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Purchase plans and books of shop drawings for Arts & Crafts furniture by Senior Editor Robert Lang |
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The founder of the Tools for Working Wood catalog writes about tools, the tool business and the life of a tool maker. |
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Planemaker Konrad Sauer invites you into his workshop. Lots of great (and dangerous) photos of work in progress. |
The Windsor Institute
Michael Dunbar's school of Windsor Chairmaking |
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A great video podcast site by Marc Spagnuolo that we follow closely here at the magazine. |
Archive
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 Wednesday, August 20, 2008
Old-School Joinery with a New Tool
 Freud invited us to an early meeting to present a number of new woodworking related products. Some were router bit designs, some were geared to industrial consumers and one was a new machine designed to properly cut and position holes for dowel joinery, appropriately named a Doweling Joiner. Dowels aren’t a new concept, but this machine is, at least to the United States market. The best way to explain this tool is to think a biscuit joiner, but for dowels. The tool operates in much the same way and is designed for many of the same uses, such as face-frame construction. We feel this tool may have more of an impact in the kitchen cabinet area or for those building projects with adjustable shelves. The bits for this joiner are the same bits used in straight-line boring machines; they lock into the tool with set screws and are exactly 32mm or 1-1/4" apart.
Does 32mm sound familiar? That’s why we think kitchen cabinet builders might jump on this tool right away. The 32mm system is a complete European kitchen cabinet concept that’s been in this country for some time.
As for adjustable shelving, this Doweling Joiner is great for installing the 1/4" holes for shelf pins. This tool drills two holes at a time (one if you remove and work with a single drill bit) and uses two retractable pins that are fully adjustable to maintain alignment as the holes are drilled. Like with a biscuit joiner, place the base of the tool against a straight edge to keep the holes in a line.
The Doweling Joiner has a 6.5-amp motor, drills for dowels that are from 3/16" to 1/2" (5mm – 12mm) and is adjustable for depth up to 1-3/8". Look for this tool to sell for $329. We’ve been told the Doweling Joiner will be on the market very shortly. And we also noticed that Triton was showing a similar machine in its booth.
— Glen D. Huey
Read other entries by Glen D. Huey
8/20/2008 11:33:49 PM (Eastern Daylight Time, UTC-04:00)
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In the Future with Festool

Two years ago if I would have mentioned the company Festool, more likely than not, you wouldn’t have known the name. Then the Domino was introduced and the name Festool jumped in popularity. The next year the company delivered two routers, the OF2200 and the MFK 700, along with Kapex, the Festool miter saw, and the company name is now well known throughout woodworking.
Of course Festool is here at the International Woodworking Fair. The main draw in the booth is the Kapex. That saw wasn’t at the big Las Vegas show last year. There wasn’t even a prototype to look at. So, even though we’ve all heard tons of information about this miter saw, this is the first look for many woodworkers.
For those of us covering the happenings at IWF, Festool scheduled appointments that were held outside the booth in a “secret” room. I think the team at Festool had a great idea. With scheduled appointments, the team met with everyone on a one-on-one basis to show us what was waiting in the wings from Festool – what the company planned to bring to the table in the next couple years. And we get to deliver to you that look into the future.
I’ve always heard Festool talk about “the system.” I knew a router or plunge-cut saw with a multi-function table (MFT) wasn’t the system. Today the concept of system came into focus. Festool envisions woodworkers setting up complete shops with Festool tools. That’s what was displayed in the secret room.
The big concept was a Compact Module system. The table for this system attaches to an MFT by way of the v-grooves along all edges. The top of the table, where you change plates in and out, is where the action takes place. 
In one module the Festool team set up a router station. Simply mount a router on the bottom of a plate, flip the plate as you place it into the table and turn a normally hand-held tool into a router table. (That’s not a new concept until you add in a number of possible modules and plates, each with different tools). You can use an OF1400 up to and including the super-sized OF2200 routers and the setup comes complete with a fully functioning fence that allows quick-action movement for positioning and then a fine-tune adjustment so you can dial in the cut exactly.
Another module in the display held a Festool TS 55 EQ plunge-cut saw. Again the saw was attached to the plate then inverted and extended through the plate to form a small table saw. Included on this table saw was a fence ready to position and lock as needed, along with a see-through guard system and of course, a riving knife (which is part of the plunge-cut saw). The look and feel was that of a table saw.
