Quick Poll

woodworking projectsWhen most people start woodworking, it’s to build one particular piece. Maybe a storage shelf for the garage or laundry room.  Maybe a table to fit behind a sofa.  Maybe a shoe holder for the closet.

Soon, however, things change dramatically.  That utilitarian project soon gives way to others.  More artistic.  More useful.  More well crafted.

Before you know it, you become a full-fledged woodworker. Once that happens, an interesting phenomena starts to take place.  People tend to build particular types of projects.  Some turn on a lathe, some cut intricate pieces on the scroll saw, and others tackle kitchens full of cabinets.

So, this week, we want to know what is your particular specialty.  Oh, sure, you may occasionally be pulled away from your preferred project for a need in the home.  However, what is the type of project that you are most known for?

[poll id=”53″]

Link of the week

Router Basics

Router BasicsThe router is probably the most versatile tool in the shop.  It can surface wood, cut joinery, route interesting profiles… the list goes on and on.

This site hosted by Reader’s Digest takes readers through the basic familiarization and operation of this handy tool.

First, you’ll learn all about the tool and what its parts do.  Then, it’s on to bits where you can see what some of the more common ones will cut.

Helpful tips accompany the technique sections on this page, helping to make your routing easier and leaving you with better results.

Sure, it’s not an advanced class in sophisticated router techniques.  But, if you are just starting with this tool or you only break it out to route decorative edges on boards, it’s worth a look to see just how you can make the most of this essential tool.

Mortising ‘Under Glass’

Remember that Frank Klausz guy?  You know, the fella who can cut dovetails with his giant bowsaw in 3 minutes flat?

Well, he’s back at it again!  Frank was a presenter at the recent Woodworking in America conference held in Berea, Kentucky. This time, he offers viewers a unique perspective on how he can quickly and efficiently cut a mortise in a block of wood with a proper mortising chisel.

Some things you might notice about Frank’s technique:

  • He works well within the scribe lines of his mortise, only paring to them at the very end of the process
  • Even though the walls of the mortise are kind of rough looking, a mortise cut this way is just as strong as one cut with a hollow mortising machine or plunge router.  Remember, craftsmen cut millions of copies of this very joint with little mechanical help for thousands of years.
  • Notice also that he never scratched the glass…
  • Sure, this does require some skill, but Frank is using some pretty smart mallet blows to cut.  It’s not a skill that requires a long time to master or an overly gentle touch.
  • Again, a mortising chisel is the only way to achieve such results.  Bench chisels aren’t designed for this kind of application and shouldn’t be used for such work.
  • For projects that require only a few mortises, this method might be faster than dragging out and setting up a hollow chisel mortising machine.

In case you were wondering, the photographer is none other than Roy Underhill, from TV’s The Woodwright Shop.  I’m kinda surprised – I didn’t know Roy knew how to use a modern tool…

Stuff I’ve built: Christmas Gifts for 2008


The Christmas GiftsI FINALLY got them done!

With Christmas – and the corresponding drop-dead postal service holiday mailing schedule – breathing down my neck, I finally managed to complete my hand made gifts for this year’s festivities…

Now, of course, I have to post the standard disclaimer – if you are one of my relatives and you are reading this post, please avert your eyes from the photo to the immediate left.  You MIGHT be receiving one of these in the next week or so.

I chose to go with some simple plans straight out of Wood magazine.  In the back row are two sets of picture frame bookends.  One set’s frames are made with zebrawood and the other’s are made of sapele.  Both of the uprights are made of maple.  Since this photo was taken last Friday, I have also finished another set with sapele frames and red oak uprights.  The frames are sized to hold a portrait 4 x 6 photo in a slip-in acrylic photo frame.  We found those at a local Target store, and they fit perfectly. I love using up those shop scraps on these small projects.

In the front row, you can see some of the end-grain cutting boards I cranked out.  These were some fun projects to build, again, because I had the opportunity to use more of those beloved shop scraps.  The woods in these babies are maple, cherry and walnut, and it was glued up with Titebond 3 for its water-resistant properties.  While they came out looking great, I discovered that I really need to improve my sawing and glue up technique.  For some reason, the blocks I cut and started to glue up for the final assembly were not a consistent thickness (operator error, without a doubt).  So, I had to spend quite a bit of time with the belt sander to grind them down nice and smooth.  Hey, that only took a day or so.

I finished them with the technique Marc Spagnuolo uses – thinned polyurethane.   The boards readily soaked up the thinned finish, and a final sanding with 220 on my random orbit sander gave them a very slick and smooth surface.

Finally, I can check that big to-do off my list and get busy with my son’s desk I promised… and the new workbench I have to build… and…well, I guess I’m booked through next Christmas!

Quick Poll

Time!  Time! I need more time!

Wrangling the hands of timeThere are few more common refrains heard from woodworkers.  OK, maybe measure twice, cut once sort of rolls off the tongue a little better, but the complaint that many woodworkers have is that they can’t get into the shop enough to do everything they want to accomplish.

The day job.  The family.  Those obligations we agreed to.

For this week’s poll, I need you to take a long, hard look at how much time you spend in the shop during an average week.  And, yes, I’m aware that some weeks are so busy, you forget to eat and sleep, while other weeks turn into full-fledged shop vacations…

But, on your average, typical week, how much time do you get to cut, plane, pare, shape, turn, sand, scrape and finish your creations?

