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 Saturday, October 20, 2007
Three New Classes at Kelly Mehler’s School of Woodworking

Kelly Mehler
has opened the registration for his 2008 classes, including three
classes that I’ll be teaching on precision handsawing, planecraft and
building the Holtzapffel workbench from Issue 8 of Woodworking Magazine.
There
are still spots available (as of this posting). If the classes fill up,
I encourage you to sign up for the waiting list. People’s schedules
change and so many of the people on the waiting list get in.
Before I drone on about the classes I’m teaching, I also want to point out that Larry Williams and Don McConnell of Clark & Williams will be teaching a class on making wooden moulding planes
at Kelly Mehler’s school on Feb. 25-29. I would take this class if I
had the time in my schedule available. These two gentlemen are a living
treasure, and the way they build these tools is without compromise or
shortcut.
OK, now for the self-serving part of the entry that helps keep my children in Nikes.
Precision Handsawing: March 1-2
This is one of my favorite weekend classes
to teach because I think there is so much to learn about sawing and
sawtooth technology. During the weekend, we’ll be learning all about an
English-style of sawing (though you don’t have to use Western saws to
do it). And we’ll be building a traditional sawbench. That’s a good
thing, because I keep giving my sawbenches away to woodworkers as gifts.
Building Furniture With Handplanes: June 14-15 This is a new weekend class
that I’ve developed based on requests from other woodworkers. Many
handplane classes focus on the bench planes but they ignore the joinery
planes and how to actually use the tools to build furniture. In this
class, we’ll learn a bit about sharpening and a great deal about using
both bench planes and joinery planes, such as rabbet planes, plow
planes, router planes and shoulder planes. And we’re going to use all
these planes to build a Shaker silverware tray.
Build the Holtzapffel Workbench: Sept. 8-13 This six-day class
is going to be the highlight of my fall. We’re going to build the
Holtzapffel Cabinetmaker’s Workbench, the bench on the cover of Issue 8
and the bench I use in my shop at home. I’ve modified the construction
process slightly so we’ll be building benches that can be knocked down
and shipped back to your home when we’re done. You’ll be able to build
the bench in ash, yellow pine or maple. We’re going to source all the
wood for you and do the brutal machining before you arrive so the first
day we’ll be gluing up the top.
If you have any questions about the classes, feel free to drop me a line. Also, I’ll soon be posting my schedule with the Marc Adams School of Woodworking as well.
— Christopher Schwarz
Read other entries by Christopher Schwarz
10/20/2007 11:40:49 AM (Eastern Daylight Time, UTC-04:00)
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 Friday, October 19, 2007
Hand Tools for Power Tool Woodworkers
Confusing the Beginners-In Person
I don't make many personal appearances, but next Saturday, October 27, I will be at the Woodcraft store in Roswell, Georgia. I'll be giving some presentations and hanging around to talk to people. If you're in the area I hope you'll find the time to stop by and say hello.
A week or so ago I wrote on the blog about what hand tools I use, and one of the things I'll be talking about in Georgia is using hand tools in a modern woodworking shop. One of the things I see happen is that people who want to learn to use hand tools get overwhelmed and confused by the variety of tools, and the tendency of experts to get bogged down in minutia. One of the most frequent questions we get asked at the magazine is, "What tools and skills do I need to get started?" My answer is, "You don't need them all, and if you can shave your face without cutting off your nose, you're well on the way to developing the skills."
My plan is to go through the basics, give some recommendations on the most often-used tools, the skills to use them effectively, and some techniques you don't see every day. I will also be talking about the Festool Domino the experience we've had with it here in our shop, and how it compares to other methods of making joints.
 In between the formal stuff, I'll be there to answer questions and talk about almost anything. If you have a copy of one of my books I'll be glad to sign it, and if you want to pick up a book or a set of large format plans, I'll have them on hand. I hope to see you there. — Bob Lang Read other entries by Robert W. Lang
10/19/2007 2:43:20 PM (Eastern Daylight Time, UTC-04:00)
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 Thursday, October 18, 2007
Greene & Greene Fans: This is Your Holiday Weekend
Fans of Greene & Greene furniture often refer to a trip to Pasadena as a pilgrimage. Pasadena (and the nearby Huntington Museum) is home to the majority of original Greene & Greene work that can be seen by the public. This coming weekend, Pasadena Heritage, a community organization, is hosting an event that to a Greene & Greene fan is like the Super Bowl, New Year's Eve, St. Patrick's Day and Mardi Gras combined. The 16th Annual Craftsman Weekend is the one opportunity to see things that are normally kept behind closed doors. If I thought I could get away with it, I'd hop on a plane and go. One of our authors, David Mathias has done just that, and he promises to fill us in on what he sees this weekend.

