Link of the Week

Greco Woodcrafting

Woodworkers have a wide range of talents. Some are gifted turners, others can make gorgeous inlaid and veneer panels.

And, then, there are the folks who are exceptional toy builders.  John Greco is one of those woodworkers.

His creations run from the plain and functional to the intricate and ornate.  John’s talent can easily be seen in his attention to detail in items such as this hand-crafted biplane.  These toys make great stocking stuffers, just in case you were looking for a last-minute tip!

Even if you are just young-at-heart, John’s storefront site is worth a visit.

Get the Lead Out

Helping others, especially needy children is a wonderful thing to do.  The Northwest Indiana Woodworkers Association has been doing this for 19 years.  However, due to a new law concerning protecting children from finishes containing lead, we will not be able to continue giving toys after February, 2010 unless we have them tested.  This applies to everyone according to the Consumer Products Safety Commission.

You will be breaking the law if you distribute items to children age 12 and under unless they have been tested for lead.

It does not make sense because the the problem of finish containing lead comes from imported products, not items made by you and I.

We have told our congressman and senators about this situation, but they do not seem to be concerned.

— Robert Roach

When I get e-mails like this one, my first reaction is to think that it is some kind of Internet chain letter hoax.  I mean, it sounds too crazy to be true.  With all of the problems in the country today, to think that the government would concern itself with the products coming out of my  – or anyone else’s – workshop just seems too unreal.

But, Robert and the rest of the woodworkers in the Northwest Indiana Woodworker’s Association are indeed telling the truth. As of February 10, 2010, it will now be considered against the law to give a finished wood project intended for a child under the age of 12 – or a piece of furniture to be used for a child under the age of three – without having it tested in an independent laboratory for lead content.

For real.  You can read about it here.

Crazy, ain’t it?

Now, it’s not the wood that’s the problem.  In fact, wood is specifically listed as a non-lead containing material.  Make a thousand unfinished wooden projects and give them away freely. It’s  the finish that is what’s at issue.

To understand what’s going on with this, let’s go back a few decades.  For centuries, lead was an important part of the paint and finish industry.  Lead was an excellent pigment for white and bright yellows, and also sped drying, increased durability, retained a fresh appearance and resisted moisture that causes corrosion.  It was everywhere…

Until lead paint was linked to severe health issues.  It is especially damaging to children under age six whose bodies are still developing. Lead causes nervous system damage, hearing loss, stunted growth, ADD, ADHD and delayed development. It can cause kidney damage and affects every organ system of the body. It also is dangerous to adults, and can cause reproductive problems for both men and women.

So, in 1978, lead was banned in paints for residential applications.  However, there are some finishes where lead can still be found.  And, when products are imported from overseas manufacturers, it seems as if there are new reported cases of elevated lead levels in toys nearly every year.

This regulation is now in place to help prevent possible future lead poisoning cases.

But, doesn’t it seem to cast a net too widely?

To help get to the bottom of this issue, I made a call to the Consumer Products Safety Commission.  I identified myself as a woodworking blogger and asked to speak to someone knowledgeable about the topic.  I was connected to a nice gentleman named Joe Tsai, who was able to answer my questions.

First, I asked Joe the question that’s on the minds of just about all woodworkers.  If you are building a cradle for a grandchild or a rocking horse for a niece or nephew, do you need to have in tested?  “No… you really aren’t distributing the items if you are building one at a time for an individual child.  We’re counting on woodworkers to use their common sense and seek out  lead-free products for finishing on their own.”

What about Robert’s situation, where a number of woodworkers are building projects to donate to a charity? “Well, in that case, we would advise you to get one of the items you are building tested.  This way, you protect yourself and the group should someone later have it tested and want to sue.”  Yes, that’s right, Joe said that as long as the same finish product is being used on the projects, just one of the batch will need to be tested, not the entire lot.

Joe said that the CPSC offers a list of independent laboratories that can do the testing for a fee.