[poll id=”52″]

Link of the Week

Atlanta man creates furniture from tornado-felled trees

This is one of those stories that can’t help but warm your heart.

Stephen Evans with one of his worksLast March 14, a powerful tornado ripped through the heart of downtown Atlanta, Georgia.  News about the damage to large buildings dominated headlines as this close encounter with a heavily-developed metropolitan area threatened thousands of lives and hundreds of millions of dollars of property.  The tornado – with winds in excess of 150 miles per hour – claimed three lives.  However, the death toll could have been much higher but for a  Southeast Conference championship basketball game that went to overtime, keeping the sizable crowd indoors as the storm passed.

While the major damage caught the attention of the public, the storm also tore through other, more quiet areas of the city, notably the historic Oakland Cemetery.  Caretakers at the historic site observed that more than 60 mature trees were toppled, and hundreds of grave markers were damaged or destroyed in the violent winds.

Rather than watch the historic trees be ground into mulch, Atlanta-area woodworker Stephen Evans decided he would so something about it.  Shortly after the damage, he arranged to have the downed trees sawn into usable lumber.  He is drying the wood right now for what will become a very interesting project.

What Evans has planned is to build a piece of furniture from the historic trees that will be sent to auction.  All proceeds from the sale of the piece will help pay for repairs to the cemetery.  The piece he has in mind is a white oak bench.

Since he came up with the idea, other woodworkers and artists have stepped forward to build other pieces – including platters, jewlery and sculpture – to auction off to further help the effort.

The Crack of the Bat

Broken Bat at home plateYou know you have come to a new place in your life as a woodworker when the mention of a monumental baseball decision involving wood draws you away from your morning coffee.

That’s just what happened to me this morning while ESPN was on the back room TV.  During one of the updates about the Major League Baseball (MLB) owner’s meetings in Las Vegas, a decision was made to allow players to continue using maple baseball bats.

What’s the big deal?

Well, it’s actually kind of important.  But, first, let’s talk a little bit about bats.

In officially sanctioned MLB games, wood is the only material allowed for bats.  In other leagues and age groups – from Little League games for kids through NCAA games, aluminum bats are the  norm.  In fact, you can tell what level of competition is being played by simply listening to the sound the bat makes when it strikes a ball – a ping for an aluminum bat, and a satisfying crack for wooden models.

A collection of batsFor MLB’s formative years, two different types of woods were used to make bats.  Hickory, due to its very tough nature, and ash, due to its strength and lighter weight.  Hickory became less popular through the years because it is a heavier wood.  With pitchers throwing faster balls, bat speed (which is higher with a lighter bat) became a much more important trait than plain slugging power provided by a heavier bat.

Ash bats reigned supreme in the major leagues until 1997, when MLB sanctioned the use of maple bats.  Maple, again, has several favorable characteristics when considered as a bat material.  It has tremendous strength and durability.  Maple is, however, a heavier wood than ash – so something had to be done to level the playing field between these two woods.

Enter the folks at Sam Bat, the first manufacturers of maple bats.  What they discovered is that by cupping (hollowing) the barrel end of the bat, they could lighten the weight and shift the balance to fine tune the bat’s sweet spot – the area where the batter can get the most power out of his or her swing.

Broken Bat at pitcherThe maple bats caught on like wildfire.  Slugger Barry Bonds used a maple bat the year he broke the MLB home run record, which led many hitters to switch to maple.  Today, approximately 60% of MLB players prefer maple bats.

So far so good, right?  Well, not so fast.  While the maple and ash bats both do a great job smashing line drives into left field, observers started to notice a disturbing trend in how the bats performed when pushed beyond their limits.

Broken wooden bats are a fact of life in the major leagues.  Pitchers routinely throw in excess of 90 miles per hour, with some fireballers throwing at or near 100.  Today’s hitters also do a tremendous amount of weight training to increase their power at the plate – something almost unheard of during baseball’s golden era.  And, of course, that’s without even touching on the recent steroid controversies…

As you can imagine, the forces at work are incredible.

When these bats break, the two woods behave differently.  Studies have shown that bats made of the more traditional ash wood tend to crack and splinter when they break, while maple bats tend to shatter violently and in large pieces.  It has a lot to do with the different grain structures of the woods.  Ash’s structure tends to be ‘longer’ while maple’s is a bit ‘stronger’.

Broken bat into standsTwo serious injuries occurred at Dodger Stadium in April this year. Pittsburgh Pirates coach Don Long suffered nerve damage after a piece of a shattered maple bat struck him on the side of his face as he stood in the visiting dugout, watching the flight of the ball. And Susan Rhodes, a fan seated four rows behind the visiting dugout, needed surgery to repair a broken jaw after a chunk of a broken maple bat sailed into the side of her face.  Numerous near misses and minor injuries have also taken place at stadiums, leading to questions about the future of these bats.

While there is considerable documentation that the maple bats tend to be more prone to catastrophic failure, MLB’s safety committee has reviewed more than 1,000 broken bats from the past season and determined that they are still approved for use in games.

The smart thing might be to mandate that everyone use ash bats exclusively.  However,  North American ash production is being threatened by the spread of the emerald ash borer.  Should the harvest be further threatened, other woods may need to be considered for bat production, or the major leagues could possibly have to adopt a different material, such as composite bats or aluminum bats.

Then, we’ll all have to look forward to the sound of the ping of the bat…

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