All posts by Tom

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Tools I use – My Keller Dovetail Jig

Keller 1500 Journeyman Dovetail Jig

Keller Journeyman 1500 jigWhether fair or not, dovetail joints are widely considered the mark of true craftsmanship when it comes to woodworking. While some find hand cutting dovetails with a saw and a sharp set of chisels a rewarding experience, others want to cut the joint with a minimum of fuss and a great deal faster.

Back in the 1970’s, David Keller perfected the through dovetail jig that bears his name – the Keller Dovetail Jig. Since those early days, a number of other manufacturers have introduced their jigs and other dovetailing systems. Some are relatively simple, while others have a rather steep learning curve.

When I went to Woodcraft a few years ago to buy a dovetail jig, the Keller Journeyman 1500 came highly recommended. An excellent balance of price, ease of use and flexibility, this jig has proven itself time and again in my shop.

Projector StandThe kit comes with special bearing guided bits (1/4″ shank) that work with the jig, the jig fixture itself and a clearly-written instruction manual. You have to secure the jig to a backer block made of wood or a stack of sheet goods that fit a particular measurement. To adjust the tightness of the joint’s fit, you adjust the jig forward or backwards on this backer block.

Since I had never used a dovetail jig before, it took some time to carefully go through the measurements, but it was worth it. The results were very good the first time out.

Variably spaced dovetails can be made easily by cutting the necessary tail slots in the pin board, and then cutting all of the pin slots on the tail board, then removing the unnecessary ones with a sharp chisel.

My first dovetailsThe one caveat with this jig – as with many others – is you have to carefully mark where the joints will align. This is a very important skill to master whether you cut the joints by hand or by machine. A striking knife – even a cheap Xacto knife from an office supply store – will work well.

Also, this jig only allows you to cut through dovetails. To make drawers which appear to have a half-blind dovetail, you can glue a thin piece of material to the drawer’s front. A simple and elegant solution that will allow you to stretch your showy wood supply.

An important tip – when you arrange the jig and the wood in your vise, be sure to put the backer block between you and the wood – this ensures the router cuts into the wood from the side opposite you, throwing the wood chips away from you while you are cutting.

While there are other jigs out there, I can see myself coming back to this jig time and time again. It’s really that easy. And, judging from what I saw on the Keller website, there are even more applications that can be mastered.

Quick Poll

Problem? Who has a problem? Some woodworkers are wood hoarders, snapping up bargains on any supply of boards they can get their hands on. Others buy what they need, refusing (or unable) to keep a stockpile on hand. So, where do you fall?

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A tour of my shop

Have you ever wondered just what the heck my shop looks like? Sometimes, with my work schedule this time of the year, I wonder too…

Well, my old digital camera died, and I got a new one. Rather than snap pictures of the kids, I took the opportunity (or used it as a good enough excuse) to finally get out into the shop and take a few pictures.

Welcome to the shop!

This was a gift from my wife – sort of a little bit of a welcome to the shop sign. I kinda like it – and I remind everyone about its status when they arrive.

Shop Overview

This is the shop overview shot – what you might see on a typical weekend day if you stroll past the front of my house. Yes, I have converted the two car garage into my shop. It’s a comfortably sized space that I share with some kids toys, some mechanical systems and the laundry equipment.

Clamp Corner

This is what you see at first when you look to the right as you walk into the shop. Here’s where the rolling clamp rack, 14″ band saw and dust collector are parked here. This is also where I keep the scrap buckets for offcuts.

The tool stack

This entirely unattractive piece (which doesn’t lean nearly as badly as the camera is making it appear to – guess I have to learn how to take better pictures) of shop storage I threw together from two pieces of 3/4″ CDX plywood. I needed a way to stack up some of the tools I had acquired, and this fills the bill. Compressor at the bottom, router equipment up from there, pocket screw jig and sharpening equipment above that, and tool rehab projects in the plastic bins on top.

The side bench

This is my side bench. The cabinets came from a friend’s kitchen remodel, and serve me well in the shop. The uppers store my finishing supplies, the lowers store hardware, finishing rags and other goodies. This is also the location of the plane shrine. The top is an excellent place for me to stage project parts when I’m working on other components on the main bench.

Also, you’ll notice my rolling tool cart I got last Christmas. It holds most of my hand tools, keeping them dust free and easy to grab.

The front bench

This piece is my front bench. The lowers store power hand tools, while the uppers hold fasteners, glue, tape and other goodies. I will do some work on smaller projects and parts of larger ones, and I do most of my sharpening here. Unfortunately, this is also the surface closest to the door, so my wife will leave things that have to go back out to the garage here as well. It can get cluttered!

The Table Saw

Of course, this is my Ridgid table saw. Since it’s right at the garage door entrance, I can rip longer pieces easily by opening the door. You can see I also built a router table top into the right wing. I have a Freud FT2000 mounted under there, which does a great job. I spend a good deal of time in this area.

Big Ugly

Here’s my big ugly bench. Work on the top, and storage for the spindle sander and planer below (which also happens to add a great deal of mass to the bench – a big plus). The bench serves as and outfeed table. Normally, I can work up near the vise and rip off the table saw and not have issues… I just have to make sure I can clear the stuff on the bench top.

My wood stash

Shhhh… I don’t want anyone to know about this area… but most of my wood stash was given to me by some friends and other ‘people’ who don’t want to be named. It’s a decent pile of cherry, walnut, maple, poplar and oak. I could tell you where I got it, but I’d have to kill you after. Ultimately, I need to find a better place for this stack somewhere else in the shop (perhaps overhead). But, for right now, it’s an OK set up.

