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 Tuesday, June 24, 2008
Tool Test: Beadlock Pro
It’s a well-known fact that a mortise-and-tenon joint is the strongest woodworking joint (if it’s made correctly). On the web, there have been lengthy discussions about loose-tenon construction – creating mortises in the two mating pieces then installing a single loose tenon that fills both mortises.
With an improvement to the Beadlock system, a jig that’s been around since 2000, Rockler added to the discussion. The Beadlock, either the original or the Beadlock Pro, does not require expensive investments in tooling because mortises are created by simply drilling a series of overlapping holes, guided by a jig.
The Beadlock system is very easy to use. Clamp the jig in position, slide the guide block to one side of the jig, then drill holes. Next, slide the guide block to the opposite side of the jig and again, drill holes. That’s it. You’ve created a mortise. The jig comes standard with a 3⁄8" guide block. With additional interchangeable guide blocks, you can also create mortises that are 1⁄4" and 1⁄2" wide. You can purchase router bits designed to produce tenon stock or purchase pre-made tenon stock, which has a matching profile, to complete the joint. Matching pre-made tenon stock is available in pre-cut lengths or in 12" pieces that you cut to size. The result is a strong, totally concealed joint with plenty of glue surface.
The Beadlock Pro is the newest evolution of this jig. With it you can create mortises in material up to 3-1⁄2" wide by adjusting the guide-block frame along the rails of the jig. In addition, the Beadlock Pro has a block that is used to create traditional smooth-sided mortises. After using a drilling-guide block to excavate waste, change to the paring block, then use your chisels to pare a smooth side. The guide keeps the chisels in place and positioned correctly. You can then cut your own flat tenon stock.
The Beadlock Pro includes the fully adjustable jig (as shown in the photo above), a 3⁄8" drill bit, a matching stop collar, a Beadlock 3⁄8" guide block and the matching paring block. All the contents are fit into a molded case that includes storage areas for any 1⁄4" and 1⁄2" optional equipment (drilling guides or paring guides) that is sold separately.
If you’re just discovering the mortise-and-tenon joint or are looking for simple and quick method to create this solid joint, check out the Beadlock (street price at $30) and the Beadlock Pro (street priced at $120) available at Rockler stores and Rockler.com.
If you've used either version of Beadlock, leave a comment to let us know what you think. — Glen D. Huey
Read other entries by Glen D. Huey | Read other Tool Tests
Tuesday, June 24, 2008 9:23:08 AM (Eastern Daylight Time, UTC-04:00) 
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Jointmaker Pro: Its Origins and Our First Day
Yesterday morning I started getting serious with the Bridge City Jointmaker Pro that John Economaki loaned us for a month. I'm building a quick and dirty prototype of a Frank Lloyd Wright-style table for a future issue and I needed to make a bunch of crisp cuts for the latticework between the legs.
At first I set it up to cut miters on some 5/8" x 5/8" x 5" pieces for a small open square in the middle of the lattice. The first lesson I learned is that you really need the sandpaper-faced fences to hold the work securely. Even with the awesome beveled hold-downs, the work would rise up a bit on the plain poplar fence. Economaki said we would experience this, and he was dead-right. So sandpaper is definitely your friend. 
I added some #120-grit sandpaper to the fence, and the thing cuts like a dream now. By way of comparison, I also cut the same miters on our table saw (which felt very dangerous, even with the guard in place), then I made the same cuts with our miter saw. The miter saw did a fairly good job, but there was a lot of rigging to hold the 5"-long pieces in place so that my hands were away from the cut. Also, the cut wasn't as perfect as the ones on the Jointmaker Pro.
Then I made a bunch of straight cuts for the latticework, and that is when I finally got into the rhythm of the machine. One hand was on the sliding table and one hand was on the crank that raises the blade. It's very much like riding a bike. Stroke. Raise the blade. Stroke. Raise the blade. Yesterday I went from: "Herky-jerky" to: "A-ha. Got-it."
The cuts turned out as perfect as I could expect: Dead on, smooth and glass-like. The latticework came together as per plan. However, I'm not happy with the prototype. The legs are too chunky. I think this table is going to look a lot better when I throw it in the dumpster.
Also, Drew DePenning, our associate editor for the web, shot some video last week of Enonomaki discussing how he developed the Jointmaker Pro. We thought it was interesting enough to edit and show you here on the blog. See below.
— Christopher Schwarz
Read other entries by Christopher Schwarz
Tuesday, June 24, 2008 8:46:44 AM (Eastern Daylight Time, UTC-04:00)
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Thursday, June 19, 2008
Jointmaker Pro: A Few Test Cuts
John Economaki from Bridge City Tools is in our shop today before he demonstrates his new Jointmaker Pro saw to about 60 of our readers. As we were setting up the saw we took a few test cuts.
The walnut above is so smooth it's hard to describe. It reflects light. The scratches indicate one stroke with the saw. There is no roughness to the end grain at all. All I could say was, "Wow."