The picture above is a reproduction that David made of the Gamble House entry table, featured in our February 2007 issue. That issue also featured a second Greene & Greene project, an adaptation of the Thorsen House side table based on drawings from my book "Shop Drawings for Greene & Greene Furniture." David is also working on a Greene & Greene-inspired bench that will be featured in our February 2008 issue.
One of the highlights of the weekend will be a "Behind the Velvet Ropes" Tour of the Gamble House, hosted by Jim Ipekjian. Jim has been working on repairing and reproducing Greene & Greene furniture and original homes for nearly 30 years, and is probably the most knowledgeable person in the world on original construction details. We featured Jim and his work in our December 2006 issue.
 Other makers of Greene & Greene-style furniture will be displaying their work Saturday and Sunday, including Thomas Stangeland and Darrell Peart. Darrel made the table shown above, featured in our November 2007 issue. In addition to the article, there are additional photos and other information online.
To those of you in Southern California who are able to attend, have a great weekend, and let us know what you saw by leaving a comment or sending me an e-mail. For the rest of us, we will have to wait for David's reports from the field. Sign up for free updates to the blog (in the upper left hand corner of the page) and we'll let you know when those are posted.
— Bob Lang
Read other entries by Robert W. Lang
10/18/2007 2:54:39 PM (Eastern Daylight Time, UTC-04:00)
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 Wednesday, October 17, 2007
Fix It or Just Split
Each month I receive newsletters from woodworking clubs and guilds around the country. Some come from groups I’ve spent time with and some arrive from people I’ve met while doing furniture and woodworking shows.
This month I was particularly interested in a newsletter from the Washington Woodworkers Guild – "The Wooden Word." On the first page of the newsletter (open the pdf below to read the page) a man is pictured standing next to a Massachusetts Block Front Chest. That would normally catch my eye by itself, but this article had my name associated with it as well. What did I do this time?
Tom Witzig is an accomplished furnituremaker and member of the guild who decided to build his Block Front Chest using a chapter from my book “Building Period Furniture” (Popular Woodworking Books) as a basis. As I see it, he builds pieces exactly as he should. Tom changes the design to fit his style of craftsmanship, he allows the material on hand to dictate the size of the piece, and he makes the necessary adjustments along the way. In my opinion, not following the plan and directions to the letter makes you understand the process better. Understanding the process allows you to apply those methods to future projects. If you follow the directions, you build one piece. If you understand the process, you can build any number of projects employing the same techniques.
On the downside of the article, Tom nailed the drawer runners to the case (as I indicated to do) and the case side split. That upset him and he vowed to add rear drawer dividers and not nail the runners if he built the piece again.
That would upset me too, but only for an instant. I don’t mind cracks in the case side due to wood movement – although my customers weren’t real fond of them. I think it makes the furniture more authentic looking when building reproductions. If you examine period pieces in museum collections, you’ll notice many case pieces that are cracked at the sides. It’s what happens over hundreds of years. Some of the pieces show old corrections or fixes while some stayed as they were.
You wouldn’t dream of fixing an original John Townsend chest – would you? I let time take its course on my pieces. What would you do?
