Subscribe | Renew | Give a Gift

Sign In  
 Wednesday, August 13, 2008
For This I Get Paid? Part 2

To start off the second day in Phil Lowe's "Building a Demilune Table" class, we rub jointed 34 pieces with 15° angles on each end into chevrons (shown above). I thought I knew how to smear on glue and rub two pieces of wood together, but Phil showed us how to first size the end grain with a very thin layer of glue rubbed in to fill in the xylem and phloem. That, Phil says, keeps the glue used in the rub joint from being sucked up into the end grain and makes the resulting joint stronger.

After our 17 chevrons were made, we screwed and glued six of them around the edge of the pattern we routed yesterday (being careful to keep screws out of the leg-joint areas). Then, we cut close to the pattern edge on the band saw, and touched up any wonky spots with a spokeshave. Let's just say I got some spokeshave practice. The final step for each layer was to pattern shape it on the router table. The rim was built up with three more bricked layers of chevrons and half pieces, sawing (spokeshaving) and routing each layer as we went.

The most exciting moment of the day for me (and no doubt for many of the class members), was unscrewing the rim from the pattern and seeing the shape emerge. That poplar sure is pretty – but I suspect I'll like the bird's-eye maple veneer even more. We scribed lines back from the front edge, and some people have already cut away the waste from the back. I was at the end of the line at the band saw and there's no power-tool use after 6 p.m. at the Marc Adams School of Woodworking (more on that tomorrow). So my first task on Wednesday (after plugging in the glue pot for delightful olfactory ambiance), will be to remove that waste. Then it's on to planing the tapers on the legs.

Read Part 1 of this series here.


— Megan Fitzpatrick


Read other entries by Megan Fitzpatrick
8/13/2008 7:45:09 AM (Eastern Daylight Time, UTC-04:00)  #  Comments [4] 
 Tuesday, August 12, 2008
Greene and Greene from a Woodworker's Perspective
Many talented and able photographers have published photographs of the work of Charles and Henry Greene. I own most of the books and have spent many hours studying these, as well as images online. I usually feel some frustration because what I really want to see is often missed. I'm one of those guys that lags behind on historic home tours, down on my knees or laying on my back to get a close look at how things go together. The docent gets frustrated, the security guard gets ready to move in, but the other woodworkers understand.


The series of articles by David Mathias on Greene and Greene feature photos that are different than any that I have ever seen. The first article, the August 2008 issue of Popular Woodworking presented an overview of the style. The second article, in the October 2008 issue focuses on the furniture and joinery details. The October issue is due from the printer any time now, and will soon be on its way to subscribers. As was the case in August, we had more photos than we had room for in print, so we are putting the extras online in PDF format.

My favorite thing about these photos is the point of view and attention to detail that comes from having a fellow woodworker behind the camera. Several of the photos are of familiar pieces, but you will see construction details you haven't seen before. Many of the photos are of objects that are rarely if ever seen. This is a rare opportunity to get a closer look at an amazing body of work, through the eyes of someone who knows what you want to see.

Click the link below to download the PDF slide show of additional photos.
0810GnGSlides.pdf (1.45 MB)

The slide show from the August article is available by clicking here

--Bob Lang


Read other entries by Robert W. Lang
8/12/2008 9:22:28 AM (Eastern Daylight Time, UTC-04:00)  #  Comments [1] 
 Monday, August 11, 2008
For This I Get Paid? Part 1

Monday morning, I left my house at 5:30 a.m. to drive to Franklin, Ind., to the Marc Adams School of Woodworking. I had to be there by 8 a.m., and while it’s only an hour-and-a-half drive or so from Cincinnati (if one drives too fast, as I am wont to), I tend to get lost. And I got lost. Twice. But, I made it by 7:30, and I had my bench set up by the 8 a.m. start.

I’m taking Phil Lowe’s “Building a Demilune Table” class. Not only is it my first foray into curved work, I’ll also learn to hammer veneer. I’m using mahogany for the legs and top, and bird’s-eye maple veneer will be applied (along with banding of a species yet-to-be-determined)to a substrate of poplar. Monday, each class member cut a series of short pieces of secondary wood, which will be bricked to make the curved substrate for the apron (we’ll pattern rout to an MDF template once the polygon is assembled).

While all of this is new and exciting, what I found most revelatory was the planning process. On a piece of butcher paper, using only a T-square, two triangles, a 6” rule and trammel points, Phil produced beautiful full-size orthographic and isometric drawings of our project in less than two hours – all with seemingly no math. I must learn this.

