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 Tuesday, April 15, 2008
My Take On Dovetail Angles
 My take on dovetail angles might appear to be strange, but I have solid reasons for my choice – if I do say so myself. Here goes.
Dovetail angles are most notably described in degrees, but is often stated as a ratio, either 1:8 or 1:6. These ratios translate into a 7º or a 9º angle. These are the established angles; the angles we’re suppose to bow to upon pulling our marking gauges from the bench drawer as we prepare to cut the parts of the joint. One angle is suggested (a better word might be mandated) for softwoods (9º) and the other for hardwoods.
So, do you need two sets of marking or layout tools? One set for working dovetails in softwood and one for hardwoods? Why would you want to purchase tools that do the exact same task, only at a different angle? And, where is the dovetail joint used for the most part? That’s right, in drawer construction. Many woodworkers use a combination of hardwood drawer fronts with either hardwood sides (poplar) or softwood sides (pine). Yes there are other combinations, but I venture to say these are the most common in American antiques throughout the major furniture periods of Queen Anne, Chippendale and Federal.
I use Newport, R.I., as a demarcation line for typical woods used to build drawers and if you’re building reproduction furniture from Newport south (not Southern designs that use yellow pine as a secondary wood), you are probably using two hardwoods for your drawer parts; poplar as the sides, backs and bottoms with another primary hardwood as your drawer fronts. The two hardwoods traditionally dictate using a 7º slope.
But, what about us poor souls building drawers based on New England designs? Designs built north of Newport, R.I., where drawers use hardwood for the fronts and softwood, namely pine, as other drawer parts. What angle should we choose for our dovetails: 7º that matches the use of hardwood, or 9º used for softwoods? What a conundrum. Additionally, we have the development of the dovetail jigs that suggest (there’s that word again) we use a 14º-dovetail router bit to make the tails and a straight bit to cut the pins. I can say I like the slope of these dovetails much better. Aesthetically, these are more pleasing to my eye. And that’s what I think should drive your dovetail angles – aesthetics.  Don’t accept the traditional ratios. I’ll bet a study of furniture and drawer construction from the 1700s through today would turn up many different dovetail angles. Of course, I’ve used the 7º, 9º and 14º angles during the period I used dovetail jigs to cut my joints. I’ll bet when I switched over to hand-cutting dovetails I used a few angles in between as well – as a beginner, it’s nearly impossible to stay on the layout lines. I know of no joint failures and not once have I seen the angles break or shear along the slope of the tail (something preached if the slope grows well beyond the traditional ratios).
The Angle I Use
So, where am I today with this dovetail angle question? I use a 12º angle. Why 12º, you may ask? Here’s my reasoning. I certainly wasn’t going to switch angles depending on the application (too much wasted time) and I wanted an angle that fit somewhere in the middle of the established slopes. And how many places does the number 12 show up in our world? We have 12 months in a year. Two sets of 12 hours in a day. Most people know that a dozen of anything is 12. And to bring it in line with woodworking, if you’re fitting a raised panel into a 1/4" groove and the panel needs to be the full width of the groove as it rests tight to the bottom of the groove (a snug fit so the panels don’t rattle), you need to set a 12º-angle cut for the panels.
And most important, I like the angle when I look at it.
Is it just me? Am I crazy? (That’s a question I’m sure I’ll get a few comments on. Remember the glove incident?) What degree slope do you use for your dovetails and why? – Glen D. Huey Read other entries by Glen D. Huey
Tuesday, April 15, 2008 2:09:45 PM (Eastern Daylight Time, UTC-04:00)
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Tool Review: Veritas Dovetail Saw Guide
 Lee Valley Tools sent out a new product release for a guide used for cutting dovetails. It’s not really a new guide, but a new angle for the guide. The reconfigured Veritas 14º Dovetail Guide (05T0205) has a 14º-angle cut instead of the 7º or 9º slope that's associated with the oft-quoted dovetail ratios of 1:8 and 1:6. (For more on my thoughts about dovetail angles, click here or at the bottom of this entry.)
I’ve had occasion to use a 1:6 ratio guide, and although it was for a limited amount of time, I was very impressed with the way the guide held the saw in the correct position for woodworkers. So, I was interested in getting the new design into the shop to evaluate after a lengthier period of use.
The guide is made with an anodized aluminum body and has a 3/4" rare earth magnet embedded at both ends of the jig. Those magnets grip your saw and hold it at the correct position, angled at 14º. Each end of the guide is covered with UHMW plastic to protect the jig, and your saw, as you make cuts. The guide and complete instructions come as one package, or you can purchase the guide, instructions and a saw as a second package.
