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Link of the week

Wood and Transience

The Writing Hall of a Zen Monistary in Kyoto, JapanIn the western tradition, we tend to build structures we want to see last a long time. Imposing stone castles from the Dark Ages and stone Roman Aqueducts still stand, hundreds or even thousands of years after they were built.

The Japanese philosophy, however, is quite different. This article – with some amazing pictures of master woodwork projects – gives an interpretation of the Japanese mindset when it comes to building structures and furniture.

Besides the fact that the Shinto culture reveres trees as having a spiritual identity, the choice of timber and joint selection also allows the structures to flex and move in the event of an earthquake – a common occurrence in this seismically active island archipelago.

Even if you just visit to view the incredible architectural photos, the site is worth the trip.

Woodworking Spotlight – Joe Gorleski, Jr.

Hey, look, it's Joe!Mention the world ‘veneer’ to some woodworkers, and they may turn their nose up at you. “That’s for cheap, mass produced furniture. I only use REAL wood!”

Well, surprise. Veneer IS real wood, applying it is a venerable woodworking skill to master and there’s a website that can show you just how impressive veneered projects can look.

Joe Gorleski, Jr, – known far and wide as Joe Woodworker – is a retailer of fine wood veneers that can take a woodworking project from nice to Woah!

Hammer VeneerJoe’s beginnings in woodworking were pretty humble. “I had inherited a used jigsaw that was gathering dust in my parent’s basement. One evening, we were cleaning out the basement and I had to decide if I wanted to keep the jigsaw or toss it out. I saw this pine board lying on the floor, grabbed a pencil and drew a pig shape on the board. I cut it out with the jigsaw and I discovered that I loved it!” Within a few days, Joe had plunked down some of his hard-earned cash and bought some other essential tools. The woodworking bug had bit him hard, but the biggest discovery was yet to come.

 

Veneered folding tables“Veneer is definitely cool. It has dramatically affected the way I look at wood. I used to spend hours at our local saw mill looking through hundreds of freshly dried boards to find anything unusual. The hard part was finding enough lumber with character to make a project. Now when I buy lumber, I look more often for perfectly un-figured boards so I can highlight any veneered portion of a project and keep the visual focus on these truly figured parts.”

 

 And, what figured parts they are! The selection of wood species available is stunning. Walnut burls, fiddleback maple and sapele pommele are just some of the stunning offerings on the site. It seems that you can find exactly what you need – regardless of your requirement for wood color, figure or even cost. Some breathtaking veneer lots can be found for cheap – offering multiple sheets for book matching or other eye-catching effects.

 

Quilted Bubinga Veneer SheetFor his first projects, Joe cobbled together a vacuum pump from plans he found online and by talking with other woodworkers. Since he was learning on his own, sometimes these early projects worked, other times, they didn’t. “Sure, there was trial and error. But, some of the techniques I’ve picked up from our gracious customers who very frequently share their success stories with me. One of the greatest things about woodworking is the incredible amount of sharing that goes on between woodworkers.”

From those humble beginnings, it didn’t take long for Joe to realize that he had way more veneer than he could ever use. “When I got to the point at which I was storing veneer under my bed, my wife and I realized it was time to let some of it go. Between veneer and vacuum press parts, we figured there was enough to get a small business going.”

Today, Joe’s commercial site VeneerSupplies.com provides quality veneers, equipment and – most importantly – know how to thousands of woodworkers around the world. “Our customers are quite varied. We have a lot of customers who are not woodworkers. They just want to veneer over something unsightly. I’ve had strange questions about veneering everything from refrigerators to turtle shells. I don’t recommend veneering your turtle!”

Joe's first Veneer projectVeneering might sound intimidating – and expensive – at first. However, there are some affordable options that the hobby woodworker can look into. First is a glue called Heat Lock. By using this glue, veneer and a clothes iron, the average woodworker can get good results. The ancient art of hammer veneering is also an option. But, for woodworkers looking to really expand their veneer options, vacuum pumps are the easiest – and sometimes the best – option. Some build it yourself kits start at $150, and complete systems can run about $400.

