A project post-mortem

Sweet redemption.

How many times has it happened to you?  You are cutting a part for a project and something goes wrong.  Maybe you get a little splintering on one edge.  Instead of a crisp edge, you round it over.  There. No need to throw it away.

How about that board you cut too short?  Easy.  Just cut another piece and start over.  Issue resolved.

Maybe something else goes wrong… well, that’s just a design feature.

In fact, in many cases, anything that does go wrong can be gracefully recovered from with minimal fuss. The projects look great, and no one is the wiser.

But, there are projects that could be declared dead on arrival after a big boneheaded move.  Unfortunately, I had one of those last week. Remember that beautiful box I had milled the parts for weeks ago and had glued up on my triumphant return to the shop?  Yeah, the one with sapele sides and the sweet elm burl veneer lid? I had that sucker looking good, and I had even gotten to where I had routed dovetail slots on the corners to take some beautiful maple splines.  It was on its way to being a sweet little piece.

Well, I made a big time mistake.  The veneered panel was wider than the grooves I had milled for it. So, I had to rabbet the panel about 1/8″ in order to make it fit. Now, when I designed the box, my plan was to put the rabbet face up, shortening the distance between the top of the lid panel and the top edge of the box.  Of course, I glued it rabbet down.

Part of the construction process is to build the box and later cut the top off to make a lid.  I carefully marked where the bottom of the groove was located and was sure that I cleared the bottom of the groove in order to carefully free the lid.

Of course, you can see how with the new internal measurements this wasn’t going to work.  Please, feel free to laugh.

Yeah, that’s pretty ugly.  My first thought was to see how this could be saved.  How could I possibly fix this mess and make things better?  My wife had a few suggestions, including routing out the inside of the lid and gluing in a mirror or making it a picture frame.  Interesting, but something I would be thinking about whenever it was opened.

No, friends, this one looks pretty doggone dead.  A fatal flaw in my execution.  I can just say that I am fortunate that there was only a small amount of material involved.  It doesn’t happen frequently – even in my shop.  But, when it happens, it happens in a bad way.

Oh, well, at least I still have all ten fingers.

Quick Poll

Woodworking is a hobby with lots of options.  Turning.  Veneering.  Cabinetry. Antique reproductions. Woodworking from different cultures.

Unfortunately, many woodworkers fall into a rut.  They build the same stuff over and over again because that’s what they are comfortable doing.

This week, take a look at your shop habits and let us know when the last time you tried a new woodworking techniques.

[poll id=”126″]

Link of the week

Den’s Model Ships

Back in the days of wooden ships and iron sailors, the shipwrights who built these craft were masters. Every single piece of wood was cut, shaped and joined by hand to create a ship that could sail the oceans blue.

Today, there are still craftsmen who build ships piece by piece, but, in the case of a woodworker named Den, the ships are at a much smaller – but no less impressive –  scale.

The work is stunning.  Recreations of historic ships such as British Men-of-War, the U.S.S. Constellation and other ships are done in painstaking detail. Every wooden piece is hand made to be as accurate as possible, as are the rigging, sails and other features.

Definitely worth a look. If you want to buy, just remember that each ship takes hundreds of hours of labor, and the prices  certainly reflect the hard work and dedication.

Pushing the envelope

Sure, there are lots of vocations that claim to be the ‘oldest profession’ on Earth, but I’d have to wager that woodworker would vie for the title.  Think about it.. even if our distant hunter-gatherer relatives were just using a stick to fend off angry saber-toothed tigers, that would have to qualify as some kind of woodworking.

From there, you had the whole shelter/tool/roasting stick/furniture evolution where woodworking came into its own.  And, all along its development, and number of innovations have taken place.  The development of the mortise and tenon. The development of the dovetail. The discovery that the gooey mess that lac bugs secreted would make a nice furniture finish.

Since there has been so much development throughout the centuries, you might think that it would be difficult to see true innovation in woodworking.