 Any saw without a back can be used with the guide and Lee Valley has the saw they recommend (click here to see the guide with that saw), but I had another idea. The Autumn 2007 Woodworking Magazine (issue #8) ran an article discussing flush-cut saws. In that article we listed Lee Valley’s kugihiki (60T06.20) as "highly recommended." I used this flush-cut saw with the guide and found it worked great. I recommend purchasing the kugihiki and making the saw work double duty as both your dovetail guide saw and your flush-cut saw.
This guide does not automatically produce a dovetail joint. You need an understanding of dovetails at the outset. You’ll need to know the difference between "tails" and "pins" as well as have a certain understanding of layout and what’s the waste side of your layout lines (information provided in the included instructions). With that information at hand, this guide helps improve the quality and accuracy of your cuts.
I’m a "pins first" dovetailer, so naturally I began cutting the pins. This is the only experience I had with the guide earlier and I knew the jig worked great here. I started with a half pin on both ends of my board, then positioned and cut two full pins in between. Once the guide is clamped at a layout line, the saw snapped to the magnet and was held perfectly vertical as I made the 14º cut. The cut came out perfectly straight. Next, I chopped out the waste to finish my pins and used the pin board as a layout tool for the tails.
 A sharp pencil provides tight, accurate lines and that’s exactly what I needed to position the guide. The clamp portion of the guide can be removed and repositioned to cut the tails of the joint, too (see the photo at right). I set the guide so my pencil lines were just covered – that forces you to cut on the waste side of your lines – and made the cuts that define the tails. Clean out the pin waste and the tails portion of the joint is complete. Slide the pins into the tails and the dovetail joint is made. This guide can also be used to cut half-blind dovetails.
To read more about dovetail angles, click here.
– Glen D. Huey
Read other entries by Glen D. Huey | Read other Tool Tests
Tuesday, April 15, 2008 1:57:14 PM (Eastern Daylight Time, UTC-04:00)
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 Wednesday, April 09, 2008
Steel City Contest Winner
The winner of the Steel City Tool Works 10" Granite-topped Table Saw is (drumroll please): Ron Burris, Sr., a retired chief master sergeant with the United States Air Force.  "I can’t tell you enough how thrilled I am to be the lucky one that was chosen as the winner of such a wonderful table saw," wrote Burris. "This saw will help me continue to improve my skill level as a woodworker. When I retired from the Air Force I wasn’t sure what I was going to do with all my spare time. Over the past seven years, I have spent a lot of that time renovating an old house. It’s hard to believe but I really enjoyed learning how to DO-IT-YOURSELF and it really sparked my interest in working with wood. "I have been upgrading some of my power tools over the last year or so with plans for a new table saw and drill press this summer. Thanks to all of you at Popular Woodworking and the folks at Steel City Tool Works, now I can add a dust collection system to my fledgling work shop sooner than planned. This has been incredible, thanks to everyone ." Congratulations to Burris from everyone at Popular Woodworking and Steel City Tool Works. And thanks to all of you who entered the contest (and be on the lookout for a new contest in the very near future!). — Megan Fitzpatrick
Wednesday, April 09, 2008 2:57:47 PM (Eastern Daylight Time, UTC-04:00)
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 Tuesday, April 08, 2008
Bookcase Challenge Running Full Force
The LumberJocks/Popular Woodworking Bookcase Challenge is in full force. Since the full-fledged announcement in our March 26th newsletter, entries have been trickling in. We expect a plethora of entries as we approach the deadline due to woodworkers’ procrastination – my style of work – and because most of us want our designs to be a surprise. But whatever your excuse, I hope you’re working on your drawings and designs.  Just to give you a taste of the competition, if you haven’t been following the event at lumberjocks.com, I thought I would show a few of the early entrants. These woodworkers stepped up and delivered their designs right out of the gate. And, these few morsels should help to inspire your designs, but remember your design has to be original. The first entry is from Gwurst (not his real name). Gwurst says he was stymied while trying to make a traditional design stand out. So, he did what any woodworker worth his salt would do, he turned to curves. He also says he couldn’t build this design, but it appears he has an eye for design. Will he get a chance to build his bookcase? How does his piece stack up against the competition?  Here’s another reason to participate in the contest. Huck and his spouse teamed up for their entry. Huck explains that his wife designed the bookcase and he did the SketchUp work. The original concept was to build the unit from sustainable material. Good idea! Now he is sure that he’ll have to build the bookcase whether it’s the winning design or not. I plan to stay tuned to this entry to see if Huck follows through and completes the bookcase. That’s a very nice “honeydo” for the list. Next up is a look at Joey’s design. Joey decided to bypass Google SketchUp and put pencil to paper. (That’s in keeping with the rules; you don’t have to be a computer whiz or spend time learning a design program – although we think once you get a taste of SketchUp you’ll find many uses for the program while working wood.) Joey's inspiration for design came from a huntboard that captured his eye, so he submitted a bookcase with loads of storage, many curves and smartly used sections of inlay banding. I hope he decides to build this design. I would enjoy seeing this project completed.  There’s more eye candy to see. Take a look at submitted designs ( click here), then add your own. I wouldn’t wait until the last minute if I were you. The challenge ends on April 20th and there’s no sense taking chances. Besides, I think getting the comments from fellow LumberJocks and other woodworkers would be half the fun. What do you think? Do you see a design that has you stepping out to the shop to build? – Glen D. Huey Read other entries by Glen D. Huey
Tuesday, April 08, 2008 8:48:09 AM (Eastern Daylight Time, UTC-04:00)
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 Wednesday, April 02, 2008
Glen-Drake Founder to Visit Popular Woodworking

Kevin Drake, the founder and owner of Glen-Drake Toolworks (glen-drake.com), is visiting the Cincinnati-based Popular Woodworking shop for a free seminar on May 8 from 6-9 p.m.