What makes both these setups so cool is a sliding table that is positioned directly beside the saw and in front of the router. These sliders fasten to the Compact Module table using v-grooves and are very smooth in operation. Now you have a setup for crosscuts or, if the sliding attachment is used at the router module, you have a great way to mill the ends for rails and much more.
I think we can look for additional modules down the road. One that is in the works, but you might not see due to Underwriters Laboratory hurdles concerning guards, is a plate holding an inverted Festool jigsaw.
Also, Festool gave us a look at a couple new tools, one of which is a vacuum-clamping system. This system has a vacuum built into a systainer and it was as quiet as a church mouse. We could talk in normal volumes and easily hear what was said as the vacuum powered up to hold firm.
Attached to the vacuum is a stand that can be clamped to an MFT or can be held to a smooth tabletop via vacuum action at the base of each pod. At the top of the pods are interchangeable hard rubber-like platforms (four designs in all) that immediately grab most any surface. We watched as a rough-sawn, straight-from-the-sawmill chunk of mahogany was grabbed strong and tight. And with a smooth surface such as a piece of melamine, the hold was incredible. So incredible that using this as a mount for edge routing would be a walk in the park. Also, the platforms can be rotated and pivoted as needed bringing to mind the possibility of holding work while carving or shaping cabriole legs. 
Additionally, Festool has two new T-handle drills about to hit the scene. These drills are well-balanced and very comfortable in your hands and there are interchangeable chucks designed for a variety of duties. The first is what Festool labeled a 12 + 3, which is equal to a 10.8-volt drill, and a 15 + 3 that’s equivalent to a 14.4-volt drill. Each drill comes with a lithium-ion battery made of the highest quality (what else would you expect from Festool?) and is backwards compatible with earlier Festool batteries and chargers. Look for these drills to come to market during the second quarter of 2009.
— Glen D. Huey
Read other entries by Glen D. Huey
8/20/2008 11:25:03 PM (Eastern Daylight Time, UTC-04:00)
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An Adjustable-height Band Saw (yes, you read that right)

If you own a 14" band saw, then you know that you have a conundrum on your hands when you set it up.
 You could leave it stock, which would allow you to cut material up to 6" thick. Or you could add a “riser block,” which allows you to cut stock up to 12" thick. Many woodworkers add the riser block in case they ever want to resaw veneer material on their machine. But adding a riser block has downsides: The machine is less stable, harder to tune and the longer blades cost more.
General International has developed a new band saw that allows you to have the best of both worlds. It’s a bit of a shock to see it work the first time. In essence, the spine of the band saw is like the post on a drill press. Turn a crank and you can raise the head up so you can resaw thick material with a 102"-long blade. Or crank it the other way so you can enjoy stable cuts with a 93"-long blade.
Changeover takes about two minutes, plus changing the blade on the machine. When we first saw this new saw at the International Woodworking Fair we just shook our heads thinking it was a gimmick. But after a moment of thought, we could see that it was a bright idea. Most woodworkers rarely use their band saw for resawing and would be best served by keeping their machine set low. But when you need to resaw, it’s a simple thing to raise the head and give yourself that extra capacity.
This band saw, which should be available this year, is fully loaded. It has a 1-1/2 hp motor, ball-bearing blade guides, cast-iron wheels, a laser, a rack-and-pinion table-tilt mechanism, rack-and-pinion guide adjustments, a quick-release blade-tensioning mechanism, wheel brush, a tall aluminum fence, two speeds and a nice one-piece base. The price? About $1,400.
— Christopher Schwarz
Read other entries by Christopher Schwarz
8/20/2008 10:08:42 PM (Eastern Daylight Time, UTC-04:00)
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 Monday, August 18, 2008
For This I get Paid? — The Final Installment
 I got back to Cincinnati late Saturday after six days at the Marc Adams School of Woodworking, where Phil Lowe taught me and 11 others how to build a demilune table with a veneered apron. I promised to post a picture of my table today. The one you see above is Phil's. The one you see below (not quite completed...) is mine. 'Nuff said.