Not so exciting? Prepping for hammer veneering. While I’m delighted to be learning this traditional skill, Phil prefers his hide glue well done. So although we won’t be dipping into the glue pots for at least another day, the redolent scent of cooking collagen hangs in the air. That ought to go well with breakfast.

— Megan Fitzpatrick

Read part 2 by clicking here.


Read other entries by Megan Fitzpatrick
8/11/2008 10:20:09 PM (Eastern Daylight Time, UTC-04:00)  #  Comments [1] 
 Thursday, August 07, 2008
The Mystery of the Dangerous Flying Bats

Broken baseball bats are becoming so commonplace that Major League Baseball has undertaken a study to determine what’s behind this growing phenomenon.  The concern, of course, is the busted barrel-end is hurtling into crowds – not to mention million-dollar players – and posing a serious safety hazard. Baseball czar Bud Selig wants to know what’s going on so he’s collecting every chipped, broken and cracked bat and shipping them off to the University of Wisconsin’s Forest Products Laboratory to have them studied.

Reading news reports on the subject can be entertaining for people who’ve been around and worked wood for a while. For example, I learned the problem is due to the increased use of maple instead of ash. Maple bats break clean in two while ash bats just crack or splinter. OK, I can buy that. We all know ash is a good choice for bending while maple would be avoided. But when players and other clubhouse types weigh in on the “why,” it seems maple has no “grain” while ash does. I thought all wood had grain. Here’s another: switch to beech, which I read is a hybrid between maple and ash that’s imported from Europe. Learn something new every day!

Hitters are notoriously superstitious about their bats as they seek every advantage to improve their stats. The move to maple got serious after Barry Bonds made the change and hit 49 homers in 2000 and 73 in 2001 (and we all thought there were other factors at play!). Today, some 48 percent of MLB bats are maple with a typical bat fetching $58; ash bats are significantly less at $45. That adds up when you figure the team buys 11 to 12 dozen bats for each player each season.

So is the broken bat mystery merely a question of maple vs. ash? As a woodworker, I doubt it. I will concede that the safety question is best answered with the choice of ash over maple because I’d bet the ash will be far less likely to break in two and send a hurtling projectile. More likely, ash will just crack or splinter.



No, I believe the scientists at the Forest Products Laboratory will conclude the breakage epidemic is due to the shape of bats today and the relationship between its weight and length. Players’ preferences today are bats that are longer and weigh less with a thinner handle and bigger business end.  This preference is a result of the widespread use of aluminum bats on the college circuit that have this shape, and lots of MLB players are from the college ranks. Used to be, most bats were made with weight about equal to the length; a 32” bat usually weighed close to 32 ounces. Today’s bats are often longer, 34” inches, and weigh between 30 and 32 ounces. And to make the handles thinner, some players are shaving them. Can’t you imagine the MLB clubhouse equipped with a Brian Boggs shavehorse and set of spokeshaves?

Given these guys probably lack much woodworking know-how, I have this mental image of the rookie hearing about shaving the handle to improve his performance. I see this kid with his bat all lathered up and his razor stropped and ready to shave. That cracks me up!

Steve Shanesy, publisher & editorial director
  photos courtesy of MLB Advanced Media



8/7/2008 3:28:51 PM (Eastern Daylight Time, UTC-04:00)  #  Comments [27] 
 Monday, August 04, 2008
Greene and Greene Fans Get Ready

Last October, David Mathias reported from Pasadena's Craftsman Weekend with photos and first hand accounts of the events. The only criticism we received was that these reports were too late for those who wanted to attend. Consider this as a wake up call, this year's events have been announced, and tickets go on sale in a few days. If you're a fan of the work of Greene & Greene, you'll want to be there. This is also the one hundredth anniversary of the Gamble House, and there are a number of special events taking place to commemorate this milestone.


(photo above by Darrell Peart)
We couldn't keep David here in Ohio, and last March he returned to California, camera in hand to take the photos we're featuring in a special three-part series of articles on Greene and Greene. If you've seen the August issue of Popular Woodworking you've seen part one, along with an online slide show of detail photos we couldn't squeeze into the printed magazine. The second article, coming in the October issue will show details of Greene and Greene furniture that have never been published before. The picture above is one example, and once again additional photos will appear online when the article is published.

