • Non-Mortised:  Obviously, this family doesn’t require mortising – they gain all of their strength from either screws, spikes or some other metal-to-wood connection. Sophisticated non-mortising hinges, cranked leaf hinges found on kitchen cabinet doors and old time H and strap hinges show up here.
  • Non-Metallic:  This category is a bit of a catch-all for the different styles of hinges that can be crafted by a woodworker.  Wooden knuckle joints, leather straps or the like can serve as outstanding and decorative joints, showing off the skill of the woodworker.

Whatever style of hinges you decide to go with, you will want to follow the instructions very carefully.  Each has its own unique layout concerns and issues.  And, it doesn’t take much for  the hinges to get out of line and cause binding.  And, believe me, you can spend a day and a half trying to correct incorrectly installed hinges.  Been there.  Done that. Got the T-Shirt.

What kinds of hinges do I use?  Well, I have a few favorites I tend to go to time and again:

Blum Concealed Hinges:  When you don’t want the hinge to show, it’s hard to go wrong with these hinges.  They do take some getting used to if you have never installed them before, but WOW, do they ever work smoothly.  Installation does involve a 35 mm diameter forstner bit, so you will have to lay out some money to get that. But, that cup that is drilled works as a mortise for the door, giving outstanding support.  Have your project plans handy, because you can buy these hinges in many different flavors – face frame vs. frameless, inset vs. overlay, etc. – and you  want to order them properly.

Overlay Door Hinges: I love these hinges to death.  The cranked leaf that mounts to the face frame of the door has a preset overlay amount.  So, if you have hinges with a 1/2″ offset, just build your door an inch wider than the opening and you will  have a perfectly fitting overlay door.  I have used these hinges for years and they tend to be my ‘go to’ style for lots of projects.

No-Mortise Hinges: Very easy to work with – and very similar to the overlay hinges mentioned above.  These work for inset doors and are very easy to install.

Pin Hinges: If I am building a small box and need an unobtrusive hinge, this is what I choose.  Easily installed with a drill  and a dowel center, these babies function easily and have never failed me.

The best advice for hinge selection is to do your homework.  Go through a home-improvement center’s kitchen cabinet display and open the doors.  Go to a furniture showroom and see how their doors are hung.  Read up on Internet reviews of different hinge styles and see what is out there.

It just might open a few doors for you!

Quick poll

a tidy shopSome are huge.  Cavernous. You may need a road map and a GPS device to find your way around in them.

Others are tiny.  Places barely large enough to serve as a storage facility for your tools and materials.

Be they huge or tiny, our shops are our retreats from the everyday grind.  Places we can go to in order to escape the family, the bills, the job, the neighbors and connect with the craft we love.

This week, I want to know just how large your sanctuary is.  Whether it’s a converted basement, a garage that hasn’t seen a car in years or a detached building, share with us just what sized space you are working in.

[poll id=”59″]

Link of the week

Toxic Woods List

exotic hardwoodsExotic woods are some of the most beautiful timbers in the world. There presence in a woodworking project can take the most ordinary piece and turn it into a work of art.

While they are beautiful, these woods can cause some woodworkers develop lung, skin or eye irritations.  The oils, resins and other chemicals that give these woods their beautiful colors and working properties can be pretty potent, leading to allergic reactions and other health concerns.

Which woods are most likely to cause these kinds of reactions?  This list from the musical instrument makers forum lists dozens of wood species, and the likelihood they will cause eye and skin irritation, respiratory problems, nausea and cancer.

While there is a potential for these kinds of reactions, proactive dust control and personal safety precautions can help to significantly reduce the risk of a reaction.

Tools I use: my band saw

This was one of those purchases I made because I ‘thought’ I should have one.  It turns out that while I don’t use it for every project, it has become an essential tool for several of them.

My Delta Band SawThis is a Delta model 28-276 14″ band saw I bought at Lowe’s about four years ago.  Oh, sure, I looked at some of those fancy smaller models (the guys at Home Depot really wanted to sell me the 12″ Ryobi band saw), but I decided on this model because 14″ is a common size for most home machines. That way, it  would accept the most common upgrades.  Boy, am I happy I considered that.

I set it up in my shop exactly as described in the manual, turned it on and – boy – was I disappointed by the performance.  Unlike my Ridgid table saw I had set up a few years earlier, I discovered that band saws take some fiddling to get them to work properly.

Yes, this is a warning to all of you prospective band saw owners – don’t be disappointed if you don’t get perfect cuts right off the bat. It take some time.

Some things I like about the saw include the blade tension release control, which means I don’t have to change the tension setting after a day at the saw.  I can just flip the tension off and take the pressure off the blade.  I also added a rolling tool stand to the purchase, so I can move the saw around the shop as necessary.

Once I got the saw tuned up – it took a day or so – things started to improve dramatically.  The saw began to track more easily.  The cuts were a little smoother.  Things were definitely looking up.

