Quick Poll

Yawn, ANOTHER set of oak kitchen cabinets...According to the American Hardwood Information Center, red oak is by far the most commonly used North American hardwood. Four out of every ten North American hardwood boards sold are red oak.  It’s the state tree of my former home state, New Jersey, where it grows just about everywhere you look.  It’s one of the most common woods used in kitchen cabinet construction. It’s an extremely common flooring material. Entire bedroom suites are made out of the stuff…

And, sometimes, all that familiarity breeds contempt. I’ve spoken with woodworkers who have flat out said, “Boy, that would have been a great project, except for the fact that they built it out of oak…”

So, in this week’s poll, I wanna know exactly what you think about red oak and its place in your shop.

[poll id=”55″]

Places I Shop – Eagle America

I remember when I was doing a video about how to shutter windows with plywood before a hurricane approaches.  I was given a draft copy of the video while my mom was down on vacation.  As I showed the step-by-step instructions, my mom turned to me and exclaimed, “How do you expect anyone to do this?  No one has all those tools!”

Oh, sure, I was using some clamps to hold a 2 x 4 in place so I could screw it down as a brace, but most of the tools I was using, I picked up at the local home improvement center.

Eagle America's SignBut, when I needed to do more involved work, those basics at the local big box just didn’t cut it anymore.  That’s when you need to turn to a true woodworking supply company.  One place I have had quite a but of success buying from is Eagle America, located in Chardon, Ohio.

I had the opportunity to ask a few questions of Tim Walter, the company’s vice president – and the son of the founder and president.  “We are a family company and everything can trace back to my dad, Dan Walter.  He has always been one of ‘those guys’ – you know, the kind of guy who can fix anything in the house.  He took his love of home improvement and woodworking and combined it with a little marketing savvy and determination, and here we are today, 20 years later.”

Eagle America's CatalogDan, and his business partner and wife Linda, took a big risk starting this little company two decades ago.  With a  mortgage, two young children and a dream, Dan and Linda had to follow the woodworking expo show circuit to make their sales in those early days before a catalog and the Internet.  “I think the fondest memories for me of the startup were just being a part of something new.  My brother and I used to help stuff envelopes and put labels on mailings at the kitchen table at night.  I used to walk to the office after school to help in any way I could.  There was an energy there, an excitement, that made things fun to be a part of as a child.  It didn’t hurt that we also got to travel and occasionally miss school.”  Tim paused.  “Ah, the good old days!  The shows really were a blast.”

Today, Eagle America carries tools, accessories and other sundries for woodworkers of any talent level or interest.  “Production shops are an important part of our business as you can imagine but the majority of our customers are woodworkers.  They may be weekend warriors, beginners, experts, cabinet makers, finish carpenters, or people who simply play around in their shop.  We enjoy novice woodworkers and the questions that they ask as much as we enjoy more seasoned veterans who bring a different level of perspective and critique to what we do.  The sum of all woodworkers and the feedback that they give us make us who we are today.”

Evaluating tools at Eagle America's ShopEagle America spends a great deal of time evaluating all of the tools they sell to ensure that woodworkers approve.  “We have a lot of woodworkers on staff and they are all involved in the product evaluation process.  We even survey local woodworkers from time to time to get their opinions on products before we add them to our line.  Everyone out there should take comfort in this, knowing that someone at Eagle America who is an actual woodworker has seen, touched and used all of the products we sell.”

It’s not only the woodworkers on staff that come up with all of the creative ideas.  Eagle America even offers rewards for new product suggestions that are adopted, developed and sold through the store.  “Our customers are very creative and provide us with a number of excellent suggestions.  Not all of them can be turned into products that can be mass marketed but each suggestion is taken very seriously and those that are made into products tend to be successful.”

The Eagle America ShowroomWhile Eagle America is one of those quintessential family businesses, the ‘family’ concept goes far beyond just those blood relatives.  “Our staff is fantastic. We are blessed with the talent that we have on our team. From our warehouse to our call center to our Outlet Store and woodworkers on staff, the majority of them have been with us for a while which means they can handle almost every question that is asked or problem that may arise.  We take pride in making the customer experience as easy and enjoyable as possible.  If we are not meeting people’s needs, we want to know about it so we can do it better the next time.  That mindset is a part of everyone here at Eagle America since we would be nothing without our customers!”

Even though, as with any business, the folks at Eagle America are there to make an honest profit from selling quality products, there’s nothing quite like the reward of seeing how they can help woodworkers turn their visions into successfully completed projects.  “That is one of the best parts of what we do, seeing the woodworks of art that our customers create.  They use our tools to create beautiful works of art, wonderful pieces of furniture, things that can become family heirlooms for generations to come.  They are used to create functional pieces that simply do a very important job, like making shelving or storage bins for a garage.  Our products are used to solve problems. They are used to express someone’s creativity. They are used to make an idea in someone’s head come to life.  That is amazing!”