— Megan Fitzpatrick Read other entries by Megan Fitzpatrick
8/18/2008 3:46:33 PM (Eastern Daylight Time, UTC-04:00)
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The Wood Whisperer’s Favorite Power-tool Accessories
How lucky are we? This issue of Popular Woodworking magazine has a second article written by Marc Spagnuolo, a.k.a., The Wood Whisperer. In this installment, Marc examines power-tool accessories. You might be surprised to find out what actually powers these accessories. Have fun watching The Wood Whisperer, and if you didn’t catch his premiere video click here. You can also watch this video at popularwoodworking.com/video. –Glen D. Huey Read other entries by Glen D. Huey
8/18/2008 2:50:06 PM (Eastern Daylight Time, UTC-04:00)
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New CD: The Best of Arts & Crafts
 The revival of the Arts & Crafts Movement isn’t just in the furniture store. Woodworkers of all levels of experience have named it one of their favorite styles to build in their workshops. Why? Clean lines and honest joinery. So we've put together a new CD that features our 49 favorite articles from Popular Woodworking and Woodworking Magazine from the last decade that deal with this important furniture movement. All of the articles on the CD are in pdf format, so you can view them on any computer with the free Acrobat Reader program. Plus you can print the articles out and take them to the shop when you're ready to build. If you've never used any of our magazines' articles in pdf format, we'd like to give you a sample for free. We think you'll be pleased. To give it a try, simply click on the link below to download the complete plans for Gustav Stickley's No. 72 Magazine Cabinet, a very popular project from our April 2003 issue. Magazine_Cabinet.pdf (1.66 MB)
Here's what else you'll find on this CD, which is available in our store for $15 (that includes free shipping in the United States). ■ 42 Furniture Projects: We feature comprehensive plans and cutting lists for a complete suite of furniture for your home, including two Morris chairs, sideboards, side tables, bookshelves, outdoor furniture as well as home accessories, including lamps and wastebaskets. Every project includes step-by-step instruction and measured drawings.
■ 7 Technique Articles: Arts & Crafts furniture uses straightforward joinery like the mighty mortise and tenon. We show you a wide variety of ways to cut this essential joint, plus articles on achieving an Arts & Crafts finish with home-center materials and detailed plans for the jigs and fixtures that will make your shop time more efficient.
This CD is in stock and ready to ship. To order your copy, visit our store today.
— Christopher Schwarz
Read other entries by Christopher Schwarz
8/18/2008 8:25:00 AM (Eastern Daylight Time, UTC-04:00)
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 Saturday, August 16, 2008
For This I Get Paid? Part 5

Friday, my fellow students and I got into a very sticky
situation. That hide glue that Phil Lowe had us start cooking on Monday
finally came into play. But first, we were directed to glue up our
tabletops with a spring joint. I was elated – I actually knew how to do
this (the first thing about which I felt truly confident all week). But
after the glue set, Phil told us to flatten the top. With a smooth
plane. My kingdom for a No. 5.
He then proceeded to use an 1-1/4” chisel to very quickly cut a deep
chamfer on the underside of his top, then cleaned it up with a
spokeshave in just a few minutes. Very impressive. My top isn’t ready
for a chamfer. It isn’t yet flat (but it sure is thinner). I’ll have to
go in before class on Saturday to finish planing and scraping, before I
can band saw the edge, clean it up and cut the chamfer. Our final task
before packing up will be to attach the top with buttons, and I want to
get that accomplished – in large part so the top of my wonky bridle
joints are covered up, and the guys won’t have an immediate and obvious
target for mirth. 
So I set my top aside as we moved onto veneer. This was a lot of fun –
and a hot sticky mess. After cutting the veneer pieces a little
oversized, I opened the glue pot and swatted at the dozens of flies
that immediately converged on my bench, glue pot, arms and substrate.
Then I painted a layer of glue onto the bricked poplar substrate, laid
down the veneer strip, added another layer of glue, then squeegeed it
off the top and out from the bottom with a veneer hammer (a heavy hunk
of metal with a 3” - 4” rolled edge and a handle – it has nothing to do
with hammering). The glue tacks very quickly – to everything. While
squeegee-ing in the demo, Phil scooped and scraped the excess neatly
into his palm and calmly and cleanly returned it to the glue pot.
While we were all squeegee-ing, we scooped and scraped the excess into
and onto everything around us (my marking knife was at one point firmly
attached to my forearm). But hide glue is easy to clean up – just a
little hot water and my tools (and my forearm) were clean.
On Saturday, we’ll add the banding, and hopefully get through assembly.
I’ll post of picture of my finished project on Monday – or at least a
picture of however finished it may be. But I guarantee those bridle
joints won’t be visible.
– Megan Fitzpatrick Read Part 1 of this series here. And Part 2 is here. Part 3 is here. Part 4 is here.