David also traveled to several museums, tracking down original pieces of Greene and Greene furniture, such as this table from the Blacker House. If you're wondering how the table extension mechanism works, we'll be showing a photo from below. You can always tell the woodworkers when you visit a museum or old house, they are the ones with dust on their knees and backs from crawling on the floor to get a better look. This article is the next best thing to seeing this amazing furniture in person, and you won't have to worry about setting off an alarm, or having a security guard escort you to the nearest exit.

If you'd rather see things in person, or want more information on Greene and Greene, David put together a resource list, which you can download by clicking on this link.
GNGWWResource.pdf (48.49 KB)
That should keep you busy until the October issue arrives. If you're looking for more, try a search on "Greene and Greene" here on the blog, or on the main Popular Woodworking web site.

--Bob Lang


Read other entries by Robert W. Lang
8/4/2008 1:33:30 PM (Eastern Daylight Time, UTC-04:00)  #  Comments [0] 
A Preview of the October 2008 Issue of Popular Woodworking

The next issue of Popular Woodworking will be heading into mailboxes in the next two weeks, so we thought we'd give you a quick look at what you can expect inside.

21st-Century Workbench: For at least a year, Senior Editor Robert W. Lang has been working diligently on plans for a new kind of workbench that blends the best of modern and ancient designs. He succeeded beyond my expectations. This bench performs all the workholding tasks for power or hand tools. It's simple to build. It knocks down in less than 10 minutes (we timed it). And it looks great. We were so impressed with the design that we've even made a complete hour-long DVD of the construction process. We'll tell you more about the DVD when the issue comes out.

Tool Test: Random-orbit Sanders:
If you own only one sander, it should be a random-orbit tool. But which one? Senior Editor Glen D. Huey tested nine popular brands in our shop here and found one tool that we liked better than all the rest. Here's the best thing: It's definitely not the most expensive in the test.

Details & Joinery of Greene & Greene: Trust me on this – the joinery and level of detail found on Greene & Greene-style pieces is far beyond what is typically done in today's shops. We sent woodworker David Mathias to the West Coast to get inside the casework and under the tables to reveal the inspiring level of work found in these masterpieces. Read the first installment in this series here.

Taming Handplane Tear-out:
Battling tear-out is one of the most vexing things about using a handplane. Everyone has an opinion about what reduces it, but not all these strategies work all the time. We investigate.

Layout Tools: Michael Dunbar surveys the 16 tools you need for accurate layout in any shop. With his typical practical approach, Dunbar shows you how you don't have to spend a small fortune to do precision layout work.

Marc Adams on Table Saws: The table saw is the most used (and misused) tool in the American workshop. Marc Adams shows you how to set up and use your machine so you get accurate results without becoming one of the thousands of casualties each year. You can read another installment in Adams's series on safety here.

Arts & Mysteries: Adam Cherubini builds a 17th-century "joynt forme," a type of low seating bench with turned legs. Adam gives you hints on angled mortises and riving your materials using traditional methods.

The Wood Whisperer: Marc Spagnuolo runs a power-tool shop, but he uses hand tools to improve his joinery. He shows you how.

Flexner on Finishing: Bob Flexner takes on the common perception that shellac is best used a sealer when finishing. He shows you how you might be making your finishing harder than it has to be. Read more of Bob's articles here.

— Christopher Schwarz


Read other entries by Christopher Schwarz
8/4/2008 11:12:42 AM (Eastern Daylight Time, UTC-04:00)  #  Comments [0] 
 Friday, August 01, 2008
New Tools from Porter Cable


Porter-Cable (PC) held a press event in New York on Tuesday. The event was to introduce new tools, both cordless and corded. After the release, we were invited to attend a Yankees baseball game. (I know it’s a dirty job, but I don’t mind taking one for the team.)

Let’s talk tools. PC introduced a line of tools that will be sold at many regular dealers, but the only home center where these tools will be found is Lowe's. The majority of the line, due out in November 2008, focuses on 18V cordless tools in nickel cadmium (Ni-Cad), with one using lithium ion (Li-ion).

In this category the company is bringing out a four pack of tools that includes a drill/driver with a 1/2" chuck, a 6-1/2" circular saw, a reciprocating saw and a flashlight ($150). A second group of tools is a two pack that includes the drill/driver and the circular saw ($110). Each package has a charger and two batteries as well as other miscellaneous parts including a saw blade, bit tips and a soft-sided carrying case. Interestingly, PC decided to stay with Ni-Cad for these tools although they are compatible with the 18V Li-ion batteries too. In addition, Porter-Cable introduced a hammer-drill kit (the tool plus two batteries and a charger) expected to retail for $140.

