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Link of the week

Hand-Cut Dovetails After Fifty  

Hand-cutting dovetailsWow, if this week’s quick poll is any indication, it looks as if the majority of our readers prefer to hand cut their dovetails. That’s quite a surprise to me.

This site’s author Norman Havens proves you can teach an old dog new tricks. This site offers step-by-step instructions with clear photographic illustration of the hand-cut dovetail process – from the initial steps of marking out the pins to the final fitting of the completed joints.

The most valuable part of the site is that Havens not only describes the process, he also discusses the difficulties and mistakes he made along the way.  This way, the novice dovetailer can hopefully avoid some common pitfalls.

While there are many other processes to cut these complicated joints, this site will get the novice up and running with the basics.

The Roller Coaster ride of experience

Kumbaat Busch Gardens - WOW!I’ll remember it like the day it happened. I was standing in Busch Gardens, the Dark Continent in Tampa one steamy August afternoon. Looking up, my sight fell upon the aqua and red tracks of Kumba, the new enormous roller coaster the park had just opened. 143 feet tall. 114 foot vertical loop. Batwing maneuvers. Not one, but TWO inverted cobra rolls. This thing was a monster.

As the train whooshed by at 60 miles per hour, I could feel myself being knocked backward by the rush of air and deafened by the roar.

And, I was in line to take a ride on it.

I grew up in a family where my mom couldn’t stand to see her sons in peril. She cringed through six football seasons as my younger brother took to the gridiron. We grew up within short driving distance of a ski resort, but never went because it was too dangerous. Needless to say, whenever we went anywhere with a roller coaster, we were told just how perilous they were.

So, you could imagine my fear when I boarded the train – my first real roller coaster train – and it started to go up the lift hill.

Now, sure, it may not be as dramatic as that first rush down the hill in the coaster, but why do I sometimes feel the same apprehension before trying anything new when I woodwork?

My first dovetailsFor instance, a few years ago, I was building a shadow box for my dad to house his military badges and medals. I found some choice maple that would be perfect when finished. I also found a nice scrap of cherry molding that would be just long enough to dress the piece up and serve as a glass stop. Everything was going to be perfect.

In order to make this piece extra special, I decided I was going to use dovetails. My first ones. Ever. Gulp.

No one could accuse me of not doing my homework. I read everything I could get my hands on about machine vs. hand cut. I visited every woodworking forum I could think of. I asked every woodworker I knew for their opinion.

Finally, after nearly two months of weighing my options, I went to my local Woodcraft, walking with the swagger of a seasoned woodworking veteran, and headed straight to the dovetail jigs. When I got there, I froze. The choices were staggering. Akeda. Leigh. Shop Fox. Stots Template Master. I had that blank look in my face when one of the employees walked up and asked me what I was looking for.

When I told him I was a complete novice and never had even seen a dovetail jig before, he recommended the Keller setup. I plunked down my hard earned dead presidents and headed to the car.

When I got home, there was no bravado or swagger left. I found myself staring at the manual, trying to make heads or tails of what I was reading. Tentatively, I assembled the jig and put the bit in the collet. I laid the router down, wood clamped to the jig, and walked inside.

Six days later, when I finally got the courage up to actually make a cut into the lumber I had lovingly jointed, planed and cut to length, I gingerly stepped into the shop and plugged the router in. The router whined to life and, after stopping six or seven times to ensure everything was the way it had to be, I touched bit to wood and stared cutting. Sawdust flew everywhere. Cut, cut, cut.

When I was done, I flipped the jig around and cut the pins. Cut, cut, cut.

Much to my amazement, the joint slipped together – perfectly – on the first try. I was so jacked, I took the pieces inside and showed my wife, who happened to be taking a nap on the family room sofa.

“Wha… Oh, that’s great.” She closed her eyes and lay back down to sleep.

I walked back to the shop, and proceeded to cut the rest of the joints. That afternoon, I had met dovetails, and I had kicked their butts.

When I stepped off Kumba after my first ride, I was pumping my fist in the air.

Now, THAT’S what I’m talking about!