Kevin will be demonstrating and discussing some of his tools, including the Tite-Mark gauge (the favorite cutting gauge of four out of four Popular Woodworking editors surveyed), the "Wild-West" Joinery Saw (a two-handed dovetail saw), Plane-Adjusting Hammers, Chisel Hammers and more. Plus, all attendees will get a free copy of his "Tools and Techniques" DVD!
We have room for 60 visitors, and dinner is included. Slots are available on a first-come, first-served basis. Please send me e-mail me if you'd like to attend this free event.
— Megan Fitzpatrick
(megan.fitzpatrick@fwpubs.com)
Read other entries by Megan Fitzpatrick
Wednesday, April 02, 2008 1:28:05 PM (Eastern Standard Time, UTC-05:00)
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 Tuesday, April 01, 2008
The Greatest Woodworking Show on Earth

A few years ago, I attended the Woodworkers Showcase show in Saratoga Springs, N.Y., and I was amazed. It was the most perfect woodworking show I had ever attended. Why? Because of four things.
1. The free classes and seminars were extraordinary. That year I learned more about cold-bending from Jere Osgood and furniture design from Garrett Hack in a single day than I'd learned by reading (too many) books.
2. An amazing display of furniture, turnings and other objects (even a canoe!) that were built by the members of the club who put on the show, the Northeastern Woodworker's Association.
3. Hands-on displays and demonstrations of jigs, fixtures, carving and sash-making that were ongoing the entire weekend.
4. And, of course, booths and booths of vendors selling new equipment and vintage tools.
And amazingly, admission for all this was just $7 for adults.
This year, I was asked to demonstrate at the Woodworkers Showcase – a huge honor – on April 5 and 6. It's this coming weekend at the Saratoga Springs City Center. Click here for information on the event.
I'll be demonstrating the scraper sharpening technique I developed after plumbing the historical record, and I'll be showing off the three kinds of handsaw cuts that I discuss in the newest issue of Woodworking Magazine.
In addition to my demonstrations, you can also catch demos from chip-carver Wayne Barton, box-maker and instructor Doug Stowe (ask him about Sloyd if you see him) and Peter Korn, who runs the Center for Furniture Craftsmanship and is a talented woodworker. Plus, there will be demonstrations from members of the club on every topic imaginable, from marquetry to miniatures to turning to rustic furniture construction.
When I'm not teaching, I'll be in a booth selling a few books, magazines and DVDs. If you're at the show, do stop by and say hello.
If you live anywhere in the northeast, this is a show that shouldn't be missed. People drive from all over the eastern seaboard to attend the Woodworkers Showcase. It's worth it (heck I flew up from Cincinnati when I first attended).
Hope to see you there.
— Christopher Schwarz
Read other entries by Christopher Schwarz
Tuesday, April 01, 2008 1:56:11 PM (Eastern Standard Time, UTC-05:00)
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 Monday, March 31, 2008
Shaker Village of Pleasant Hill
The restored Shaker Village of Pleasant Hill, Kentucky, has been on my list of places to visit for a long time. It is only a two-hour drive south of Cincinnati, and I can't count the number of times I've driven through the area and thought: "next time, we'll stop." This past weekend we made a special trip, and stayed overnight.