Setting a proper table

The router is one of the most versatile tools in the shop.  Dovetails, mortises, tenons, decorative profiles, rabbets… the list goes on and on.

While they are extremely useful hand held, mounting them into a table dramatically expands their usefulness. I discovered this when I first bought a little bench top Skil router table for my tiny fixed-base Craftsman router.  Suddenly, I was cutting joints and profiles I never knew were possible.

Norm and his deluxe router tableThings have really changed since those early router experiments, but I still turn to my routers to do dozens of chores in my shop.  While my skill with a router has increased, so has my experience in dealing with router tables.

I’m gonna come right out and say it.  If I had the space, I would definitely build a full-blown all-the-bells-and-whistles router tables just like the one that Norm Abram built.  It would be a dedicated router station where I could do everything I would ever possibly need to. Unfortunately, in my two-car garage shop, space is at a premium, so a dedicated router station all by its lonesome is out.
The next option I considered – and built – was a table saw wing mounted router table.  It seems as if everyone who is space challenged in their shop has built or installed one, and they all seem to swear by it.  So, I went out to the local Home Depot and dipped into their scrap offcut bin.  Much to my surprise, there were two offcuts of melamine covered particleboard in the bin for a few bucks each.  So, I took ’em home, biscuited them together and with the help of a few piece of angle aluminum and some bolts, I was able to replace the right wing of my Ridgid saw.

Router table wing in sawThere.  All of my router problems were solved.  Weren’t they?  Oh, sure, the router table takes up absolutely no new space in the shop – just the footprint already reserved for the table saw.  And, I can use the table saw fence to guide my work past the bit.  I even built a pair of router fences that secure to the slots in the rip fence in case I had to bury the bit behind the fence.  All seemed ideal…

But, then it happened.  I was routing a profile on the edge of a piece of oak to make molding for a project.  Basically, I would route this profile on each of the long edges of the board and then rip them free.  That’s when it hit me – how could I use the same rip fence for both operations?  I tried setting then resetting the fence for each operation, but the pieces never seemed to come out right.

Auxiliary Router TableThat’s when I built my auxiliary router table.  Made from a sink cutout of Corian, this router table is designed to sit on a pair of sawhorses or to be clamped in the jaws of a Workmate.  Since this photo was taken, I built a fence based on a design in found in Danny Proulx’s book 50 Shop Made Jigs and Fixtures.  I even routed slots into the Corian for t-track so I could run the fence on the table.  And, in the event I ever need to bring my router table on the road, it’s ready to travel.

This setup works very well as a router table.  And maybe one day, I might consider removing the router table from my table saw’s wing.  But, since I went through all that work to begin with, I’ll just leave it there in case I ever need to use it again.

In the photos, you may have noticed that I have attached my Freud FT2000 router to a Rousseau router plate.  Permanently mounting a router base or a dedicated router to a router plate is one of the smartest ways to use a router table. This way, rather than trying to unscrew a router base from your hand held model and screwing it to a table, you can just pop the router out and mount it into another router table in mere seconds.  Sure, router plates tend to run about $40, but that cost is easily recouped after you realize just how much time it saves you.

Another important thing is that I never use a miter slot when working with a table mounted router.  Sure, they seem convenient.  However, unless you are using a self-squaring table saw style fence for your router setup, there’s a very good chance that it won’t be parallel to the fence.  What I do us use a backer push block to guide the workpiece along the fence. Not only do I get incredible control, the push block also prevents any blow-out on the back side of the work.

Hey, every shop really does need a router table.  Just take your time and carefully consider what you want to build or to buy before commiting to one.  And, if you move into a large enough shop, you’ll be certain to find plenty of space to build a proper router table to satisfy all your wishes.

Quick Poll

Protect these babies!When we think of workplace safety, things like hearing and eye protection typically come to mind.  Or, is it hold downs, feather boards and push sticks?  Dust collection? Not drinking before you operate power tools?

My point is that we often overlook one very important part of shop safety – what we’re wearing on our feet.  There are lots of hazards that could affect us down there – from dropped objects to stepping on sharp items.  And then there’s the slipping hazards, splashed chemicals and other concerns.

If a foot or both feet are hurt, you could be out of the shop for quite a long time.

This week, let us know what kind of footwear you slip on before you head out to the shop.

[poll id=”54″]

Link of the week

The Chicago School of Violin Making

Violin MakingWhen it comes to specialized woodworking, I’d be hard pressed to find a more exacting field that instrument making.  Not only do the woods have to look beautiful and the instruments strong enough for vigorous handling, the dimensions have to be extremely precise, otherwise the instrument simply won’t sound right.

I saw a show about the Chicago School of Violin Making on the DIY channel, and I was stunned at the quality of the craftsmanship being demonstrated.