 

Veneered Drum Kit

 “Our website often conveys the image that we are a huge company. There’s a fine line between an average website and a professional one. I prefer to have a professional website but it’s not easy to communicate that we are still a small company consisting of just my wife Christine and myself. Our customers like the personal attention they get from us because it means that our answers and comments to their questions are always genuine.”

 

While Joe’s website is impressive, his personal approach with customers can leave some people a little off guard. “I always smile when someone calls to place an order and asks my name. When I say “Joe”, they always reply “the Joe?” I can’t help but smile because I’m thinking who else would answer the phone in my shop?”

Making centered mortises with a plunge router

I was working in my shop this past weekend using this mortising base kit I picked up at Eagle America to make centered mortises in a project I’m working on. It’s fitted out with two roller bearings that ride along the side of the piece allowing a gliding action over the surface of the wood.

Sure, there are lots of plans out there to build a base like this, but for $19, well, I couldn’t pass that one up!

The mortising base plateFirst, I had to drill the base plate to fit the base of my DeWalt router. Proper alignment is essential so the base is perfectly centered over the collet. Believe me, if you don’t get the base perfectly aligned, it’s not going to work as advertised. You may want to use a centering pin to ensure proper alignment.

Marking the mortise limitsThe next step is to mark out the limits of the mortise you want to cut. Since the mortise will be centered on the piece, marking the left and right sides of the mortise isn’t critical – the length, however, is.

Router in placeI put a 3/8″ up-spiral into the collet and set the router up on the workpiece. I set the depth of the bit at 9/16″ – allowing space for a 1/2″ deep mortise with 1/16″ space at the bottom of the joint to serve as a glue reservoir. When I rotated the base on the workpiece, the bearings made contact with the sides of the piece, ensuring the base is aligned with the work and the bit will land dead center.

Plunge cutsNext up, I started cutting the mortise. Rather than try making the mortise pass by pass, I started by plunging the bit to its full depth at both ends of the mortise. This established the start and end limits. Then I made a series of full-depth plunges the length of the mortise to remove the majority of the waste.

Clean mortiseFinally, I ran the router bit from end to end in the mortise to clean up the areas I had missed during the plunging action. Since there was very little to remove, I could plunge right to full depth and run the length of the mortise to get a clean mortise ready for a tenon.

Link of the week

WoodProjects.com

Woodworking plansSo, you want to build a woodworking project, but you are not sure where to find a set of plans to get started with?

This site should be your first stop. WoodPlans.com has links to plans you can buy as well as free ones from many sources – magazines, tool companies and private plan designers.

The secret to their 9000+ plans in the inventory is that they have agreements to sell plans from many different sources, and they scour the internet for offerings.   Their free plans are links to truly free plans.

The plans are broken down into very logical subsets, and you can browse or use the search feature to find what you need.  You’ll find plans for every room of the house – and for outside projects as well.

You want a plan to build a four post bed?  They’ve got links to 21 plans.  Dining tables?  24.  Workbenches?  99!

They accept credit cards, online checks, PayPal, money orders and even telephone orders, making the site a convenient resource for finding what you need.

Planing a bevel on a panel

So, you want to put a bevel on the edge of a panel? Well, you could use a special router bit. Or, you could rig up a high fence that works on your table saw. But, what if you don’t have the bit or feel uncomfortable with a large panel on edge?

Have you tried hand planes?

The tools you needIt’s not as tough as you think. In fact, with just a few tools, this is a fast method that will work quickly on any size panel.

First of all, you have got to have at least one tool, and the other one makes the job a whole lot easier. The tools I used are an old Stanley Bailey No. 5 Jack plane (essential) and a wheel marking gauge. The gauge is going to mark out what needs to be removed, and the plane’s gonna do the removing.

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Marking the depthMarking the width The next step is pretty essential, I’d say. You have to carefully mark the depth and width of the area you want to bevel. This way, you know exactly what you need to remove, and you’ll be able to keep a consistent bevel. For this exercise, I used one inch wide and one quarter inch deep.