Now, for a quick matter of blog housekeeping – my wife and I are celebrating our 15th anniversary this week – so, don’t look for a link of the week this week. I’ll be back on Sunday, however, with a brand new quick poll.

Thanks for visiting!

Quick Poll

As woodworkers, we are always doing something when it comes to the project we are currently working on.  Buying materials, building or finishing – maybe even planning our next adventure.  So, in this week’s poll, we wanna know…

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Link of the week

The Maloof Foundation

Sam Maloof in his shopSam Maloof is a living legend in woodworking. There. I said it. And, I doubt there would be many who would disagree.

Since he started building furniture, his projects have showcased the strong, flowing lines of his design and craft. His pieces have been sought out by presidents of the United States, museums and private collectors from around the world. His works have been emulated by thousands.

Now that Sam is 92 years old, his thoughts have turned toward the future of the craft and showcasing masterworks of up and coming artisans. The Maloof Foundation was founded in 1994 in the original structures of his home and workshop.

A principal responsibility of the Foundation is protection and conservation of the art, furnishings, structures and grounds entrusted to it. The residence itself is one of the most treasured parts of the collection, reflecting the living spirit of the arts and crafts movement throughout. The Foundation also makes the Maloof Center available to the public, artists and researchers and is developing a variety of programs, including visiting craftsmen, workshops, and arts and crafts exhibits. The Jacobs Education Center provides gallery and meeting space.

This site is definitely worth a visit to learn more about the master and his methods of work.

Raider of the lost arc

Well, it might be hard for me to hide my excitement…

I was published!

Drawing the arcLee Valley Tools has published an article I wrote about two easy ways to draw arcs on projects. Rather than rely on a bent piece of masonite or some other contraption, simple shop algebra or geometry (OK, stop laughing!) can ensure your arc will perfectly fit what you have in mind for your project.

You can click here to read the entire article and maybe learn a thing or two!

Click here if you want to read Lee Valley’s current newsletter or subscribe to receive a copy by e-mail.

If you would like to read some of my older published woodworking articles, visit my Woodworking Chops page.

Yes, but is it art?

So many things in life are subjective, aren’t they?

Do you think that was a good movie? Wasn’t that the best wine you ever tasted? Hot enough for ya?

As a hundred people the same question, and you will no doubt get 100 different answers. “That movie has plot holes so large, you could drive a truck through them.” “The wine reminded me of a subtle mix of mouthwash and pine tar.” “If you say another word about how hot it is, I’ll kick you in the shins.”

There are no right or wrong answers, just opinions.

Dogs playing pokerThen, why is it that when it comes to woodwork, there are so many ‘experts’ out there who claim to know exactly where the line between craft and art is drawn?

Sure, I can appreciate that the oak pantry I built for my kitchen is 100% utilitarian with just a little bit of decoration so it could pass as ‘furniture’. And, a famous painting, like the one of the dogs playing poker (I love that one) is art that you hang on the wall.

Stele II at the National Sculpture GardenThe line does get blurry when considering other forms. Last year, I was taking a family trip to Washington D.C., and had a chance to walk through the National Art Museum’s Sculpture Garden. Some of these large-scale pieces were really eye-catching, showing a lot of originality and creativity.

Then, I came across this piece. It was ‘sculpted’ by Ellsworth Kelly in 1973, and it’s called Stele II. It is exactly what you would think it is… a one-inch thick piece of steel cut with rounded corners and allowed to weather naturally, thereby losing its shiny nature through the past three and a half decades.

No doubt, the artist did put a great deal of time, energy and thought into crafting this dramatic piece… about the same amount of time, effort and care you might find that a steel worker at a shipyard put into cutting an identical piece out of a larger plate. Yet, this qualifies as high art, and is ensconced in one of the nation’s premiere sculpture venues.

Shaker ChairNow, take a look at a gorgeous piece of furniture, and there will be a different classification. Here’s a chair built by a Shaker brother sometime around 1850. Knowing about the Shakers and their practices, there’s a very good chance the wood was carefully selected for its strength and joint holding abilities. It was precisely split – not sawn – from the blank to provide even more ruggedness. Turnings were done by either a treadle or hand-cranked lathe. The joints were cut by an expert hand using keenly sharpened hand tools. Except for the turned finials at the top of the seat back, it is devoid of all ornamentation.

Yet, the chair is a work of sculpture in its own right. It looks like there is an impossibly small amount of wood to support a person’s weight, yet these antique chairs can support 250 pounds or more.

But, don’t expect to find piece like this in an art museum. No, you’ll find those pieces in a craft gallery. Not quite fully recognized as art, a piece like this is viewed in a completely different light.

Why would I bring up such an esoteric point? I’m glad you asked.

National Art ProgramAt my job, this is the third year that the National Arts Program is holding an art contest for current and retired employees and their family members. As I have for the past two contests, I’m entering this year’s with a project that will spotlight my woodworking talents.

The past two years have been very successful for me. I took first place in the Intermediate Adult class for my Contemplation Bench and Pagoda Box. Both brought pretty hefty prize money, which I immediately put toward the purchase of new tools.

While I was enjoying my accolades last year, one of the artists who didn’t win came up to me and told me that I shouldn’t enter an art contest with a craft project. “It’s not fair to the true artists in the field.”

I chalked that comment up to being her opinion.

And, of course, it’s my opinion that I might have another winning project in the works.