If lithium power is your choice, PC is bringing out a drill/driver kit. The drill features a 1/2" metal chuck and a 24-position clutch with a two-speed gearbox. The kit also includes two batteries and a charger ($180). The batteries are P1-level batteries with a 1.1 amp hour rating.

The kit prices look pretty good for PC tools and each of these tools will be available individually. I had the tools in my hands at the event, but didn’t have time to get a good look at each. My question is this: Why continue to use Ni-cad technology when most others are using, and consumers are knowledgeable about, Li-ion? My best guess about the battery choice is that the older technology allows the company to hit specific price points that enticed Lowe’s to the table. I can’t think of another reason to stick with Ni-cad when the buying public is changing gears to accept Li-ion-powered tools.

When PC Vice-President Dan Gregory said DeWalt tools were their professional-line tools, I was astounded, as were others. He explained that PC is attempting to position these tools for tradesman – an area of the market that PC feels is full of value-conscientious, value-driven buyers. PC is being sandwiched between Black & Decker (at the low end) and DeWalt (the high end). I’ve always thought my Porter-Cable routers and PC sanders were better than the DeWalt counterparts.

So what’s to happen to the regular Porter-Cable tools that we all know today? As for the existing tools PC has produced for years (the routers and random orbit sanders), I’ve been told the company doesn’t plan to change them at all. I hope we see packaging that differentiates between the new line and the company’s current tools.

In addition to the new tools mentioned above, Porter-Cable introduced a battery-powered, 6-1/2" circular saw with a laser that was pretty cool. It was priced at $60, but you also have to buy a battery and charger. New in corded tools: hammer drills, reciprocating saws, small angle grinders, 1/2"-chuck drill/drivers and laser-equipped circular saws. For the suggested retail price for the kits or for individual tools, open the PDF below.

—Glen D. Huey

PCPrices.pdf (3.46 MB)

Read other entries by Glen D. Huey
8/1/2008 1:48:25 PM (Eastern Daylight Time, UTC-04:00)  #  Comments [25] 
 Monday, July 28, 2008
Teaching at Marc Adams - A Wrap-up

If you’ve been following my blog about the class at Marc Adams School of Woodworking (MASW), you’re waiting for photos from the last day of class. I will tell you that many of the projects look as they did when the class ended on Thursday. But the progress accomplished on Friday was outstanding.

Most class participants vetoed drawer dovetails in order to gain additional time to shape their drawer fronts. However, a couple took to dovetails and Thomas Older (shown in the photo at left), who is the intern at MASW this year, installed his base mouldings and feet while sculpting only one drawer front. The photos taken Friday certainly don’t look like those I snapped on Sunday evening as I arrived at the school. (You can see those photos by clicking the appropriate link below.)

In the Thursday entry, I mentioned the pranksters in class. During the discussion about drawers someone asked about installing metal drawer slides in this project. Needless to say, he heard a chorus of boos, but we did discuss why I would never attempt such an act and how the drawer building would need to change if someone were to install slides. The Questioner has broad shoulders and sustained the admonishment from the crowd.

Two of the guys in the class took a road trip to the Indianapolis Woodcraft store and I guess the entire drawer-slide episode was still fresh in their minds. They decided to purchase a pair of full-extension slides to add to my case. Upon arrival the next day, the slides were installed with double-stick tape and we all got a good chuckle. That looked very different from what I’m used to seeing.

In addition, I mentioned a use for blue painter’s tape that The Wood Whisperer would never have thought about. Marc Spagnuolo’s first article for Popular Woodworking (in August 2008) was "The Magic of Masking Tape" (issue #170). Marc uses painter’s tape for quick clamps and veneer clamps, just to name a couple.

In class when the time arrived to shape the drawer fronts, one woodworker decided that working without a glove was not going to cut it. However, the file was cutting his hands. To offset the mild abrasions, he covered his hand with blue tape. I must admit this was a first for me, although I have seen use of tape on fingertips when working large jobs of hand sanding. It worked in this case too. Before the class wrapped up, this guy had the drawer fronts shaped and was ready for dovetails. I heard from more than one participant that this was a great class.

If you have a minute, please leave a comment about any school experience that stands out in your mind. I’m not looking to bust any schools, so please don’t mention names. I’m interested in what separates a good experience from a bad experience. And given that experience, would you return?


p.s. Click here to read “Teaching at Marc Adams – Day One,” here for “Day Two,” here for “Day Three”, here for “Day Four” and here for "Day Five."