 Pleasant Hill was one of the largest of the western Shaker communities, and the only one remaining that is open to the public in this part of the country. I had been to the Shaker Museum in Chatham, New York, and the Hancock Shaker Village in Massachusetts. Several of the pieces from Pleasant Hill have been featured in Popular Woodworking; most recently a firewood box was our "I Can Do That" project in our February 2008 issue. I saw three or four variations in different locations.
 One of the unique aspects of Pleasant Hill is that a good portion of the property is an inn, with a wonderful restaurant and rooms available in the original buildings. I've been to a lot of museums and restorations, but I've never spent the night in one. It added immensely to the experience, giving us a much better feel for what life would have been like for the community members. (It also gave us some much needed peace and quiet.)
 Our room was next to one of the most famous features of the village, the twin spiral staircase in the Trustee's Office. As a museum visitor, I would have gone up once or twice and taken a good look, but as a guest I enjoyed the stairs every time I left our room. It truly is an amazing piece of woodworking; there are actually two stairways on either side of a central hallway. Each side is two flights, twisting up to the third floor where a skylight provides both light and the feeling that these stairs lead to heaven.
 Most monumental stairways are full of intricate details such as carved newel posts and turned balusters. The details in the stair are incredibly simple, yet the combination of shapes, and the subtle changes as the stairs turn and rise, make this an elegant statement of design and craftsmanship.
So if you're ever driving through Kentucky, make it a point to stop and enjoy as much time as you can spare. And don't leave without trying the lemon pie.
— Bob Lang
Read other entries by Robert W. Lang
Monday, March 31, 2008 11:47:52 AM (Eastern Standard Time, UTC-05:00)
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 Tuesday, March 25, 2008
Bookcase Design Challenge Grand Prize
The time has come to let the cat out of the bag. You’ve waited an entire week to find out about the LumberJocks/ Popular Woodworking magazine Challenge Grand Prize – a week I hope you’ve spent eyeing bookcase designs, including those linked to in the previous newsletter ( click here) where we announced the challenge. We boasted that neither Popular Woodworking, nor any other woodworking magazine that we know of, has ever offered this prize before. You can be part of this first-ever woodworking event. Here it is.  The winning original design will be published in Popular Woodworking magazine. We’re talking a full-out article, not just photos of the best design shown in a gallery. You’ll become a published contributing author – a fully paid contributing author – with your own byline.  We’ll work with you to develop step-by-step photos with captions as well as an opening photo for your story. (If we need to arrange for a photographer to come to your shop and take that shot, we will.) We will be with you at every step of the way. We hope this will sweeten the pot, but we also don’t want to scare anyone from the contest. So, if you want to design but not necessarily build your bookcase, we’ll take on the project here in the Popular Woodworking shop and write the article based on your input. It’s going to be your choice. Either way you choose, your name will be on the article. The entire woodworking community will see, read and probably build your bookcase design. This may open up a completely new path to meander down, or you may be happy just to get your design and name in front of thousands of fellow woodworkers. To get a complete set of rules, how to post your entry and to become a LumberJock (remember you have to be a LumberJock member to enter the contest) click here. – Glen D. Huey
Read other entries by Glen D. Huey
Tuesday, March 25, 2008 12:56:48 PM (Eastern Standard Time, UTC-05:00)
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 Monday, March 24, 2008
Woodwork Joints by Charles Hayward
A Weekend With an Old Friend Sometimes a search for one thing leads to the discovery of something more interesting and a change of plans. Friday night I was looking for a book and as I was going through my shelves I came across a small volume I hadn’t seen in a while. Woodwork Joints, by Charles H. Hayward had been tucked out of sight between two larger books and I pulled it out and flipped through a few pages. It was like bumping into an old friend and forgetting the task at hand to spend some time catching up. I spent several hours over the weekend going through the book, and remembered why it is one of my favorites. The first thing I like about it is that there is absolutely no fluff; no introductory chapters on buying tools or setting up shop. Hayward dives right into common and not-so-common joints – how to cut and fit them with hand tools, what they ought to be like when you’re done, and what can go wrong. Except for the use of Britishisms such as "cramp" instead of "clamp," the writing style is clear and straightforward, and there is more useful information per page in this book than in any other woodworking book ever written. In addition to the text, the book is amply illustrated with both line drawings and black & white photos. The photos look dated because this book is rather old (and unfortunately out of print) but they clearly show how to hold the work and how to hold the tools. The tools and bench accessories shown in the photos are well worn – evidence that the advice given is based on experience. And the drawings are worth several thousand words apiece. But my favorite thing about this book is the way the author uses the language. It reminds me a lot of getting instruction from my Scottish-born grandfather. In an understated way, Hayward lets you know when you should be able to figure something out or when you are behaving like a rookie. He gives you the choice of the techniques of the beginner, the competent but in a hurry carpenter, and the ideal of the “skilled worker” or “man of the trade.” He talks about “complications” that can arise when you aren’t careful and the “detriment to the saw” if you cut into a hidden screw. This all looks like step-by-step technical instruction, but it really is training to think like a cabinetmaker.  