Stoning your Saw

By stoning, I don't mean that if your handsaw is misbehaving, you should go all biblical on it. Instead, I mean there is a way to gently persuade it back to the straight and narrow by using your sharpening stones.

If your saw is consistently listing to one side when you are trying to saw a straight line, the problem might not be with you, but with the set of the saw's teeth.

If it's listing to the same side all the time, that means it is cutting more agressively on that side, which in turn means the teeth have a greater set on that side. You can decrease the set by laying your handsaw on a flat surface and lightly dragging your fine grit sharpening stone along the aggressive side of the saw's teeth. Take light passes and test the saw often. It doesn't take much to correct the cut. By doing this, the saw kerf will be made a bit thinner, so if you don't want that to happen, you might want to enlist the help of an expert sharpener.

Or, play it safe, and just purchase Lie-Nielsen saws.

Last photo added afterwards because one sharp reader noticed that I had used a rip saw to make the crosscuts. (I used my dovetail saw because it is my favorite, it was within reach, and I like the physically smaller size of the saw, compared to my crosscut saw). Nonetheless, the proof is in the photo—both the rip and crosscut Lie-Nielsen saws work great!

Product vs. Process

A friend said to me the other day "So when are you going to start building tables and entertainment centers? I mean, you do all these little things..."

Now this guy is not a woodworker but I've met non-woodworkers who understand the joy of having a hobby and just fiddling around while accomplishing nothing. In my opinion, there are people who are product-oriented, people who are process-oriented ("it's the journey" people) and those who are both. I think this guy falls into the product-oriented category. I'd say I'm both, but I always get a little maudlin when I finish a project, so I suppose I'm a process-oriented gal.

Other friends ask me to build furniture for them and when I say I'm not for hire—woodworking is my hobby—they seem incredulous. They look at the size of my shop and all my tools and can't believe I'd spend that much money on a hobby.

How do you convince product-oriented folks that even just handplaning boards makes you happy?The guys in my ww club think I'm nuts for handcutting dovetails. They tease me that "there's this new thing...it's called electricity." (okay, that one's pretty funny...)

I don't have a response. I just laugh. Any suggestions?

Finished Cupboard

Here is a photo of the finished reproduction Ephrata Cloister cupboard alongside the original. Some parts of the door (the handle for one) on my version are thicker pieces of wood because I was concerned that the wood might split when I drove the dowels in.

At right are close ups of the bottom corners.

If anyone would like to have a cut list and construction notes for the cupboard, send me an email: goodwoodworkshop@comcast.net. One reader was interested in plans, so I'll write them up in pdf format.

The Village Carpenter

My blog title is named for a book by Walter Rose, called The Village Carpenter. It's a book that I wished would never end. The author writes about carpentry, working in his grandfather's shop in Victorian England, at a time when the carpenter was vital to the life of the village and whose duties encompassed a much broader range of skills and projects than what we think of as carpentry today. The village carpenter in the late 19th c. was responsible for building everything from windows & doors to coffins to fences & gates to furniture to buckets & washboards and more. He was a thread that tied the community together, often having to work on sight, gaining an intimate understanding of the villagers in whose homes he would work for weeks on end.

Walter Rose eloquently recounts stories about the men who worked in the shop, their tools, their projects, and their interaction with the villagers. Here is an excerpt from his book:

"It is in the workshop and at the bench that an insight into the soul of wood craftsmanship can be truly gained. There are tools, there is the wood—rude planks, ungarnished, their surface scored with the saw. Between them, and without which each is useless, must come the soul and spirit of the designer and craftsman; the deft hands prompted by an alert mind; the knowledge attained only through years of study and service; the creative instinct and ability that will, by the correct use of the tools, transform the mere plank into a thing of usefulness and beauty—possibly a joy for ever."

The entire book is filled with memorable passages and woodworking wisdom that has since been forgotten but is still relevant. He reflects on the personality of wood and the connection between the carpenter and his tools—a connection so absolute, that the same tool in another woodworker's hands would not respond the same.

It's a must-read for anyone who is passionate about woodworking or who would like to gain insight into the soul of a woodworker.

Bullet Designs & Finger Pulls

The bullet-shaped carving found in 16th c. New Mexican furniture is also found in chipcarved decorations that adorn 18th c. Dutch planes. A similar shape, an inset finger pull, is found on sliding lid candle boxes from the 18th and 19th c.

Maybe that shape has shown up all over the world because it's so easy to make.

In the photos at right, I did not make the Dutch planes* (of course), but I did make the New Mexican style cabinet and sliding lid box.













For the bullet shape, use a gouge with a pronounced curve. I used a #10/12mm straight gouge. Hold the gouge about 60 or so degrees to your workpiece—leaning the tool back a bit so the outer tips of the blade do not enter the wood—and strike it with a mallet. If you make this cut perfectly vertical, your bullet shape will look like it has little horns, which of course you might prefer.

Next, begin the second cut as far back from the first cut as you would like for the length of the bullet to be. Start with a shallow cut that increases in depth until you reach the initial cut. The chip should pop right out.
















The finger pull is a similar procedure, except I make the initial cut with an exacto blade, and a more shallow gouge (I used a #5) is used to make the second cut. The knife incision is a straight line and deepest at its center. I keep a little nylon brush on hand to remove chips that don't want to "pop right out."









*Photo of Dutch planes is from Sandor Nagyszalancy's book The Art of Fine Tools.

Almost Done

I don't think I've ever been more disappointed to see a project come to its final stages. I have only to add a few more dowels and apply finish and this project is done. The amount of handwork involved provided so many quiet hours of meditation-like focus that I forgot all about the things I "should" be doing. (Which isn't necessarily a good thing!)

After final shaping, I used a burnisher on the edges of the handle to shine it up a bit. The original handle is shiny and smooth from years of oily hands opening the cupboard.

I tested a few finishes on scrap pieces—Boiled Linseed Oil, Tung Oil, and Watco Wipe-On Poly—and found that BLO darkened the wood the right amount. A couple coats of that, a week or so to cure, and then a topcoat of dark paste wax ought to age the cupboard enough that it will look a little more like the original.

Wooden Hinges

This was the part of my current project that I was most looking forward to making: wooden hinges. I roughed out the pieces on the bandsaw and achieved the final shape with a Murphy carving knife and spokeshave. The facets created by the carving knife added to the handmade look that I was trying to replicate in the original cupboard. I don't know what tools the maker of the cupboard used, but the surfaces of the hinges and handle unit appeared (in the book) to be carved rather than planed, chiseled, or filed.

The last photo shows the hinge attached to the door. The design enables you to remove the door by lifting it up off the hinge pins.

Making these hinges was so much fun, I'll be on the lookout for other pieces that employed them.

"But it's only one room"

That's what my partner said when I told her my ww club was coming over for a shop tour on Saturday. "How do you take a tour when it's only one room?" she asked.

Have I taught her nothing?

Help me out guys. It's not just a "room". It's a sacred space that's filled with power tools, hand tools, antique tools, jigs, workstations, books, setups that enable different woodworking procedures, works in progress, stories of anguish and triumph, and wood. Lots of pieces of exotic wood and buried treasure.

I expect the guys will be in my shop poking around, asking questions, cutting up, and jokingly trying to "swipe" little tools (I'll have the surveillance cameras on just in case) for about 2 hours.

And they'll be touring not just a room, but my little piece of heaven.