That would be the case if you never opened your eyes. There are many companies out there developing new products or processes that make woodworking a more enjoyable pastime.

One of the companies consistently out in front is Kreg Tools.  From the development of the first practical pocket hole jig to the precision after-market fences and other cabinet-making tools, the engineers at Kreg have truly pushed the envelope.

“We’re always amazed at just how clever the folks are at Kreg,” said Tim Walter of Eagle America.  “I mean, the beaded face frame set up they produced last year was a real stroke of genius, cutting a tremendous amount of time necessary to perform that task.”

Eagle America is a proud retailer of Kreg tools, offering a wide variety of products. “If you are starting your shop from scratch, you can pick up a sweet router table, pocket hole jig – even a whole pocket hole system. And, if you are just looking to upgrade, you can add a precision fence to your band saw or a new miter gauge for your table saw.”  Tim even pointed out that if you are simply restocking pocket screws after building a previous project, you can do that at Eagle as well.

“The Kreg tools can also break you free from your shop. Many are portable, allowing you to work right on site.  The new deck jig concealed fastening system can get you out on a sunny weekend to help you build that deck you have been putting off for a while.”

To sweeten the deal, Eagle America is also offering a $20 gift card for all Kreg purchases over $149.  “In this economy, every little bit helps.  We’re glad we can do something to help make your woodworking easier and more enjoyable.”

I’m so happy…

Did I tell you how much I missed being in my shop?

Does this picture tell you how happy I was to get back into it?

After weeks of yard work, stitches, hurricane conferences and all sorts of other ‘issues’, I finally got some shop time yesterday.  First, I had to  get to the bench to clean it up.  Things such as string trimmer spools, extension cords, hedge trimmer manuals (the one that instructed me NOT to put my fingers near the moving blades was fun to read) have this nasty habit of piling up on the bench if I don’t take care of them.  Heck, I even had a plastic tub full of Easter decorations that still had to get put back in the attic.

While cleaning wasn’t what I had in mind, it did get me into the shop and back into the woodworking mindset. As the stuff was put away, more space became available for woodworking.  Which is exactly what I need.

Soon after, I had found the things I was looking for.  The four sides of the box I was working on.  The veneered elm panel. The measurements I had jotted down for the box.  It was almost like I had never left the shop.

I cut the veneered panels to fit the top and bottom and rabbeted the panel edges to fit the grooves I had machined back in April. The fit beautifully… better than I had imagined.  And, it glued up nice and tight.

Now, I still have some more work to do on the box.. cutting some dovetail splines for the corners, cutting the lid free, sanding and finishing.. but, for now, it’s good to be back!

A Special Sunday post

Bell from Coast Guard Cutter ‘Blackthorn’ returns to Largo

With this being Memorial Day weekend here in the United States, it’s only fitting that we take some time out to honor those servicemen and women who made the ultimate sacrifice for their country.

Back in 1980, the US Coast Guard cutter ‘Blackthorn’ collided with the freighter Capricorn in the mouth of Tampa Bay, killing 23 crew members. This was one of the deadliest disasters in Coast Guard history and a moment of Tampa Bay history that will never be forgotten.

A local military museum has now built an exhibit that enshrines the ship’s bell for visitors to see and remember the sacrifice made that dark night.

The article also happens to have been the first written by my wife Rhonda for the St. Petersburg Times .  Way to go, Rhonda.

Link of the Week

The Insurance Information Institute

Have I ever mentioned that my ‘day job’ is educating people about the hurricane risk?  No?  You must be pulling my leg.

Since I do spend a lot of time telling folks about disaster preparedness, I answer a lot of questions.  How do I protect my home?  When should I evacuate?  And, how do I make sure I have enough insurance for my home and its contents?

The Insurance Information Institute is a rich source of information about the insurance process, how claims are handled, how to prepare for disasters and many other topics.  There’s even a link to an online home inventory program.  Valuable for people at risk from hurricanes and any other potential disasters.

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