After that, I looked at all roller coasters with a sense of anticipation. “Honey, when can we go to Sandusky, Ohio to ride the coasters up there?” I want a new challenge.

Funny how that first success can breed so much confidence…

Stuff I’ve built: The office media center

  • January 2008

In my real job, I work in a busy communications office where we frequently hold meetings about important happenings. In our conference room, we have a laptop computer and an LCD projector. We can tie into the Internet, play PowerPoint presentations, show video etc.

But, yuck. The tangle of cables. The exposed computer. So, one day, my boss turned to me and asked, “Can you build us something?”

Tabletop LCD projector stand

Does that qualify as something?

The design was one I had sketched up from scratch. It’s a mahogany box with a maple top hinged on. There’s a ‘garage’ where the computer can go in to hide, a hole in the bottom of the box for the power and internet connections and a cable hole for the data and power cords for the projector. I dovetailed the corner with the Keller dovetail jig.

The finish was a 1# cut of dewaxed shellac, buffed out with #0000 steel wool after it had cured for four hours. Then, I used two coats of Watco natural Danish Oil. After that cured, I waxed the piece with Minwax furniture wax. It’s not a table top, but it should stand up nicely to the rigors of long meetings.

Nice piece sez everyone.

LCD projector box open

And, if you have to work on the connections, the top lifts up for easy access to the works. This is a better set up than having a projector permanently mounted from the ceiling, because if we ever have to move the equipment to a new location, we can disconnect it and take it with us.

So, what about you? Do you have a project you want to brag on? Be sure to e-mail me if you want to share.

Link of the week

Patrick’s Blood and Gore Page

Old Stanley PlanesSure, it sounds like a page where people might talk about gruesome murders or the latest shoot-em-up video game, but this is actually one of the best resources for Stanley hand plane information on the Internet.

Patrick Leach of the Superior Tool Works assembled this virtual library of information on the hundreds of different styles of hand planes build by Stanley Tools from the mid 1800s through the 1960s.

Leach concentrates his efforts primarily on the Bailey and Bedrock offerings, not delving too deeply into the lesser-quality lines such as Handyman.

While his style is pretty tongue-in-cheek, and he does lean heavily toward offering his own personal opinions (especially when it comes to the transitional offerings from New Britain) there is no doubting that he has done his research. Sole lengths, blade widths, special features and the like are all offered in meticulous detail. If you are looking for a new hand plane, this site is a must see.

Is he the Norm?

Get a group of woodworkers together, and, eventually, the topic of Norm Abram will come up.

His NormnessIt’s not difficult to figure out why. He’s been a fixture on This Old House since the show’s inception in 1979 – nearly three decades. This year, the New Yankee Workshop marks its 20th anniversary.

He’s built projects that can fit in nearly every room of the house – including the workshop! Different period styles – from the plain, strong lines of Shaker to the ornate Hepplewhite – have been tackled in detail. He’s worked with high-tech plywood and antique timbers.

His plaid shirts, safety glasses and beard are as essential to his persona as Santa Claus’ red, fur-trimmed suit and black boots.

One other thing Norm does is bring strong opinions to the surface. Some woodworkers see him as a bad influence, cheapening the craft. Their knocks on Norm include:

