Stain on my brain

So, the end of the line is coming for the step ladder bookshelf project. Finishing. The part of the project that scares me. Because, well, I usually mess things up in this phase.

Deep breath, Tom. Take it easy and relax. It can’t be all that bad.

Wait a second. I’m going to use stain.

Aaaaaaaaaaaaaaaaaaaaaaaaaagh!

Yup, this is the first time in a long time (like perhaps a decade) that I’ve used stain in a project. The cherry I was using was such a mix of sapwood and heartwood, I just had to go and use some stain to – as Norm says – unify the look of the piece.

The only choice for cherry that made sense was to use a gel stain. Minwax’s cherrywood, to be exact. Since cherry is so blotch prone, gel stain absorbs slowly, preventing the inevitable nasty stain job. That is, of course, if the user applies it right. Gulp.

So, I had to sand. And, with my random orbit sander, I was able to sand through 180 grit with relative ease. I’m still amazed how quickly an thorough sanding can take a project with imperfections and really perfect it. Of course it takes time, but hey, that’s the way stuff goes.

Next up, I brushed off the dust and cracked the can of stain. It was some wild looking stuff.. kinda clotty. I stirred it up, dipped a cheap brush into the mix and started applying it to the project. Unlike the thin stuff you normally use,  you really have to move the stain around with your brush. I worked it into the corners and across the flats, keeping it as best I could to one plane at a time. This way, I hoped to prevent issues with lap marks.

Now, since gel stain is thicker than the thin stains, it also presents a challenge when wiping off the excess. Even when I followed the can directions to wipe off the excess within three minutes, the stuff on the board was already tacky and tough to wipe off. To help get around this, I dampened the wiping cloth with some mineral spirits, which took off the gummy surface residue without affecting the nice color I had gotten on the surface of the boards.

The results – not too bad. Remember that stain accentuates whatever sanding scratches you leave on the surface, so there were some areas that I had to resand. Oh, well. That’s the way it goes.

Now, I’m going to have to let it dry at least 24 hours before I can start applying a wipe-on poly to get a protective surface for the project.

And, I’m going to have to build that surface over the next few days, because I’m headed to Cincinnati for Woodworking in America 2011 this coming Thursday. More on that in Wednesday’s post…

 

Quick Poll

They are the first places we head to when we get to our shops. Whether it holds that first cup of joe in the morning, a delicate  piece that needs to be fitted into a project or a massive piece that needs some joinery cut into it, your bench is the center of your workshop.

And, as that central hub in your shop, your workbench can play into just how much enjoyment you get from being in the shop. In some cases, the bench is a real pleasure to use. In others.., well…

This week, let us know just how happy you are with the bench in your shop. Is it the pinnacle of woodworking enjoyment, or does it make you want to turn it into kindling?

 

Link of the week

The Furniture Finishing and Restoration Wizard

For many woodworkers, finishing is not their favorite part of the craft. There’s the proper sanding. Then, do you stain, dye or glaze the piece? And, what kind of finish should you use if the project is an entertainment center? Should that be different if it’s a dining room table?

Wouldn’t it be great if you could wave a magic wand and the get answers?

Well, it’s not magic, but woodworker Paul Snyder has put together an interesting site that deals with preparation and finishing issues. The site covers such diverse topics as how to finish blotchy woods such as cherry, why a washcoat can help make your finish a winner and which finishes are good for different applications.

It looks as if it may have been a while since the site was updated, but the information here is still worth a read.

Slow and steady…

I’m a big fan of turtles. The mascot at my Alma Mater, the University of Maryland? The terrapin (no, it’s not scientifically a turtle, but dude, I wasn’t a biology major). My favorite cold war era nuclear attack preparation video?  Duck and Cover, featuring Bert the Turtle. And, in the fable of the tortoise and the hare, the turtle beat the rabbit (I told you I wasn’t a biology major!) by sticking to the game plan.