Here are two more photos. First the joint together: 
Then the joint apart: 
Here's the best part: These are coffee stirring sticks from the Starbucks we stopped at on the way back to the office after a Japanese lunch (yum). And, by the by, these joints were cut by eye – no measuring.
We'll have more photos tomorrow, I'm sure.
— Christopher Schwarz
Read other entries by Christopher Schwarz
Thursday, June 19, 2008 5:08:43 PM (Eastern Daylight Time, UTC-04:00)
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Wednesday, June 18, 2008
Bob's Bench-Week 2 Becomes Week 3
Sometimes it's hard to get enough shop time in, and that's how it's felt the last week and a half. We've been scrambling to get the next issue of Woodworking Magazine ready to send to the printer and getting our October issue going. It wouldn't be so bad, but I'm taking lots of photos and we're shooting video and that can really slow things down. Even though I've been moving at glacial speed, I've made progress.  The other thing slowing me down is me. This bench will be around for a long time, and will likely be the object of scrutiny, so I'm fussing over things more than I otherwise might. I don't look at this project as a piece of furniture, but I don't want to make any compromises. Ten years from now I'd like to look at the joints and say "that looks pretty good." At that distance I know I won't be saying "I'm sure glad I got home in time for dinner the day I made that ugly joint." The picture above is the last joint in the base and leg assembly. This is the inside of the outer half of one of the legs. A wedge gets knocked in the empty space and holds the rail to the legs.  That's what it looks like after the legs are laminated together and the base is assembled. It's nice to be at this point but there is still a lot of work left. The base needs to be prettified by planing all the surfaces smooth and flush, and I'll need to knock off the sharp corners. The upper rails will attach with lag screws, and I'll attach the top the same way. Then it will be on to installing the vises, drilling the dog dog holes, and making the tool trays and shelf. All of that by this time next week, when the final photo shoot is scheduled.  It wears me out just thinking about it. --Bob Lang
Read other entries by Robert W. Lang
Wednesday, June 18, 2008 5:35:36 PM (Eastern Daylight Time, UTC-04:00)
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Tuesday, June 17, 2008
Five Questions with The Wood Whisperer
Marc and Nicole Spagnuolo, The Wood Whisperer and The Wood Whisperer's videographer and wife, were in town and stopped to visit Popular Woodworking magazine. The visit was a result of a Cincinnati wedding they wanted to attend, curiosity about our shop and due to the magazine adding Marc to its growing list of contributors. "The Wood Whisperer" is a new column added to the pages of Popular Woodworking magazine. The first installment is in the current issue on newsstands now, August 2008.We couldn't let The Wood Whisperer slip into and out of town without having him sit down to answer five woodworking-related questions. You'll find his answers to be interesting and informative. In fact, you'll find a touch of humor too. Marc believes woodworking should also be fun. Watch the video by clicking the link below the screen. For an all-access pass to The Wood Whisperer, you need to read Editor Chistopher Schwarz's blog entry introducing our readers (those who aren't familiar with Marc) to The Wood Whisperer, click here. And, you need to check out the video that is a companion to The Wood Whisperer's first column about masking tape, click here. If that's not enough – and it' not for many of us – Marc is working on the second column and video as you read. Look for those to show up in the October issue of Popular Woodworking magazine. —Glen D. Huey
Tuesday, June 17, 2008 1:32:20 PM (Eastern Daylight Time, UTC-04:00)
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New Jig Saw Blades From Bosch
Bosch has just announced the introduction of a revolutionary new blade for jigsaws. Designated the "T 308B Xtra Clean for Wood," this blade promises – and delivers – better cuts than we have ever seen from a jigsaw. A couple months ago we received some samples for testing in our shop, and late yesterday we got the green light to be the first to announce this new blade.  Until using this blade, I always regarded a jigsaw cut as a preliminary one – a cut that would need some extra work to remove saw marks, straighten a wobbly cut, or fix some tear-out on the top or bottom of the work. But thanks to the unique tooth geometry on this blade, I now think of the jigsaw as extremely capable for making finish cuts. I used the blade when making the Craftsman Bookcase for our August issue, and I've been using it to cut the large dovetails for the workbench that I'm currently building.  Here is a close-up of one of the joints, immediately after cutting. The light reflecting on the just-cut part of the joint indicates how smooth the surface is. If you look at the blade, you can clearly see that the teeth on the lower portion of the blade are a different shape from those at the top. Bosch refers to the top teeth as "pointed teeth" and the lower ones as "scalpel teeth." This arrangement allows the blade to cut both on the up and down strokes, leaving a clean cut on both faces.  The cut edge is also exceptionally clean and smooth, and I found that the blade cut with far less resistance than most blades, allowing for a greater amount of control during cutting. At the moment we do not have a specific date for when these will be available for sale, or the price. When I have an answer, I'll let you know. The 12 tpi blade will be available soon from Bosch distributors. We shot some video yesterday, and you can view it by clicking on the player below. --Bob Lang
Read other entries by Robert W. Lang | Read other Tool Tests
Tuesday, June 17, 2008 8:06:05 AM (Eastern Daylight Time, UTC-04:00)
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Friday, June 13, 2008
Router Jigs for a Craftsman Bookcase
In the current issue of Popular Woodworking magazine (August 2008), Senior Editor Robert W. Lang used two jigs on the bookcase shelves to cut the dados and to create the twin mortises for shelves' through tenons.