  • Reliance on the brad nailer. Looking at several seasons of the New Yankee Workshop, you’d wonder if anything could be built without the ubiquitous brad nailer. Norm uses it for assembly of dust frames, setting shelves into dadoes, attaching face frames and a whole lot more. I’ve heard woodworkers pin this on his background as a carpenter instead of a true furniture maker.
  • All those danged tools! “If I had a shop like that, I could build anything, too,” is a frequent lament of woodworkers – especially those who are just starting out. More than a dozen routers, a Unisaw, huge jointer – it would appear that Norm has just about every tool imaginable at his disposal. The biggest offender in the shop is the Time Saver wide belt sander. That piece of industrial equipment is well out of the price range of most hobby woodworkers. This tooling requirement is often seen as a reason why new woodworkers either go into massive debt or give up on the craft.
  • More Power! In his first book, The New Yankee Workshop, Norm describes the philosophy behind the show. Old Yankee furniture masters relied on tried-and-true hand tool techniques. The New Yankee approach is to incorporate power tools into the traditional methods – seemingly shunning more traditional methods. Sometimes, it seems as if Norm spends quite a good deal of time jigging up a power tool to do something that could easily be done in a lot less time with the proper hand tool.
  • He’s beholden to his sponsors. For years, whenever Norm used pocket screws, he turned to his Porter-Cable production machine – even though Kreg Tools has been offering pocket hole jigs at a much more affordable price since 1990.
  • Fast and cheap. Plate or biscuit joinery has been used in European cabinet shops since its invention in 1956. When the technology jumped the Atlantic, Norm was an early adoptor. While the biscuit speeds production, many see it as a less-than-adequate way to create a joint. Some novice woodworkers will frequently use the biscuit where other, more appropriate joints should be used – in chair production, for example.
  • Finish fussiness. Why do most New Yankee Workshop cherry projects come out looking so dark? True, many different styles of furniture did rely on dark finishes, but most modern tastes are dictating a natural look – letting the wood speak for itself. Cherry and Mahogany are two beautiful woods with just a clear finish on them.
  • Norm, Inc. What do you get when you order plans for a project from the New Yankee website? A measured drawing. No step-by-step instructions. You want step-by-step? Add the DVD – a $15 upcharge – to the cost of the order.
  • The final authority. “How would Norm do this?” Sure, he’s popular. His show is just about everywhere you look. And, many woodworkers see only this when they think of woodworking authorities. It took years for me to discover who Sam Maloof, Frank Klausz, Glen Huey, Doug Stowe and dozens of others of talented woodworkers are. Others like David Marks, Roy Underhill, Scott Phillips and Bob and Rick Rosendahl are on TV, but their growth has certainly taken place under the influence of the very popular New Yankee Workshop.

Now, for all of the knocks Norm takes, there are many more supporters out there. Their arguments include:

  • He’s an encouraging force. It’s true that many of us grew up with a parent, grandparent, shop teacher, etc. to thank for our interest in woodworking. I’d be willing to bet that many hobby woodworkers got into the craft watching the New Yankee Workshop. Norm’s friendly, accessible personality has welcomed viewers and his clear explanations have taken away most of the mystery that existed around the craft. Just think how many woodworkers would not be building today if it weren’t for Norm.
  • He’s come a long way, baby. Go back and watch some of the New Yankee Workshop’s early seasons. His spindle sander was a sleeve chucked in a drill press. His miter saw didn’t have a laser. He built a lot of jigs because he didn’t have his stable of tools. In other words, his shop has grown over time with the acquisition of new tools – just like every other woodworker’s, including mine.
  • He’s getting back to the roots. In recent seasons, Norm has put down the Leigh jig and picked up the backsaw to cut dovetails. He’s used more hand tools to sculpt and form pieces, such as the top rail support in the Dominy Clock. He’s become more concerned with aesthetics – shying away from the brad nailer to more blind joining methods. He seems to be transitioning from his carpentry background to a more polished furniture making form.
  • He’s diversifying. Over the past few years, Norm has added a number of new tools to his arsenal that aren’t the most expensive on the market. This season’s nine-part kitchen cabinet opus sees him using the affordable Kreg jig for pocket screwing face frames together. You have to admire this change in philosophy – a move to get beginners back to the table.
  • He’s offering his wisdom for FREE! Good luck trying to get a talented woodworker to take the time to explain how the lathe works. Or how to build his jigs. Norm does offer his step-by-step instructions free every Saturday (in my market). All I have to do is DVR or – gasp – tape the episode, and I can go back to watch the technique until I get it right.

So, where does this leave us? In my opinion, the case against Norm is overblown. He may have his detractors, but the contribution the guy has made to the craft can’t be ignored. If it wasn’t for Norm, where would This Old House – and the scores of home improvement shows that have followed since – be? How many folks would not have taken up the craft? And, with fewer woodworkers, how many manufacturers would have been so innovative over the past decade, bringing affordable new technology to the home workshop?

What are your thoughts? How do you think history will judge the New Yankee Woodworker?