That’s why I’m so damned happy to be reporting that the construction of the ladder-step looking bookcase is complete.  Yes, this is the project that started going together in mid June. It’s the same project on which I discovered how important square assemblies are.What slowed me down? The summer heat. Hurricane season. Wild and crazy kids.  You get the picture, right?

I think they came out looking pretty sweet. The top and bottom shelves fit into full length grooves in the upper and lower pieces. The middle shelves fit into custom cut notches.  Now, this is where things get exciting.  The notches in the back uprights is a nice and easy 90 degree cut. No sweat there.

The notches on the front legs are a tad more difficult. Those babies are slanted back, but the shelf sits parallel to the floor, meaning the notch on the shelf  has to be angled to accept the leg. This took a little bit of head scratching on my part, but I think the final product looks pretty darned sweet. For the assembly, I just glued the front notch, and let the back one float to avoid issues with wood movement distorting the frame.

I really dig the look at the side – the exposed shelves through the side frame really give the piece a lot of visual interest. It will be cool to look in there and see the stuff on the shelves.

Next step? Sand… sand… sand… sand… and sand some more. I have to ensure everything’s nice and smooth as well as breaking the corners on the pieces. Then, I’m gonna stain this one with some gel stain to unify the colors. Then, a bunch of coats of wipe-on varnish to ensure the piece is protected.

But, for now, I just wanna crash on the couch with a beer and sleep better, knowing that I have the tough stuff behind me on this big project.

 

My apprentice philosophy

There has been a move afoot recently in woodworking – a more back-to-basics approach as seen in the shops of the 18th century. In many cases, this leads  folks to eschew power tool woodworking completely and go entirely to hand tools. I have got to admit, watching someone build a project solely with hand tools is an impressive feat. Sort of hearkens back to the days of everyone’s favorite French woodworker André Jacob Roubo.

And, if you have been following the woodworking media for the past few years, no doubt you have seen the ultra-famous plate 11 from Roubo’s master work L’Art du Menuisier showing his shop in detail. There’s even a close up of the bench that he used as he worked wood in Paris before the French Revolution.

While many get fixated on the images at the bottom of the page showing the equipment furniture makers used in the day, I think the most telling part of the image is on top. There, you see nine rows of workbenches with different parts of projects spread out upon them, seven people people hard at work at those benches and one person walking into the room. Believe it or not, everything I have been doing to this point in my development as a woodworker has to do with the folks in that image.

Think about it. Say, on a typical Monday in Roubo’s shop, he would be working there as the big cheese… the head honcho. Roubo was a master carpenter and furniture maker, and his work was in demand. So, his job was to run the business as well as doing the highly-skilled woodworking. When it came to making a furniture piece work, he was the man. After all, his name was tied in with the operation – so his reputation was on the line.

But, who were these other folks? Didn’t Roubo do all the work himself?  Were there there to cheer him on and offer moral support?

Nope. If his shop was like any other shop, he had other folks who were working hard to make the shop hum. The guys doing the mundane work such as flattening and thicknessing boards were the apprentices. Starting at a young age, these up-and-coming furniture makers had to make their  bones for years learning the basics of how wood works, and how to prepare boards for those higher up the food chain. They would also be called upon to do much of the grunt work – such as pulling highly detailed profile planes with ropes while the more skilled carpenters in the shop guided them. Sure, it was a hard life, but if skills were going to be passed on, this full-immersion operation was critical.

Next up the ladder were the journeyman carpenters and furniture makers. Now, these folks had already done their apprenticeships, but had yet to be considered a master in the guild. As such, they could charge a daily rate for their work (the name journeyman comes from the French journee – the word for one day). Now, these journeymen were skilled and already possessed knowledge, but they were still working to learn more about the craft. As such, they could be counted on to do things like cutting joinery and even completely assembling less complicated pieces. Eventually, the journeyman would build a project which could be submitted to the guild for consideration to full membership. This project would be known as their masterpiece.