– Glen D. Huey
The Wooden Word October 2007.pdf (173.71 KB) Read other entries by Glen D. Huey
10/17/2007 3:54:54 PM (Eastern Daylight Time, UTC-04:00)
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 Tuesday, October 16, 2007
Wood Werks to Offer Custom Powermatic Tablesaws
One of the reasons for the success and growth of Wood Werks Supply has been the willingness of the owners to try something new to better serve their customers. When I lived in Columbus, Ohio, it was the place to go for power tools and machinery. When I visited last week, I was impressed with their expanded showroom, the addition of a Rockler store, and as always the knowledgeable and friendly staff. Wood Werks sells a lot of Powermatic table saws, and the company is launching a new program to sell customized versions of the Powermatic 2000.  In the back room of the store last weekend, they had some familiar saws sporting a new look. Wood Werks will be able to provide the Powermatic 2000 with a custom paint scheme and trim package. For guys like me, who care more about function than form, these special saws will feature Blanchard ground tops (the shiny top found on the venerable Powermatic Model 66), and an American-made Baldor motor. Wood Werks approached Powermatic with this idea, and at the moment, they are the only dealer in the country to have these customized saws available.  It will be a couple months before these saws are available, and in the works is a web page on the Wood Werks site that will allow you to add custom features such as different color schemes, cast iron extension tables, the cast iron legs shown in the photo and custom name plates. I spoke with Todd Damon from Wood Werks this afternoon, and he said the basic package of Blanchard ground top and Baldor motor would add $500-$600 to the base price of the saw. If you go for all the available options, the package would run about $3100-$3200 which would include shipping in the continental United States.
— Bob Lang
Read other entries by Robert W. Lang
10/16/2007 4:24:57 PM (Eastern Daylight Time, UTC-04:00)
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Auriou, French Rasp Maker Since 1856, Closes Its Doors

The finest maker of handmade rasps and rifflers has closed its factory in Saint-Juery, France, after a protracted labor struggle with its workers, according to a release from Michel Auriou. The Auriou company has been making rasps by hand since 1856, and have only recently become available to woodworkers in the United States and Canada, where they have been hailed as outstanding tools. Several of the North American catalog companies that carry the tools still have stock on hand (get your credit card ready), but once that is gone, no more tools are expected.
Mike Hancock, the Auriou representative for the United States and the United Kingdom, said that the company had been growing quickly during the last few years, but that some employees refused to work overtime to keep up with demand. The situation deteriorated during the factory's normal August shut down, and now the company has been handed over to liquidators.
The full text of Michel Auriou's statement about the closure can be downloaded below.
Auriou's rasps are, without a doubt, the most prized rasps in the Popular Woodworking shop, even more so than the Nicholson patternmaker's rasps that most people consider as the best. Auriou also made carving tools, adzes and other tools.
The teeth of the Aurious are made by hand, which gives them a slight randomness in their arrangement on the blank. This randomness creates a rasp that cuts quite smoothly and quickly. If you'd like to read more about how these rasps were made, Joel Moskowitz of Tools for Working Wood has written an excellent explanation of the process that you can read on his web site.
If you are looking to purchase Aurious, here are a few of the places that we know that carry them. Act fast. As to our recommendations for the rasps to have, that really depends on your work. We typically use a cabinetmaker's rasp followed up by one of the modeller's rasps. We've also used the rifflers, which are excellent, if your work demands it. I'm not sure how fine ours are. The cabinetmaker's rasp is coarser than the modeller's rasp, which is a good combination for us.
• Tools for Working Wood • Lee Valley Tools • Lie-Nielsen Toolworks • Woodcraft • Highland Hardware • The Best Things • Classic Hand Tools
And if all of those sources are sold out, we recommend you take a good look at the Gramercy Tools handmade rasps from Tools for Working Wood. Though not quite as perfect as the Aurious, they are high-quality tools.
Download the full text of Michel Auriou's statement. AuriouStatement.htm (6.47 KB)
— Christopher Schwarz
Read other entries by Christopher Schwarz
10/16/2007 1:34:36 PM (Eastern Daylight Time, UTC-04:00)
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 Monday, October 15, 2007
The Wonders (and Winners) of SketchUp
 As of September 30th, LumberJocks' Virtual Dining Table Challenge came to and end. Did you get in on the challenge? There are a number of great entries from those fluent in SketchUp as well as from first-timers that show fantastic promise with the free design program. I was a bit envious of some of the projects. Most participants outpaced my SketchUp skills quickly.
The editors of Popular Woodworking magazine were given the difficult task of picking the winners. After a group meeting in which we nominated and defended our choices, we did just that. Each winner receives a book or DVD from all four Popular Woodworking editors.