Using mostly hand tools and hide glue, absolutely gorgeous pieces of tiger maple and spruce were being turned from simple blanks into the sinuous curves of a quality instrument.

I was especially amazed by just how precise the instructors were while shaping the top and bottom sound boards with just a simple fishtail gouge. Much of the work is done totally by eye, with calipers used to ensure the final dimensions have been reached.

Students learn the same violin building techniques used since well before masters such as Antonio Stradivari created his masterpieces.

I just gotta know…

NORAD Tracks Santa

For many of my formative years, I had trouble with bedtime on Christmas Eve.  I mean, the big guy with the beard and the sleigh was coming to my house.  How on Earth was I going to sleep?

My parents would say they knew where Santa was, and that he would be at my house ‘soon’, so I had better get to bed.  But, come on, they couldn’t really know EXACTLY where Jolly Old St. Nick was at any given time.  So, they were reduced to an educated guess when they told me it was time to hit the hay.

My kids have it so much better now.  They can turn to the North American Aerospace Defence Command (NORAD) for up-to-the-second satellite and radar fixes.

Just why did this military agency directed to give maximum warning for nuclear attack start tracking Father Christmas?  Well, it all started in 1955, when a Sears store in Colorado misprinted a phone number in a holiday ad, which led to people calling NORAD’s predecessor organization the Aerospace Defense Command (CONAD).  Since then, hey, who ELSE has the technology to track Santa on his annual present delivery circuit?

Last year, my two sons and I called the operations center at (877) HI-SANTA (try it, seriously) and we were able to speak to a technician who gave us the latest location update and Santa’s ETA for our home.  Overseas callers should call the United States at (719) 556-5211, although costs may be incurred.

It’s not just for kids.  After all, I’m still a kid at heart, but my toys are now replaced with a wish list of tools!

Remembering those far from home

Lawrence and his sonsTake a look at this guy.  Who is he?

Well, he’s someone I know from the States who is now deployed *somewhere* in southwest Asia. His name is TSgt. Lawrence Richards  with the United States Air Force. This year, he’s not going to be home with his wife and two kids. Daddy won’t be there when his boys open their presents.

Why bring this guy up in the first place?  Well, I know him.  No, I’ve never met him, but he’s a regular poster with me over at the Woodworker’s Website Association (WWA).  He’s a pretty darned skilled hobby woodworker and has well developed sense of humor.  All in all, a very funny guy to get to know. We’ve become fast friends – even though we’ve never met.

When he was deployed a few months ago, he let us know over at the WWA that he was going overseas, but that he’d have the opportunity to keep up with happenings on the board. He also asked – rather hesitantly – for a few things to make life a little more comfortable for he and his buddies.  Some hooks to help keep their shower towels off the ground.  Letters and cards of encouragement.  Some decorations to bring the spirit of Christmas to their camp.

And a block of basswood for him to practice wood carving.  Something woodworking related he can do away from his shop.

If you think about it, this isn’t just a story about one  Airman deployed overseas.  There are hundreds of thousands of others out there – from nations outside of America, too.  There are British soldiers keeping the peace in Kosovo.  Canadians in Haiti attempting to bring relief to this impoverished nation.  Australians and New Zealanders in Timor Leste to restore order in the midst of chaos.  And there are dozens of other nations who have service men and women who have answered the call and are now thousands of miles from where they would most love to be. There are soldiers, airmen and women and Marines stationed at bases around the world.  Sailors and Coast Guardsmen and women stationed on ships at sea.

And, in many cases, the presence of these young men and women in these countries is all that stands between a relatively peaceful existence and deprivation, chaos and fear for the local citizens.

In their homes, there will be also that empty seat at the table and the people they love hoping and praying for a speedy and safe return.  For some of these families, this is a familiar situation due to previous deployments, and they each turn to their own way of coping.  For others, it’s the painful realization that their son, daughter, brother or sister has gown up and is now away from home for the first time – ever – in his or her life.

And, some of them are woodworkers that you or I might know.

This holiday season, while we’re all wrapped up in building holiday projects, finishing shopping and wondering how we are going to deal with our in-laws… take some time to think of the folks like my pal Lawrence and their families who will be missing them during this season of joy.

For me, I was able to box up some candies and a host of old woodworking magazines that were crowding my shelves.  Maybe it wasn’t a lot.  But, if I could bring just a moment of rest from the monotony of the daily grind, the terror of the potential of attack and the longing for home and family, maybe I might have done something worthwhile.

Here in the United States, the United Service Organization (USO) is just one organization that does tremendous work in helping our service men and women deal with the separation from home and the reunions with their loved ones.  I’m sure many other countries have similar organizations.  If you can, please remember to do something those who have answered the call of service.

It just might mean the world to them.

May each of you have a blessed and joyous holiday season.

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