I would strongly recommend that when you buy a band saw, you get a good band saw book to go along with it.  My choice was Cutting Edge Band Saw Tips and Tricks.  A book like this will give you far more information than the manual ever could.

The monumental step in my bandsaw experiece was when I started to upgrade some items on the saw.  First up, I ditched the original blade that came with the saw and bought some replacement Viking/Timberwolf blades.  These are made of a Swedish silicon steel and cut very true.  The product manual says you can run these blades at a lower tension, but I have noticed some tracking issues if I lower the tension to the recommended levels.

I also recently added the Kreg bandsaw fence.  As with the saw, I am still in the stages of fiddling with the fence to get the best fence performance.  It is a solid and easy to use fence, so I’m sure once I get it tuned up, I’ll be in the butter zone.

I have used the saw to cut curves and resaw, and the 3/4 hp motor will sometimes struggle with harder woods.  If I slow my feed rate, I can get good performance.

Some upgrades I would like to make to the saw include adding a task light to the bottom of the top case.  Where I have the saw right now, it’s not in the best lighting situation, so that will have to be addressed.  Also, one day, I would like to add the riser block.  Sure, I’ll gain an additional 6″ of cutting capacity, but I’ll have to buy new blades.  Also, I’d like to upgrade the original steel guide block with some type of bearing system to control the blade,  but that’s something to consider in the future.

All in all, the saw has been a decent performer and has served me well.  However, if I had to do it again, I would spend the extra cash to get a more capable model which would include a more powerful motor, a larger resaw capacity, a better guide roller system, a quality stock fence and a mobile base as part of the standard package.  Probably would have cost less than the saw’s original price and the upgrade money I have spent so far.

Live and learn!

Stuff I’ve Built: The low Craftsman-style entertainment credenza

December, 2004

    The low entertainment credenzaThis is the project that made me a ‘made man,’ according to some folks over at the Woodworkers’ Website Association. This was my first big commission, and it fell into my lap.  Looking back, however, I can see so many better ways I could have built it.  Different construction methods.  Different materials. Ultimately, the customer was happy, and that’s all that mattered!

    It all started when I was shopping for a desk for my oldest son, who was in first grade at the time.  My wife and I went to the nearest unfinished furniture store to look for something, and boy, was I dismayed.  Everything was made out of pine, and the joinery methods left something to be desired.  Of course, I exclaimed several times, “I could build something better than this for less money!”

    After my third pronouncement, a gentleman tapped me on the shoulder.  At first, I thought I was busted by the store staff for scaring off customers, but it was another customer who asked if I was a woodworker.  After telling him yes, he asked me to look at something for him.  He wanted a low oak credenza-style entertainment center for his big screen TV, and all the store had was a short pine unit.  “Can you build something like this?” he asked as he pulled out a drawing of a Craftsman style unit.

    Sure I could.

    Before we agreed on a price, we exchanged info and I said I would draw up a plan.  Once I e-mailed a drawing and told him of the construction details, he gave me the go ahead, and I agreed to build the piece for a $1,000 commission.  I asked for half the funds up front to buy materials, and was off to the races.

    Now, I have to confess, at this time, I had never built anything like this. There were many firsts for me.  My first glass doors.  My first inset doors.  My first big casework.

    The cabinet is built frame and stile with 1/4″ oak plywood panels.  The door on the left had shelves for storage, and the door on the right had two pull-out trays for DVD storage and the like.  The center doors had shelves for electronic components.

    I went to a local stained glass shop and had the owner inset the glass for the two doors.  It was an antique-style seedy glass, which lent some character to the piece.  The wooden grille on the front was made of half-lapped oak pieces glued together and inserted as a tight friction fit with clear silicone adhesive caulk on the back to help stick it in place.

    The top is a solid piece of 6/4 oak I sanded the heck out of.  Sure, I didn’t have to build it like that, but I didn’t know any better.

    I finished the piece with Watco dark walnut danish oil to give the darker Mission-style finish to the piece, and topcoated the top with two coats of wipe-on poly to give it more durability.  The hardware was from the Craftsman collection over at Lee Valley.

    When it was ready, I gave the gentleman a call and asked him to bring a truck and three of his biggest friends – once the piece was assembled on my bench, I wasn’t about to move it.

    The reaction when he saw it was priceless.  I opened the garage door, and he and his three buddies said, “Woah.”  They rubbed their hands over it like the monkeys did to the monolith in 2001:  A Space Odyssey.

    The owner took a shot of it with his cell phone and sent it to his wife.  Within a minute, she called back and said, “I love it!  Tell Joe to ride in the back of the truck with it and make sure NOTHING happens to it!”

    With a little grunting and groaning, the four gents were able to hoist the piece into the back of the truck, and the guy’s poor friend Joe had to ride in the bed of the truck on a chilly night with the piece until it was delivered.

    Every so often, I think back to building that piece and wonder how I managed to build it.  However, it was an experience I will never trade.  My first real commission!