– Glen D. Huey


Read other entries by Glen D. Huey
7/28/2008 1:22:40 PM (Eastern Daylight Time, UTC-04:00)  #  Comments [7] 
A British Woodworker Tours North America's Best Shops

My job lets me see a lot of cool woodshops, but even I'm jealous of an amazing journey that's going on right now by British woodworker Stuart Page.

Page recently graduated from a furniture-making course in Scotland and has received a grant from the Winston Churchill Memorial Trust to research "Traditional Crafts, Furniture Making and Sustainable Rural Living" in North America.

What that really means is that Page is driving around the United States and Canada this summer and visiting the shops you've read about in the magazines and books and seen on television. He's getting to sit down and talk to the woodworkers who run those shops. And he's writing about his travels on his blog.

The blog, cryptically titled "One Hairy Arm Goes West" is a travelogue of his journey, which began is Los Angeles and will wind his way through the Midwest, Canada and the East Coast. All the while, he's visiting woodworkers at every stop and writing about them on his blog.

So far, he's posted several entries about his travels, including one on his visit to Sam Maloof's establishment and a more recent one on the College of the Redwoods, shown in the photo above from our piece last year on the college.

We recommend you visit Page's blog and bookmark it so you can follow his travels. We know some of the visits that are coming up, but we don't want to spoil the surprise.

— Christopher Schwarz

P.S. I've also added the site to our Blogroll at left in case you forget this link.


Read other entries by Christopher Schwarz
7/28/2008 11:30:49 AM (Eastern Daylight Time, UTC-04:00)  #  Comments [1] 
 Friday, July 25, 2008
Teaching at Marc Adams — Day Five



As promised, the guys in class had the early part of the day to complete mouldings and work on the sculpted bracket feet. Each woodworker laid out the feet from the provided pattern and drilled the holes forming the spurs and with the help of Doug and Zane, our shop advisors. Everyone had their feet mitered and the spline recesses were cut, too (Doug used a method for cutting the recesses that is rather interesting and I’ll talk more on that later).

Most everyone in the class decided to take the feet and moulding back to their shops to complete the work because most did not want to glue up the cases before final sanding. Nor did they want to use valuable time when the drawer fronts awaited.

At 1 p.m. we began discussions about the drawer fronts and I demonstrated how to transfer the shape to the drawer front and make the cuts at a band saw. Everyone took to the drawer fronts with ease. I explained that shaping the fronts was as simple as a close and accurate band saw cut, proper technique and a sharp blade.

I worked with each student one on one to demonstrate the exact steps needed as they began work to shape their drawer front. To begin, lay out the flat blocked portion at the end of the drawer front, establish a line that delineates the flat sections from the beginning of the rounded fronts, then peel away excess stock to smooth the transition while leaving a distinct line.

Next, they used low-angle block planes to carefully round the curved fronts. The secret is to rub the surface with your hands and smooth any uneven spots you feel. If it feels smooth, the eye will never see different. That’s a big part of the entire shaping process. Slowly and methodically each woodworker shaped the first drawer front. As you can see from the photo below, some in the class chose to cut all their drawer fronts before beginning any shaping.

Today we’ll complete at least one drawer front and talk about how to tweak the fit and dial in perfect alignment with precise reveals. And we’ll begin the half-blind dovetails used to connect the drawer fronts to the drawer sides. The through dovetails used at the back of each drawer are the same as the dovetails they did when they joined the case sides to the bottom. Discussions on how to cut and fit the drawer bottoms will be interesting due the shaped interiors of those drawer fronts.

Because it’s Friday and class is over at 3 p.m., you’ll have to sit tight for the weekend. Come Monday I’ll post the final photos. In addition, I’ll have a couple funny stories to relate. Here’s a hint: There is always a prankster in the group. And, I’ll show you a use for blue painter’s tape that our very own Marc Spagnuolo, The Wood Whisperer, might never have thought of.

— Glen Huey

p.s. Click here to read “Teaching at Marc Adams – Day One,” here for “Day Two,” here for “Day Three” and here for “Day Four.”


Read other entries by Glen D. Huey
7/25/2008 9:04:09 AM (Eastern Daylight Time, UTC-04:00)  #  Comments [0] 
 Thursday, July 24, 2008
Teaching at Marc Adams – Day Four



Ches in Nichols, N.Y. asked me via e-mail to post a photo of the project piece so readers could see what the project looks like when finished. That way he could track the progress of the class. You ask, we respond. Not only that, I think that’s a great idea.

