My first woodworking experience

It’s been said that you never forget your first time.

If that’s the case, then I’m really scratching my head as to why I got into woodworking as a hobby.

Walter T. Bergen Middle SchoolLet’s hit the rewind button on the way back machine. The year, 1982. There I was, a skinny kid growing up in Bloomingdale, New Jersey. I was in seventh grade at Walter T. Bergen Middle School. The big time. You see, in sixth grade, things were just like they were in elementary school – you stayed in your classroom most of the day, leaving only for phys ed, art, music and lunch.

But, seventh graders actually got to change classes. This was my first experience going to a math teacher’s room. A history teacher’s room. A science teacher’s room. It was totally new, and a lot more fun than sitting in the same classroom all day.

Another very important thing happened to me – all seventh graders got to do a semester in wood shop class. Woah. Power tools. Visions of being the best in this class danced in my head.

Unfortunately, I had to get through a semester of Home Economics in the fall first. The food part wasn’t that bad, but the sewing was a nightmare. I ended up making a pair of sweatpants that had no business being worn in public.

But, as the spring semester began, we were off to wood shop. Mr. Kirkegard was a very patient man, and, judging from his looks, he was probably big into the counter-culture movement of the late 1960’s or early 1970’s. Far out, man.

We spent the first few weeks learning how to draft. While I was trying to align a T-Square and a drafting triangle with a sheet of paper, my eyes kept wandering to the big gray Delta Unisaw and the bank of power tools against the wall. Oh, yeah, I was going to DIG cutting wood!

Tom swings a hammer?How disappointed I was to discover how tight the restrictions were for the tools. No table saw. The band saw and drill press were to be used under tight supervision. And, even the power disc/belt sander was monitored carefully. Bummer.

I think those first few weeks of actually working wood were to get an idea of who knew what and who was not going to be trustworthy near the tools. My suspicions were confirmed when we were allowed to pick our assignments.

Some of the brightest and the best were allowed to build turned salt and pepper shakers. Most of the kids were allowed to build cutting boards in various shapes. (We were told we could make cutting boards in the shape of a hand with a finger extended – but only ONE particular finger was forbidden, if you catch my drift.)

Me, well, I was assigned a coat hanger. A poplar board cut – say – 18″ by 6″, with three 3/4″ holes bored into it. Then, I was given three lengths of 1″ dowel and a stack of sandpaper, and told to sand the dowels down until they fit the holes.

I must have REALLY impressed him….

No, I'm not that old....So, while the other kids in class were building their creations, I sat at my work table and sanded the ends of three dowels for weeks. It was tedious and my hand hurt, but I was going to make those dowels fit come heck or high water.

Well, the big day arrived. Mr. Kirkegard came over to me with a bottle of glue and a mallet. “So, Tom, you ready to assemble your project?”

Uhh, the other kids were busy finishing theirs, so I guess it must have been time. I nodded my assent, then handed over the components. He smeared glue on the sanded end and tried to fit it into the hole. It was a tight fit. He pounded on the dowel with his mallet. He was getting frustrated, and I think I heard him muttering something under his breath while he worked. It finally surrendered and went into the hole.

The same thing happened with dowel two. However, while he was driving dowel number three home, the poplar board split down the middle. Mr. Kirkegard stood over the piece for a second, looking down with hatred in his eyes. As if on cue, dowels number two and one took that opportunity to tip over out of the now too-large holes, roll off the bench and clatter to the floor, trailing wood glue in their wake.

Stoically, Mr, Kirkegard picked up the board, retrieved the wayward dowels, and stepped into his office. The door shut with a resounding thud and the bell rang shortly after.

At the end of the semester, I opened my report card to see I had gotten a C in shop class. I’m not sure what ever happened to the project, but, if you go to the Passaic County, New Jersey landfill and dig back through 26 years of refuse, I’ll bet you’ll find an unautographed Tom Iovino original piece of art.

Link of the week

Wood and Transience

The Writing Hall of a Zen Monistary in Kyoto, JapanIn the western tradition, we tend to build structures we want to see last a long time. Imposing stone castles from the Dark Ages and stone Roman Aqueducts still stand, hundreds or even thousands of years after they were built.

The Japanese philosophy, however, is quite different. This article – with some amazing pictures of master woodwork projects – gives an interpretation of the Japanese mindset when it comes to building structures and furniture.

Besides the fact that the Shinto culture reveres trees as having a spiritual identity, the choice of timber and joint selection also allows the structures to flex and move in the event of an earthquake – a common occurrence in this seismically active island archipelago.

Even if you just visit to view the incredible architectural photos, the site is worth the trip.

Woodworking Spotlight – Joe Gorleski, Jr.

Hey, look, it's Joe!Mention the world ‘veneer’ to some woodworkers, and they may turn their nose up at you. “That’s for cheap, mass produced furniture. I only use REAL wood!”

Well, surprise. Veneer IS real wood, applying it is a venerable woodworking skill to master and there’s a website that can show you just how impressive veneered projects can look.

Joe Gorleski, Jr, – known far and wide as Joe Woodworker – is a retailer of fine wood veneers that can take a woodworking project from nice to Woah!

Hammer VeneerJoe’s beginnings in woodworking were pretty humble. “I had inherited a used jigsaw that was gathering dust in my parent’s basement. One evening, we were cleaning out the basement and I had to decide if I wanted to keep the jigsaw or toss it out. I saw this pine board lying on the floor, grabbed a pencil and drew a pig shape on the board. I cut it out with the jigsaw and I discovered that I loved it!” Within a few days, Joe had plunked down some of his hard-earned cash and bought some other essential tools. The woodworking bug had bit him hard, but the biggest discovery was yet to come.