That’s all well and good, but something still didn’t make sense for me.  Hear me out.  Say the Amalgamated Weasel Spit Finish Factory makes a finishing product that imparts a hard-wearing, hand-rubbed finish to your wood project.  Why not test the big parent batches of finish while they are being made at the factory instead of asking the 20,000 woodworkers to get their projects tested for lead?

It’s thinkin’ like that that gets me into trouble.  But, not this time.

This time, instead, I put a call in to the folks at Minwax, arguably one of the largest wood finish manufacturers in the world.  I was connected to a really nice guy named Kyle Holtz.  I asked him what the industry is doing to help address this issue.

It turns out, quite a bit.

Back in 2007, Sherwin Williams/Minwax was working with the government and their own product safety people to determine which of their products were compliant with the upcoming regulations.  A memo was recently circulated to their consumer information techs and  reads:

We received Regulatory approval in March of 2007 to recommend Minwax Fast-Drying Polyurethane, Minwax Wipe-On Oil-based Polyurethane Finish and Helmsman Spar Urethane as coatings used on (baby or child) furniture and toys. Originally Polycrylic was on that list but was taken off back in April of 2009. If a customer wants to know what products are safe to use if they can be chewed /ingested we should make no recommendation.

OK, so the folks at Minwax can’t tell you that their products can be eaten safely, but they can indeed be used for furniture and toys that won’t be ingested or chewed on.  For Minwax, they understand that the build – and – do-it-yourself community is their main audience, and anything they can do to help woodworkers adjust to these new regulations is only going to help their bottom line.

What does this ultimately mean for the home woodworker?  Well, if you are building for your family or a friend, you have the green light.  If you are concerned about lead, call the finish manufacturer to ensure you get the safest product possible.

If you are going in on a group charity build, it would be worth it to get the Material Data Safety Sheet and any other documentation from the manufacturer and look strongly into  getting an item of the lot tested… just to ensure you are walking the straight and narrow and to head off any possible lawsuits.

And, build away!  The kids who are getting these gems are the ultimate winners.

For your reference, here are a few contacts for some of the larger finish manufacturers:

Editor’s Note:  Yes, this article deals only with toy donations… not the sale of toys.  If you build and sell toys, consult the CPCS for regulations that affect you.

Q&A About tail vises

I just noticed in your title graphic that you have a tail vise on the bench in the picture.  I’m starting to plan for building a workbench myself and I’m leaning towards a tail vise in the end vise position.  Do you have any thoughts/tips/advice concerning a tail vise, its construction/hardware/etc?

—–  Reader Torch02

That’s actually a picture from when Marc Spagnuolo and I were at a woodworking school up in Indiana.  That bench was one of ten bought from Garrett Wade for the students to work at.  Apparently, even though they cost a pretty penny when they were bought, the benches – particularly their tail vises – were pretty prone to damage.  Of course, they were getting a lot more use – and abuse –  than any bench would normally, as students were using them many times a day.


Now, what’s my own personal experience with a tail vise?  Well, let’s just say for my bench at home, it was an aborted attempt.  I was following the instructions that came with the hardware, and I got all twisted around.

My solution was to drop back and punt.  I replaced the boards that looked as if they had been chewed upon mightily by deranged beavers and just put in solid boards.  I drilled a row of bench dogs, and when I want to clamp something, I use the Veritas wunder pup and a bench dog.  It works pretty well

Of course that option does have its limitations… the Wunder Pup has only a 6″ throw on it and it is very finely threaded… so it does take a little patience to get the board clamped down.

If I had to do it all over again (I just might – I can replace the top and keep the base…) I would consider installing what’s known as a wagon vise.

You don’t need any expensive steel running gear save a shoulder vise screw.  Those are a lot cheaper than a whole tail vise setup and are mostly made of wood.

Another option would be to just simply mount another steel fast acting vise on the tail and line up the dog holes with the vise’s built in dog.  Probably the easiest way to go, and a decent face vise can be had for about $80 or so.

I saw this plan in Wood.  It’s a way to create a vise  using only pipe clamps mounted to your bench. Great if money is short and you like to MacGuyver things together.

And, if you want to go even CHEAPER than that, get a pair of bench dogs and use some opposing wedges to snug the work between them.  You can make the wedges any thickness you want so they won’t interfere with planing thin boards.