We selected, in no particular order, the Empire State Dining Table by Brad Nailor (a design that nicely showed using a plug-in called Podium that presents a photo realistic rendering. It’s worth a visit to this entry to see the design and to gather the inside information about Podium), The Backward Bridge by ThreeJs (the use of SketchUp to detail the joinery was a nice touch, and displayed a commanding knowledge of the design tool), and the Folsom Stadium Dining Room Table by Steved (a design that needed one additional view to pull it all together. After studying the design we were able to make out the “D” shape taken from the stadium view – nice work).
The big winner had to be ThreeJs. The folks at Google selected ThreeJs as the best entry and he’s been awarded Google SketchUp Pro. In addition, LumberJocks fashion wear was awarded to Damian Penney, Vanmaineac and Scottb.
Winner of prizes or not, the value of this challenge was to get involved with SketchUp. I’ll bet this program makes your woodworking better due to the ability to see projects prior to being built. It’s a great way to work out details and save time in the shop. Check out all the entries – not just the winners. I think you’ll find a reason to work with SketchUp. I plan to spend time to develop and hone my skills.
–Glen D. Huey
Read other entries by Glen D. Huey
10/15/2007 3:04:07 PM (Eastern Daylight Time, UTC-04:00)
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 Thursday, October 11, 2007
Wood Werks Supply Fall Expo, Columbus, OH
This morning I took a ride up I-71 to Columbus to pay a visit to Wood Werks Supply. It's the weekend for their annual Fall Expo, and I haven't been by the store since moving to Cincinnati three years ago. It's one of the best stores for woodworkers I've ever seen, combining stationary and hand-held power tools, hardware and lumber in one location. Since Ron Damon opened the business in 1990, he and his son Todd have expanded every couple of years, and now have about 25,000 square feet of space.
If you're the kind of woodworker who likes to see tools in person or compare things side by side, this is the place for you. Pick a machine, like band saws, table saws or planers and they have a range of them on display side by side. The employees are all woodworkers themselves and are more concerned with helping you make the right choice than making a quick sale. In addition to a full line of machines, the company also has portable power tools and all the bits and accessories to go along with them. In the back is a complete in-house repair facility.
 Way at the back of the photo above you can see a Rockler sign. Wood Werks Supply was the first independent store in the country to become a Rockler Partner Store. Pass through the doorway under that sign, and there is a typical Rockler store in one corner of the showroom. There, you'll find nearly every item in the Rockler catalog in stock. The opposite back corner of the showroom holds sheet goods and lumber. The sheet goods range from MDF and melamine board to nice hardwood plywood. There's also a good selection of hardwoods, and you can pick through the stacks to buy just one board, or you can buy it in 250 or 500 board-foot bundles. Back beyond the lumber room is a 2,000-square-foot classroom. This weekend has become an annual event in Columbus, attracting about 4,000 woodworkers, and features special prices and visits by a number of manufacturer's representatives. Among the manufacturers present is Powermatic, and if you wander back to the lumber area the company has some new ideas that it would like your input on. So, if you're in the area, take Friday off and join the festivities. If you can't make it Friday, the event continues through the weekend. The Ohio State University is playing at home Saturday, but Wood Werks is well away from traffic from the game. OSU is still in the easy part of their schedule, playing the team from my hometown, The Kent State University Golden Flashes. Kent isn't exactly known as a football powerhouse, so this would be a good game to miss. The store's phone number is 614-575-2400 if you need more information. Also, look for some very exciting things on the company's web site. Ask what they're up to, or watch this blog – I'll be reporting on it next week. — Robert W. Lang Read other entries by Robert W. Lang
10/11/2007 3:20:08 PM (Eastern Daylight Time, UTC-04:00)
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 Wednesday, October 10, 2007
Wish Her Luck
 I’ve taught a number of classes during my woodworking days. Teaching is one area that I thoroughly enjoy each and every time I’m called upon. I’ve found that most woodworkers who take classes are very receptive to direction as well as open to new or different ideas on how to go about the craft. I enjoy the looks on their faces when they grasp the idea put forth, and I like it when that bewildered look in their eye turns into a twinkle.
In my prior life, although I knew each woodworker had a certain method of work, I didn’t realize how different those methods could be. I adopted my Dad’s way of thinking – do it his/my way or do it wrong. Since becoming a part of the Popular Woodworking staff I’ve been privy to a number of different paths that all lead to the same end result. Editor Christopher Schwarz, Senior Editor Robert W. Lang and I approach woodworking from various directions, but each of us arrives at the same destination.