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Planing the bevelNow, with the panel securely clamped to your work bench, you can use your plane to remove the material to form the bevel. I start with the end grain, planing slightly ‘down’ and ‘out’ with the plane to prevent tear out. Once that’s done, then I move to the edge grain to remove any tear out – just as when you use a router.

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Finished bevelFinally, what you are left with is a crisp bevel that just needs a little sanding – especially on the end grain bevel. The beauty about this method is that you can use it to create any number of different bevel geometries. And, if you want to bevel a door panel, table top or any other piece of furniture, well, this method doesn’t require complicated jigs or expensive router bits.

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Woodworking Spotlight: Jim Heavey

Jim HeaveyWhat separates an ‘OK’ woodworker from one who has a passion for the craft? Sometimes, it’s as simple as encountering someone who can show a new, interesting way of looking at things. For Wood Magazine’s contributing craftsman Jim Heavey, showing the way for others is something that – due to a family tragedy – he took to at an early age.

Jim’s dad passed away when he was in grade school. Out of necessity, Jim assumed a leadership role as the man of the house at an very early age. “Being the oldest of seven kids in a household with very little money, repairs and projects around the house fell to me. I think that it was there that I developed an appreciation for woodworking and the sense of accomplishment that completing a project brings.”

Later in his life, Jim’s leadership ability again came to the fore. He even served as his children’s school board president for 16 years – all this after doing his ‘day job’ as a firefighter. His years at this important position allowed him to hone his presentation skills considerably. “Having audiences both happy and irate – sometimes at the same time – kept me on my toes and helped me develop a style that people seem to enjoy. I don’t take myself too seriously and I think that I can relate to my audiences.”

Does he ever! Jim’s easily approachable style allowed him to marry his love of woodworking and presenting when he landed a position doing tool demonstrations for the Skil tool company at the now-defunct Builder’s Square home improvement stores. When Bosch bought Skil, Jim’s expertise was recognized, and he was chosen to present at national shows. One day in 1996 at one of these national shows, a Wood Magazine representative approached Jim to fill in for an ailing presenter. The rest, as they say, is history.

Jim wows the crowdJim has been teaching at the Woodworking Shows for Wood Magazine ever since. You can find Jim at the Wood Magazine demonstration booth, teaching tips and techniques to dozens of very interested woodworkers. While you might assume his presentations are just tool or magazine sales pitches, Jim always keep his focus firmly on helping the audience learn new techniques. “What I enjoy the most is being able to bring enough content to the presentations to touch some aspect in every attendee’s shop experience. We have a wide skill level in attendance at the shows and I am so glad when people will say, ‘Thanks, I learned something new today.’ The challenge is to remember that I’m not selling the tools, I’m imparting knowledge. A good tool sells itself and I’ll use it to its best advantage but I want them to learn something.”

Jim’s Jewlery BoxLearn something they do. The day I met Jim at the Woodworking Show in Tampa, he was demonstrating a very simple yet elegant way to embellish a project by using an applique technique.

By cutting a shape out of a contrasting piece of wood – a leaf pattern, for example – and gluing it on the surface of the project, then sanding it down to about one sixteenth of an inch with a belt sander, anyone can create an interesting design feature with minimal work.

“I do like to watch the faces of the attendees when they see that a topic I’m talking about suddenly look so simple to them. It’s that ‘ah-ha’ moment. My hope is that attendees will try some of the techniques that I use. When they find success, they will take one more step that brings additional success. It’s very rewarding to talk to someone who had watched and tried something that they learned come back the following year even more excited about their craft.”

What’s the toughest part of the job? “The traveling part can be very tiresome. There seems to be a different TSA standard in each of the 30+ airports I’ll see in a season.”

“But,” Jim continues,”when you see the crowds at the door, you know it’s show time. They expect a good experience and I really do enjoy giving it to them.”

“In the end, a one on one discussion with a fellow woodworker brings out our commonality regardless of locale. It must be in the wood,” Jim laughs, “or maybe it’s the high from applying lacquer.”