I realize you asked me what time it is and I told you how to build a clock… but, hey, you asked!

Quick Poll

Cutting pieces accurately while building your projects is an essential skill to master.

Unfortunately, I have yet to truly master the task.  But, hey, a fire on a chilly December night isn’t the worst thing to happen.

When woodworkers want – and need – accuracy when measuring, they turn to some tried and true methods. Some involve a hand-held linear device that provides a visual readout comparing the depth of snow to a universally understood unit of measurement.  You know, a ruler.  Others involve marking the length directly from the project.

So, this week, when you need an accurate measurement, how do you get it?

[poll id=”103″]

Link of the Week

How It’s Made:  Godin Acoustic Guitars

A guitar may appear to be a simple instrument, but there are many steps involved in building one.  Even on factory made acoustic guitars, there is a tremendous amount of hand work that goes into crafting an instrument that can be played hard but still make beautiful music.

This week, we go back to the show How It’s Made to see how Godin Guitars crafts their acoustic models. Even with many skilled employees and specialized tools, it still takes nearly three weeks for a guitar to go from a rough stack of materials to a beautiful instrument.

‘Twas some time before Christmas…

Twas some time before Christmas, when all through the shop
I was just so darned busy, I thought I would drop!

The gift list was hung by the workbench with care.
“If we don’t ship these soon, they’ll never get there!”

I in my apron, glue bottle in hand,
was prepared to work hard, to make my last stand.

Sanding and planing, the dust it did blow,
covering the shop floor like the new-fallen snow.

I struggled and sweated as I wiped off my brow.
“I’m sure I can’t do this… no way or no how.”

Project pieces lay about, both tennon and mortise.
“If I progressed any slower, I just might be a tortoise.”

When what in my offended nose did I smell?
“I can place that aroma!  I know it so well…”

When in swang a monkey, hanging high by his tail.
“I’m here to help – together, we won’t fail.”

Of course, it was Iggy, the trained Shop Monkey.
He looked very dapper, his smell was quite funky.

With tool belt cinched tightly around his middle.
He looked young and  strong – as fit as a fiddle.

He was 20 inches tall, all covered in fur.
I guess it’s there so, if cold, he wouldn’t say ‘brrr…’

With eye protection on and boots on his feet,
his shop working outfit was completely complete.

“Now, what’s on this list? Something for father and mother…
We’ll finish this job, don’t you worry, my brother.”

But, raising my hand, I told the monkey to hush.
“They’ll all look simply awful if we get in a rush.”

“Not to worry, pal,” said the monkey with glee.
“We’ll get this job done, just you wait and you see.”

And, with fur and tools flying, working hard was a must.
“You know all these tools, in your skills you must trust.”

“Don’t overthink your joinery, lay out and do cut.
If you don’t get a move-on, I’ll just kick your butt.”

With motivation a-plenty, I set out to work.
“You do a good job, Tom, just don’t be a jerk!”

With project pieces cut, the work was quite simple.
I was happy it worked! You could just see my dimple.

The monkey and I, we worked at the bench.
I was no longer bothered by his terrible stench.

The tools sprung to life, and I was in awe.
Iggy shouted quite loudly, “On router and saw!

On sander and chisel! On spokeshave and plane!”
Our work was quite orderly, the pace was insane!

Together we worked, and with our combined project attack,
there, on the bench, sprung to life nine tiny wine racks.

(A note to my relatives: Right now, shield your eyes
or I will be blowing the big Christmas Surprise!)

The plans we had gotten from our friends there at Wood.
The project looked sweet, the fit was quite good.

From a stack of work pieces all perfectly milled,
from just a plain drawing, these projects distilled.

The frames are held fast with the mortise and tennon.
Try as you might, there’s just no way to bend ’em.

I sanded the pieces, then applied the finish.
Iggy said “You work faster than Popeye on spinach!”

A coat of shellac, a wipe on finish made them pop.
The look amazed both of us, our jaws they did drop.