So, you may ask, what about Managing Editor Megan Fitzpatrick? She’s the subject of this entry. Today, Megan and I began work on a project in the Popular Woodworking shop. She asked that I teach her my woodworking methods. Poor woman.
Megan has a couple challenges in learning woodworking and at least one big benefit. You might not know this, but Megan is a teacher in her own right. She is a former adjunct professor at the University of Cincinnati (and now a 4th-year PhD student). I’ve found those who teach, when learning something they haven’t mastered, are usually like a sponge when being taught. I’m sure Megan fits this model too.
What about those challenges? Chris and Bob (no, they’re not the problem) have each spent time in the shop working with Megan, filling her head full of their woodworking methods. She’s benefited from their teaching and now she’s traipsing down my path as well. She’s being shown a third method of work. This could be good – or it could be bad.
With each new teacher she must forget, or at least put out of mind for the time being, the processes she learned with other instructors. That opens her mind to accept new methods. And that, in the long run, allows her to grow as a student. (I think it’s best for students to examine a number of ways to get things done, then choose the method that best fits his or her comfort level and ideas.) Megan may end up being the better woodworker of the Popular Woodworking staff because she’ll be able to take three different methods of work (one from each editor) and apply the ones that work best for her…then pitch the rest.
If things go well over the next few weeks, I’ll keep you posted on our progress. If things don’t go so well, I expect you’ll hear about it from Megan. Maybe this should be titled, “Wish Me Luck.”
– Glen D. Huey
Read other entries by Glen D. Huey
10/10/2007 3:45:21 PM (Eastern Daylight Time, UTC-04:00)
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 Monday, October 08, 2007
Confusing the Beginners-Another Tool List
I consider myself fortunate to share the Popular Woodworking shop with two world-class woodworkers – Christopher Schwarz and Glen D. Huey. After many years of working mostly by myself, it’s refreshing to see approaches and techniques that are different from mine yet work just as well, or even better. As an old dog, it’s nice to learn some new tricks. Also sharing the shop is a less experienced woodworker, our managing editor Megan Fitzpatrick. We all try to be helpful and teach her what we consider to be the “right” way to do things as she develops her skills in the shop. Nice guys that we are, we feel free to jump in and offer unsolicited advice whenever we pass by and she is at her bench. Except for the admonition to not get blood all over the shop, I don’t think there has been an occasion where the three of us offered the same method, tool or technique. Megan isn’t shy about pointing out to us where we contradict each other (or occasionally ourselves) and we’re slowly learning not to jump in as she practices what one of us has shown her. I think all beginning and semi-experienced woodworkers go through a similar experience, but not as intensely and not on a daily (or hourly) basis. I learn things by going into “sponge-mode” trying to soak up as much as I can from different sources. I try different things until I find something that works for me. When I learned about woodworking, there was no Internet and no local woodworking store; there was one bi-monthly magazine, and only a few catalogs and resources for tools. I got reasonably good at doing things before I found out that I didn’t have anywhere near enough tools.  If I were just learning how to work with wood, it would be easy to become overwhelmed with the volume of information available today. This is especially true when it comes to tools. Many of our readers want to be woodworkers, but they aren’t yet because they are busy gathering all the tools they’ve been told they need, and getting their shops together before they actually start making stuff. There’s a good chance that many of these will pass on before they realize that gathering tools and getting the shop in order can become an eternal effort. The problem with woodworking is that there is always one more tool that promises to make a daunting task quick and painless. Special tools can indeed do that; the hard part is sorting out the tools you want from the tools you think you need – and the tools you really need from the tools that will help you do what you want to do. The list of tools I want looks like a telephone book, but the tools that will do at least 90 percent of what I want to do are in the picture above. I have more tools than this, but these are the ones that have been with me awhile – the ones that have shorter blades from being sharpened a zillion times and the ones that show some signs of age. I think this represents a good basic list for any woodworker. If your main interest is power tools, these tools will make your setups more accurate and will save the day when the power tools get you close to what you want, but not quite there. If you want to be a hand-tool woodworker, knowing how to use, sharpen and tweak these basic tools will get you well on your way. You’ll have a better idea of what more specialized tools you need, or you may decide that these are all you need. The important thing is to get going and make something. Click below for a list of the tools in the picture as a Word document. 10-05-07_list_ blog.doc (30 KB)Click below for the list of the tools in the picture as HTML RLang_list.htm (9.69 KB) – Robert W. Lang Read other entries by Robert W. Lang