The first jig, shown in "Router Jigs Part 1," walks through making a dado jig to accomodate any shelf thickness. Bob uses a straight router bit with a top-mount bearing to cut the dados. You can use the steps shown to produce a perfect fit for any dado joint, regardless of shelf thickness.
The second jig, shown in "Router Jigs Part 2," is quite innovative in how it's built. Bob uses several pieces of 1/2"-thick Baltic birch plywood and a pin nailer to construct this jig. From there, he's just a drill and router away from a simple tenon-routing setup. This is a great technique! Enjoy! —Glen D. Huey
Router Jigs Part 1
Router Jigs Part 2
Friday, June 13, 2008 12:49:04 PM (Eastern Daylight Time, UTC-04:00)
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Tuesday, June 10, 2008
Video: Buying Lumber, and Lumber Terminology
Recently, Senior Editor Robert W. Lang and I visited Frank Miller Lumber (FML) in Union City, Indiana where Bob explains how to buy lumber. He also visits with FML Outlet Store Manager Josh Brennen who demonstrates a few differences in wood selection as well as tells us all about quartersawn white oak. –Glen D. Huey
Tuesday, June 10, 2008 2:04:53 PM (Eastern Daylight Time, UTC-04:00)
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The Wood Whisperer Premiere Video
We've all been waiting for this — it's the initial Wood Whisperer video! This video is a companion to the newest column in the current issue of Popular Woodworking, which is also (appropriately) called "The Wood Whisperer." And there will be plenty more Wood Whisperer videos and articles coming your way in future issues. If you haven't yet found Marc Spagnuolo's web site, thewoodwhisperer.com, you're in for a treat. Marc has a quirky way of presenting great woodworking information for all who care to watch. And once you watch, you'll know why we at Popular Woodworking are happy that he has joined our group of woodworking devotees. If you have a comment to share, please make sure to add it below. We're looking for your feedback about Marc and The Wood Whisperer column. –Glen D. Huey
Tuesday, June 10, 2008 1:50:44 PM (Eastern Daylight Time, UTC-04:00)
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Monday, June 09, 2008
Bob's Bench-A Decent First Week
I've started on the bench, spending as much time in the shop as I could spare, and after a week and a day, it looks like I'm making good progress. The shop is messy, but there are now piles of parts where a stack of rough lumber used to be. I've probably spent about 25 hours actually working on it, it gets hard to keep track when I have to stop and take photos or shoot video. Here is a link to some previous posts showing what I'm up to: Previous Blog Posts. And here in a moment of neatness is where I was last Friday morning.  At the bottom of the pile are the two glued up slabs that will comprise the top, and the stack on top is destined to become legs, rails and stretchers. Even though milling rough lumber takes some effort, one of my favorite parts of any project is hitting this point. I tend to fuss over the rough milling, because if my parts will form a nice neat stack, it means they are straight and square. And if they're straight and square, every step that follows will be considerably easier.  One of the purposes for building this bench, and documenting it on the blog and on video is to show that a good bench can be built with a minimal amount of machines, space, experience and skill. I've set up a space in a corner of the shop with a 6-inch joiner, a twelve-inch lunchbox planer, and a 1-3/4 horsepower hybrid table saw. This is a pretty basic setup, and although at times I've pushed the machines close to their limits, they've been up to the task so far. I designed this bench to work around these tools, matching parts and subassemblies to their limitations. So if you've been putting off building a bench until you have a massive table saw, an aircraft carrier size jointer, and a planer the size of a house trailer, find another excuse and get to work.  After rough cutting the 8/4 material to manageable sizes, I milled all the individual pieces for the top, and then glued them together in pairs. Each glued up pair took another trip over the jointer and through the planer. Three pairs were glued together to make each 3" thick, 12" wide and 8-foot long top section. Because these parts were all carefully made, the final assembly went smoothly. I put two straight pieces of material the long way across my horses, and then laid square pieces across them at about 12-inch intervals. This gave me a level platform for gluing, and stock this size doesn't want to twist or bend.  One of the other myths to dispel about building a bench is that "You need a bench to build a bench". Now that I have the tops together, I have a better work surface than I've ever had, and there's no reason not to put them to work. Here's a photo from around lunchtime Friday as I work on the mortises for the leg assemblies. --Bob Lang
Read other entries by Robert W. Lang
Monday, June 09, 2008 4:50:27 PM (Eastern Daylight Time, UTC-04:00)
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