Also, I promised photos of assembled cases and here they are as well. I’m mighty impressed with the work going on in this class. I’m especially impressed with the caliber of students that the Marc Adams School of Woodworking (MASW) draws through the door. The woodworker pictured at the top of the Day Two entry completes his Master program with this class. Others in the class are well on their way to that goal. And the first-timers attending the school – at least one class participant is here building only his second piece of furniture - are all doing great work, as evidenced by the cases that are assembled after only three days of work.



A couple things happened today. From the class instructor’s point of view, today was hectic. The work on the chests rounded the corner and headed toward detail-oriented work. I made my way to each workbench more than a few times to answer questions (some on how to fix minor problems and some to get a quick affirmation of the steps that are needed to get the case assembled).

From a woodworking perspective, we set off the SawStop yesterday morning. Easy – it wasn’t an injury avoided –MASW shop advisors don’t let students get into an injury-causing set-up. This was something totally different. One student positioned his dado for the large sliding dovetail used to join the case top to the case sides in the wrong location, then painfully (you could see in his eyes he was frustrated) fit a patch in place. The patch worked and his case is assembled, but the patch caused the problem.

After letting the glue dry for a couple hours, he returned to the saw to cut new dados. The shop advisors didn’t realize the patch was in place, so they didn’t know to set the saw in bypass mode – where you knowingly turn off the safety feature. The wet glue inside the patch was enough to complete the circuit and the cartridge blew. There was a bit of down time before we were back in action at that saw, but with three others in our classroom, that simply meant no dado stack for a short time and another lesson learned.



So here’s what’s on tap for today. Most of the attendees are interested in the sculpting of the drawer fronts and building a drawer with traditional 18th-century techniques. From the opening bell through 1 p.m., we’ll stick with finishing the case work pertaining to the feet, which some guys began work on late in the day, and base mouldings. At 1 p.m., we begin on the drawer fronts, no matter what. That means there are four hours today and nearly six hours tomorrow for this most-important phase of construction.

You know you have to check back to see how things go!

— Glen Huey

p.s. Click here to read "Teaching at Marc Adams — Day One," here for "Day Two" and here for "Day Three." 


Read other entries by Glen D. Huey
7/24/2008 10:48:38 AM (Eastern Daylight Time, UTC-04:00)  #  Comments [3] 
 Wednesday, July 23, 2008
Teaching at Marc Adams – Day Three


Guys came into class this morning ready to work. They are well aware of the uphill struggle in front of them if they plan to get the first drawer completed for the chest. No one is expecting to get the chest completed. In five days, with 17 woodworkers building a complicated piece for the first time, completion would be a miracle.

As happens most of the time, the few students who were out in front ran into a couple issues during the day that slowed their pace. One front-runner had the fence slip as a dado was cut and another had to recover from a mishap that developed as he routed the dovetail sockets for drawer dividers. Each misfortune was remedied and resulted in a lesson on how to fix common mistakes. As a result, the pack has formed into a bunch as we start down the back stretch, through hump day.

I’ve often said the difference between a woodworker and a good woodworker is that good woodworker knows how to fix his or her mistakes.

Most students have cleared the hurdle for day two with the completion of the drawer dividers and are starting to assemble the pieces into a chest. Yesterday, the most time spent by far was in cutting and installing the bottom front to the case bottom. Once the large dovetail joint was fit, the shaping of the block-front profile consumed a large portion of the afternoon. The trick to transferring the pattern to the bottom, which requires an increase of size by 5/8”, is to use a fender washer. The distance from the inner wall of the center hole to the outside of the washer is 5/8”. If you place a pencil into the hole and roll the washer along your first profile, the result is perfectly sized.


Once the layout is complete, it’s off to the band saw to cut close to the line, then the rasps and files come out and hand shaping begins. To finish the profile the edge is routed. Everyone was pleased as they finished. I didn’t have the heart to tell them the same steps are used today as we create the bottom front mouldings.

What’s in store for today? By the end of the day we should have the tops in place and be finishing the beaded trim on the case side. Feet will be the afternoon’s subject when patterns are made and lumber is milled. Due to the blocked-front design being carried from top to bottom, the front feet need sculpting too. These guys are going to either have great affection for, or despise, their files and rasps after this project. I promise photos of assembled cases in tomorrow’s entry. You’ll want to check it out.

— Glen Huey
p.s. Click here to read "Teaching at Marc Adams — Day One"  and here for "Day Two"


Read other entries by Glen D. Huey
7/23/2008 9:22:38 AM (Eastern Daylight Time, UTC-04:00)  #  Comments [5]