 

Veneered folding tables“Veneer is definitely cool. It has dramatically affected the way I look at wood. I used to spend hours at our local saw mill looking through hundreds of freshly dried boards to find anything unusual. The hard part was finding enough lumber with character to make a project. Now when I buy lumber, I look more often for perfectly un-figured boards so I can highlight any veneered portion of a project and keep the visual focus on these truly figured parts.”

 

 And, what figured parts they are! The selection of wood species available is stunning. Walnut burls, fiddleback maple and sapele pommele are just some of the stunning offerings on the site. It seems that you can find exactly what you need – regardless of your requirement for wood color, figure or even cost. Some breathtaking veneer lots can be found for cheap – offering multiple sheets for book matching or other eye-catching effects.

 

Quilted Bubinga Veneer SheetFor his first projects, Joe cobbled together a vacuum pump from plans he found online and by talking with other woodworkers. Since he was learning on his own, sometimes these early projects worked, other times, they didn’t. “Sure, there was trial and error. But, some of the techniques I’ve picked up from our gracious customers who very frequently share their success stories with me. One of the greatest things about woodworking is the incredible amount of sharing that goes on between woodworkers.”

From those humble beginnings, it didn’t take long for Joe to realize that he had way more veneer than he could ever use. “When I got to the point at which I was storing veneer under my bed, my wife and I realized it was time to let some of it go. Between veneer and vacuum press parts, we figured there was enough to get a small business going.”

Today, Joe’s commercial site VeneerSupplies.com provides quality veneers, equipment and – most importantly – know how to thousands of woodworkers around the world. “Our customers are quite varied. We have a lot of customers who are not woodworkers. They just want to veneer over something unsightly. I’ve had strange questions about veneering everything from refrigerators to turtle shells. I don’t recommend veneering your turtle!”

Joe's first Veneer projectVeneering might sound intimidating – and expensive – at first. However, there are some affordable options that the hobby woodworker can look into. First is a glue called Heat Lock. By using this glue, veneer and a clothes iron, the average woodworker can get good results. The ancient art of hammer veneering is also an option. But, for woodworkers looking to really expand their veneer options, vacuum pumps are the easiest – and sometimes the best – option. Some build it yourself kits start at $150, and complete systems can run about $400.

 

Veneered Drum Kit

 “Our website often conveys the image that we are a huge company. There’s a fine line between an average website and a professional one. I prefer to have a professional website but it’s not easy to communicate that we are still a small company consisting of just my wife Christine and myself. Our customers like the personal attention they get from us because it means that our answers and comments to their questions are always genuine.”

 

While Joe’s website is impressive, his personal approach with customers can leave some people a little off guard. “I always smile when someone calls to place an order and asks my name. When I say “Joe”, they always reply “the Joe?” I can’t help but smile because I’m thinking who else would answer the phone in my shop?”

Making centered mortises with a plunge router

I was working in my shop this past weekend using this mortising base kit I picked up at Eagle America to make centered mortises in a project I’m working on. It’s fitted out with two roller bearings that ride along the side of the piece allowing a gliding action over the surface of the wood.

Sure, there are lots of plans out there to build a base like this, but for $19, well, I couldn’t pass that one up!

The mortising base plateFirst, I had to drill the base plate to fit the base of my DeWalt router. Proper alignment is essential so the base is perfectly centered over the collet. Believe me, if you don’t get the base perfectly aligned, it’s not going to work as advertised. You may want to use a centering pin to ensure proper alignment.

Marking the mortise limitsThe next step is to mark out the limits of the mortise you want to cut. Since the mortise will be centered on the piece, marking the left and right sides of the mortise isn’t critical – the length, however, is.

Router in placeI put a 3/8″ up-spiral into the collet and set the router up on the workpiece. I set the depth of the bit at 9/16″ – allowing space for a 1/2″ deep mortise with 1/16″ space at the bottom of the joint to serve as a glue reservoir. When I rotated the base on the workpiece, the bearings made contact with the sides of the piece, ensuring the base is aligned with the work and the bit will land dead center.

Plunge cutsNext up, I started cutting the mortise. Rather than try making the mortise pass by pass, I started by plunging the bit to its full depth at both ends of the mortise. This established the start and end limits. Then I made a series of full-depth plunges the length of the mortise to remove the majority of the waste.

Clean mortiseFinally, I ran the router bit from end to end in the mortise to clean up the areas I had missed during the plunging action. Since there was very little to remove, I could plunge right to full depth and run the length of the mortise to get a clean mortise ready for a tenon.

Link of the week

WoodProjects.com

Woodworking plansSo, you want to build a woodworking project, but you are not sure where to find a set of plans to get started with?

This site should be your first stop. WoodPlans.com has links to plans you can buy as well as free ones from many sources – magazines, tool companies and private plan designers.

The secret to their 9000+ plans in the inventory is that they have agreements to sell plans from many different sources, and they scour the internet for offerings.   Their free plans are links to truly free plans.

The plans are broken down into very logical subsets, and you can browse or use the search feature to find what you need.  You’ll find plans for every room of the house – and for outside projects as well.

You want a plan to build a four post bed?  They’ve got links to 21 plans.  Dining tables?  24.  Workbenches?  99!

They accept credit cards, online checks, PayPal, money orders and even telephone orders, making the site a convenient resource for finding what you need.

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