10/8/2007 10:19:29 AM (Eastern Daylight Time, UTC-04:00)
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 Friday, October 05, 2007
November Videos Added
We've added our November videos to our Video Site at popularwoodworking.com/video. Take a gander at a snippet of the Hybrid Tablesaw Shootout, see Christopher Schwarz explain and demonstrate using a bench hook, and study Rob Porcaro's upgrades to his workbench. Click here to view the Tablesaw Shootout video. Click here to view the video on using a Bench Hook. Click here to view the Workbench Upgrade video. Oh, while you're there, check out the other videos too. – Glen D. Huey Read other entries by Glen D. Huey
10/5/2007 2:28:51 PM (Eastern Daylight Time, UTC-04:00)
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 Wednesday, October 03, 2007
My Views On Cutting Glass
Last week I penned an entry about the similarity between dovetails and glass cutting (click here to read it). I wrote about confidence being a large part of success. One comment listed cooking in that mix, too. The writer also added that you have to learn the skills before the confidence kicks in to play a part. That’s true for dovetails and I can only assume for cooking. However, I don’t believe that glass cutting fits into that category. Simply pick up a cutter, etch the line and snap. There’s not much else to learn about the basics.
This week I’d like to share a few simple ideas to get glass cut for your projects. Keep in mind these are not tips from a seasoned cutter, but from an ordinary Joe just scratching the surface. (Get it?)
It all starts with the right tool. For years I tried to cut glass with the regular cutters you find at hardware stores. The task was iffy at best. Frustrated, I visited a stained-glass store where the clerk recommended a Fletcher Designer II Pencil Grip Oil Cutter. This tool costs nearly seven times what the hardware-store cutter cost. Did they see me coming when I walked through the door? Looking for an answer (or at least being a pushover when it comes to purchases), I bought the cutter and went straight for the shop. I was amazed by how well it worked. So yes – the price of a quality glass-cutting tool is worth it.
 To fit glass, you have to begin with a straight edge. Position a straightedge tool onto the glass and roll the cutter from end to end, then snap the glass at the etched line. This is where confidence pays off. If the glass doesn’t snap like a good bakery cookie, tap the cut on the underside with the ball end of the cutter. You’ll see the crack start. Then use a framing square, one that’s really square, to make a second cut resulting in a 90º corner.
Don’t try to fit a piece of glass too tight. Measure the opening and transfer the layout to the glass with a Sharpie Permanent Marker (the best marker I’ve found to write on glass). I leave about an 1/8" of gap when fitting panes into a cupboard door. That’s a 1/16" per side. Line up the square and etch the line. Have confidence and snap the glass (sometimes you’ll have to tap with the ball end). Continue until the pane is sized.
Tombstone panes (seen in the door from the previous blog entry) present a problem. I paid someone to cut the first pane. The glass vendor had a sander that he used to get the sharp corner detail. It got the job done, but I wasn’t impressed. After that I tried it myself – got my confidence up.
The secret is no sharp corners. In the Authentic Shaker Clock article, August 2007, I rounded the corner of the rabbet to make the glass fit more easily. Another method is to round the cut of the glass.
 Here’s what I do. Cut the pane to fit the opening by cutting the width and the height at the apex of the arched or tombstone top. Position the pane into the opening and draw the tombstone onto the glass with the marker. Freehand the cut making sure to round the corner of the tombstone. The cut starts at the side and terminates at the middle of the arch. Two waste pieces are removed to make the profile.
Once the lines are etched, tap the cut line from the bottom and watch the crack begin. Apply a small amount of outward and downward pressure with pliers as you tap. When the break happens the waste will be in your pliers. Don’t forget to wear your safety glasses.
For the four panes of the door on the corner cupboard shown in the previous entry, I made five attempts. One piece of glass was lost. I must have been thinking about something else and my confidence dipped.
– Glen D. Huey
Read other entries by Glen D. Huey
10/3/2007 2:20:05 PM (Eastern Daylight Time, UTC-04:00)
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