So here’s a technical book that improved the way I think, not just about woodworking but problem solving and processes in general. And Hayward goes even one step further in several places. When discussing problems with tenons, he gives an example noting that a particular problem is found: “in the work of a man who lacks confidence. He doubts his ability to cut his shoulders square, and rather than risk a joint which will not pull together owing to shoulders which are fuller at the tenon than at the surface, he deliberately undercuts them.” Now we’re talking about character, and how a simple act like cutting a tenon can both reveal and develop traits such as reasoned risk-taking and good judgment. For me, there is a lot more to woodworking than making stuff, and what I learn about myself from the process is in the end more important than what I learn about the process. I’ve made tenons that look like the ones in the drawing, and I’ve learned to examine what went wrong in order to get it right the next time. Going back to this book one more time made me realize how much I learned from this book above and beyond fitting this piece of wood to that one. While this book is out of print, used copies can be found. However, mine is not for sale. -- Bob Lang
Monday, March 24, 2008 12:55:09 PM (Eastern Standard Time, UTC-05:00)
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 Monday, March 17, 2008
Sharpening System in a Box
Norton IM83 Portable Waterstone Sharpening System
 I'm not the most organized person in the world. In fact, I'm without argument the messiest person in our office and shop. I do OK if there is a system in place that I can follow without thinking too much about it. But if there isn't a place for everything, then I just put everything all over the place. This is one of the reasons I like the Norton IM83 Sharpening Set. In one case, which is just a bit larger than a lunchbox, is everything I need to keep my edge tools honed.

In the top of the box is a three-sided gizmo that holds three waterstones: #1000, #4000, and #8000 grit. It is designed to hold two of the stones in a bath of water, and the third in position for use. As I move up through the grits, rotating the holder brings the next stone into position, soaked and ready to use. I don't have room for a dedicated sharpening station, or the discipline to keep myself from piling stuff on one if I had it, so this makes it easy to contain the mess when it's time to hone, and it only takes a minute to pack it all back up.
In the bottom of the box is a second storage compartment where a flattening stone lives, and there is space down there for a few rags and other sharpening sundries. Also included in the set is a DVD on techniques for sharpening freehand. I learned to sharpen before workable jigs to hold the chisels or plane irons were readily available, and I have a philosophical bias to sharpening freehand. My argument is this: To use edge tools effectively you need to develop a feel for the relationship between your hands, the work and the tool. Sharpening is a great way to develop this feel, although I will admit it took time to learn and sometimes I have a bad day when a jig might be helpful.
 One of the things I like about the Norton waterstones is that they are abrasive enough to cut quickly, but soft enough to provide useful feedback while sharpening. Some people may find the #4000- and #8000-grit stones to be too soft; it is possible to poke a corner of the tool into the stone. When I learned to sharpen, I was taught to try and take a slice off the stone with the tool. In the six months that I've been using these stones, I've learned to be less heavy-handed and apply more pressure coming back than going forward. I start to sharpen by putting the primary bevel flat on the stone.
 I then raise the handle of the tool a bit to make the secondary bevel a few degrees steeper. I lock my wrists and move the edge back and forth in as straight a line as I can. Swinging with my shoulders while keeping my elbows and wrists locked works for me. I'm not picky about the exact angles involved; I've found if I'm in the neighborhood, the tool will work. With the Norton waterstones, if I'm applying too much pressure to one side or if I'm at too steep of an angle, I'll remove a tiny divot from the surface of the stone. This annoyed me at first, but now I feel that it is making me a better sharpener.
Bringing the stones back to a flat surface is quick work with the flattening stone, and the stones are 1" thick. It would take a truly obsessive sharpener a long time to wear one out, but it is possible. My conclusion is that Norton has reached a good compromise with the composition of these stones. They cut fast, leave a keen edge and can be easily maintained. Having the complete set in one handy box that fits in a small space is a plus. The kit sells for around $200 from many retailers, and is also available with oilstones instead of waterstones. I think it's an excellent solution for sharpening. And if you need the jig, there's room to store it in the bottom of the box.
-- Bob Lang
Read other entries by Robert W. Lang | Read other Tool Tests
Monday, March 17, 2008 3:20:42 PM (Eastern Standard Time, UTC-05:00)
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