Eight tiny wine racks, made of maple and sapele.
(That’s a wood from Africa, not Brazil or New Dehli)

Eight were the same, but there was this one
made of dark wood –  it  looked nice – I had some.

The bottle supports are all of curly maple.
In Iggy’s workshop, that wood is a staple.

And riding on each was a bottle of wine.
Most of them cheap, very few of them fine.

The eight sapele projects they lined up to follow
the dark wooden wine rack, with a red foil on bottle.

The scene it reminded me of old St. Nick’s Sleigh
with Rudolph’s red nose a-lighting the way.

Iggy said, “We got them together, of that there’s no lie,
just try not to touch them ’til the finish is dry.”

“We now need a cheesy photo… go get the missus!”
“What if she won’t?”  “Well, go ply her with kisses!”

And so, in a flash, she came with her camera to snap.
She took some pictures, then went back in for a nap.

Iggy looked pleased as I reviewed the shots on the camera.
“That was some hard work.  Now, how ’bout a banana?”

And as I handed Iggy a big golden bunch,
he said, “At least – this time – you fed me lunch.”

And, as he swung to a tree and disappeared from sight,
Iggy shouted, “Get  to the post office now, not later tonight!”

Woodworking Spotlight: Andrew Lunn

With care… always.

When people talk about the good old days of hand tools, they often cite the attention paid to the small details. Plane mouths that are machined to tight tolerances. Comfortable handles on chisels. The look and feel of a solid performing work of art.

That’s why you might be surprised that one of the true artisans making new hand saws started out doing rough work.

Andrew Lunn, the owner of Eccentric Toolworks, got what some folks might call a late start in woodworking. “I did have a shop class in junior high school when I was 14 years old. But that wasn’t what really got me going. In fact I didn’t make anything after that until I was 27 years old! I was working in an office and started to get the feeling that I wanted to work more with my hands.” According to Andrew, this career change came totally out of the blue. “I got myself a job working on a construction crew, doing restoration work to fire damaged buildings. It was all really unfocused at first–I knew I felt drawn to working with wood, and that I felt drawn to working with my hands. But I didn’t know if that would mean carpentry, or furniture, or what. So I put together a modest hand tool shop in my garage and began making things by hand. That’s what really got me going.”

Over time Andrew realized he was attracted to the smaller, more skilled tasks that focused his attention. “Several years ago, I got the idea that I wanted to make myself a whole set of hand tools, and that I would in turn use that set of tools to make things. The prospect of making a saw felt particularly interesting so I thought I would start there–and basically I started and just never stopped!”

Today, Andrew makes some of the most comfortable, true cutting – and beautiful – hand saws available for sale. His saws are not mass-produced. Instead, just as a tailor would fit a suit to a customer, each saw is fitted to the individual client placing the order.

“Basically I start with a measurement or two from the customer then send them a poplar prototype of their handle that incorporates those measurements. I get feedback from them and incorporate their input into the actual handle. I also tune the saw for the particular woods the customer will be using.” Andrew ships the saw with the final handles made of beautiful curly maple, cherry, quartersawn beech, or walnut.

Yes, you are reading this correctly. Each saw is truly made by hand in his shop. The handles are shaped entirely by hand. Most of the metalwork is done by hand with files and other hand tools as well. “The saws are tuned and fussed over until I am totally happy with them.”

While Andrew could certainly just build some functional plain-Jane looking saws and call it a day, his signature on these tools makes his work truly stand out. Decorative cut outs at the front of the saw make what would normally be a shop workhorse a thing of beauty. “Saws to me represent a creative outlet, so the way they look reflects various openings or possibilities that I thought could be explored. I enjoy the entire design process, both with function and appearance, so as much as possible I try to meld the two into a single fabric.”

When I asked Andrew about his favorite aspect of building these beautiful tools, he had some difficulty identifying it. “I don’t know if I really have one. I like each part of it and get really absorbed while doing it. The metalwork is so important, and has a subtle art to it. The handles, those are a really big deal too. Saws are just very lean tools–there’s nothing there that isn’t important. It takes a lot of concentration and care. That’s why on some of the saws I etch the words, ‘With Care … Always.”

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