Read other entries by Megan Fitzpatrick
8/16/2008 8:48:11 AM (Eastern Daylight Time, UTC-04:00)
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 Friday, August 15, 2008
For This I Get Paid? Part 4

Today, Phil Lowe set up a jig to waste out the front
side of the bridle joint that the leg sleeves over in our demilune tables, and a
niggling thought crept in to my head. Did I really keep the screws out
of the leg locations when bricking the rim? I think I did, but… The
last thing I wanted to do was hit a screw and set off the Saw Stop. For
one thing, the Marc Adams School of Woodworking has only the one dado
stack at the moment, and I didn’t want to keep anyone else in the class
from getting their work accomplished. And it would be really
embarrassing.
Just in case, I moved to the end of the line. I figured if I did set it
off, I could handle the embarrassment – as long as I didn’t hold anyone
else up. But as I waited, I decided I’d best chop out the waste by
hand. The longer I stood there, the more I convinced myself that I’d
misplaced a screw. But my handsaw skills are, shall we say, in the
developmental stage. So at Phil’s suggestion, I clamped a guide block
along my scribed line, and kept the saw blade pressed flat to that
"training wheel" as I cut down to the shoulders at each location. Then I
chiseled out the waste and flattened the bottom with a shoulder plane.
Of course, there was nary a screw in sight.
This was the first time I’d used a chisel for precision work other than
dovetails. Dovetails are small. This joint is not. I’ve struggled with
getting things flat and even, and squaring the shoulders (among other
things). Phil makes it look so easy.

I knew coming into this class that I was jumping into the deep end. In
theory, I know why the blade is cambered in a smooth plane, and how to
use that plane. I’ve read reams on how to hold and use a handsaw. I’ve
watched editor Christopher Schwarz demonstrate plane us, and the three
classes of saw cuts – more than once. (Chris makes it look easy, too).
Heck – Chris has even stuck a plane in my hand and given me a lesson on
its use. But I didn’t pick up the plane again until this class. Using
these tools with purpose is very different than reading about it,
watching someone do it, or taking a few desultory swipes at a board –
no matter how good the instructor. Use it or lose it.
My table might approach mediocrity. My cuts aren’t great, my tenons are
loose, and I got so excited about my plane shavings that I was
overzealous – the ankles on my tapered table legs are very delicate
indeed. But it will be the best darn demilune table I’ve ever built.
The next one will be even better – and will use no screws at all.
— Megan Fitzpatrick Read Part 1 of this series here. And Part 2 is here. Part 3 is here.
Read other entries by Megan Fitzpatrick
8/15/2008 8:47:57 AM (Eastern Daylight Time, UTC-04:00)
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 Thursday, August 14, 2008
For This I Get Paid? Part 3

As I mentioned in my entry from yesterday, my first order of business this morning (after stirring in the skin at the top of the glue pot -- blech) was to band saw away the waste on the inside of my bricked rim. I wanted to go early and get that out of the way, but at Marc Adams' school, power machinery can be used only between 8 a.m. and 6 p.m. Those are the hours when a staff member is on hand to supervise.
Marc has been running his school since 1994, and in that time, there's been not one major accident on any machinery. That's because safety is of paramount importance to Marc and his staff. Exposure to blades is limited as much as possible by featherboards, hold-downs, shields, fences, sleds and more. As you can see in the picture at the top, in order to cut our table rim's tenon cheeks on the table saw, we had to keep our hands well above the blade in order to secure the workpiece against the jig attached to the miter gauge.
If there's a way to make the operation safe, Marc and his staff have found it, and they're adamant that while at the school, students and instructors follow their proven safety procedures. And they watch like hawks to ensure that happens. This can be frustrating at times -- but it also means that students go home not only with a great woodworking experience, but with all the digits with which they arrived.
On Wednesday, for example, we were crosscutting legs to length at the table saw. Two stops were set up to the left and right of the blade, attached to a sled. Plus a Lexan shield covered the blade. In order to get our leg stock into position, the sled had to be pulled far enough back to allow access to the table under the shield. And though we had a number of small offcuts, the shield prevented anyone from reaching too close (3" minimum) to the spinning blade. It seemed tedious to maneuver the pieces under the angled shield, but it caused the operation to be performed slowly and meticulously. As one of our class assistants, Doug Dale, said, "Often, the safest way is also the most accurate."
It's a great lesson, one I'll keep in mind when I get back to our shop. Now if only there were a Lexan shield to keep me from cutting into my tenons with a handsaw.
— Megan Fitzpatrick
Read Part 1 of this series here. And Part 2 is here.
Read other entries by Megan Fitzpatrick
8/14/2008 7:19:53 AM (Eastern Daylight Time, UTC-04:00)
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 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)
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 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)
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 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)
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