Now, what the heck does this have to do with my shop? Everything. Just as Roubo was busy doing several things, so am I . I have that old eight  to five gig – with additional nights and weekends for talks and events. There’s the laundry, lawn mowing, dish washing, home maintenance and other required chores. I have to ride herd on the boys with their homework. I’m coaching my sons in basketball this fall. My wife would like some time with me away from the chores. There’s this blog thing. And, yes, I also like to woodwork!

In my mind, I have come to appreciate the work that my apprentices can do for me.. by plugging in my power tools. Yup, I can tell my portable 12″ apprentice to plane project boards down to a certain thickness, and it gets done. I can also plug in my 1.5 hp apprentice and instruct it to clean up the dust and shavings, and that job gets done as well.

When it comes to the work that the journeymen would do in my shop, sometimes I like to do it. I’ll try hand cutting dovetails or hand planing edges of boards for glue ups. But, I have absolutely no problem giving these projects to the router or table saw to handle.

Of course, I keep the master work to myself. The design. The final fitting of joints. The careful surface preparation. That’s where I see the enjoyment of the craft in my shop.

Classifying the work I do in my shop into these three categories has helped me keep my sanity on many occasions. Rather than trying to achieve some mind-numbing hand tool technique, I will make an assessment on my own of where the job belongs and assign it to the proper folks in the shop, just as Roubo had to back in the day.

Keeping this in mind helps me work more efficiently in my limited shop time, and it also gives me a better appreciation for the folks who had to the do the job centuries ago – and the folks who invented the power tools to give me the option to handle them on my own.

 

Quick Poll

Simple woodworking projects are a lot of fun to build. They can be done quickly and build a lot of confidence. And, then there are more complicated projects. Ones that involve a lot of thinking, a lot of planning and a lot of tricky joinery.

For some woodworkers, this isn’t a big deal. For others, well, we need a little bit of help trying to sort out the building and assembly steps.  Will we need special clamps or a fancy jig to make things happen?

Fortunately, there’s an easy way to get to the bottom of these questions – build a prototype. Using inexpensive pine, plywood and even cardboard can help you get an idea of the building challenges and the overall size and proportions of the project.

Today’s question – which comes from our friend Allen Grayson – do you build prototypes of your projects?

 


Link of the week

The de Havilland Aircraft Heritage Center

Yesterday, the United Kingdom commemorated Battle of Britain day – the anniversary of the day of heaviest fighting between the Royal Air Force and the Luftwaffe during the crucial Battle of Britain. Had the RAF faltered and not held its ground against the Nazi air force, the history of the world would have been very different.

After the battle, the RAF realized they need a way to get more high-performing aircraft into the air as cheaply and efficiently as possible. While the Hawker Hurricane and the Supermarine Spitfire were modern, capable aircraft, they were made out of precious aluminum and had to be assembled in specialized factories.

That’s when the de Havilland aircraft company came up with the idea of the Mosquito. This multi-role aircraft handled a great deal of assignments – fast bomber, fighter-bomber, night fighter, torpedo bomber, maritime patrol, transport and reconnaissance. What also makes this plane unique is that its fuselage was made out of wood.

That’s right. The plane’s body and wings were made from plywood and wooden laminations, giving the plane some impressive strength.  The plane held its own against more advanced all-metal planes operated by both the Germans and the Japanese.  Herman Goering, the commander of the vaunted Luftwaffe, even remarked:

It makes me furious when I see the Mosquito. I turn green and yellow with envy. The British, who can afford aluminium better than we can, knock together a beautiful wooden aircraft that every piano factory over there is building, and they give it a speed which they have now increased yet again. What do you make of that? There is nothing the British do not have. They have the geniuses and we have the nincompoops.

The museum offers visitors a chance to see this game-changing plane up close to appreciate the craftsmanship of these craft and tells the story of how the Mosquito helped turn the tide of World War II.

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