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# Thursday, February 05, 2009
Building a Bed, Part Two


It has been a week since my first post on building the bed (read it here), as was pointed out by Bill in the comment section. During the week, I was handed many fine ideas to contemplate and discuss with my wife.

It seems many of you find lights mounted to the headboard of great use. Thank you, but I have nightstands on both sides of the bed to hold furniture books and copies of Popular Woodworking magazine (at least that’s what’s stored on my side). Also found on those nightstands are lamps. I have plenty of illumination by which to read. Most designs that include lights are a bit too contemporary for my tastes.

Martin, in comments on the previous post, suggested the design was stiff  (which it is) and I should add some curves to the plan. While I appreciate his idea, I’ll again have to pass. My favorite designs in furniture are Queen Anne, Chippendale, Shaker and country. There are not many curves in those designs. Granted the headboard of my previous pencil-post bed did curve, but I don’t see how that design is possible given the top cap that was requested by the spouse.

DavidB sent me an email with photos of his recently built, king-size bed. He used three divided panels across the headboard and footboard. That caused me to rethink what I had set up. Upon further discussion and evaluation, I believe the two-panel design is fine due to the wider rails and stiles and to the additional mouldings designed to wrap the panel areas. (But, don’t be surprised if my bed turns up with three panels.)

In the previous post, I didn’t get into the method I'll use to attach the head and footboard to the rails. As in early bed designs, I’ll use bed bolts to assemble the parts (shown at the right is a depiction from "Illustrated Cabinetmaking" (Fox Chapel Publishing). The headboard and footboard are each a single unit with the rails being removed and replaced when moving is necessary. Yes, CWilson, I am going to build this bed to be disassembled. The average American moves households every seven years. And Spring-cleaning rolls around at least once a year.

So the big question is how far have I gotten in the first week. Not far. I’ve milled the posts and located the mortises for the rails. And please don’t look for extensive progress next week either. I’ll be out of town the entire weekend and that wreaks havoc on my shop time.

— Glen D. Huey


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Thursday, February 05, 2009 9:07:10 AM (Eastern Standard Time, UTC-05:00)  #  Comments [2] 
# Wednesday, February 04, 2009
Grizzly Offers Free Shipping

Are you sitting on the fence waiting to pull the trigger on the purchase of a few new tools? If so, here’s something you should know about. Beginning today, Grizzly Industrial, Inc. is offering free shipping on many tools. If you’re considering a new table saw, jointer or other machine or tool, this information is exactly what you’re looking for to help with your decision.

What can you save? The easiest way to find out is to visit the Grizzly web site, click on the announcement banner and select the machine of your choice. But for an example, let’s take a look at the three tools that should be the basis of every woodworking shop: a table saw, jointer and planer.

A table saw, in my opinion, is the heart of your shop. Grizzly offers the G1023S table saw, a great saw to which many a saw is compared. Free shipping saves you $96.50.

Proper lumber milling begins at a jointer. If your stock is not flat and true, you’ll experience issues – nagging issues – throughout your project. Your next thought might be to purchase a 6" jointer, but please don’t. We think you should jump directly to an 8" model. I’ve talked with many woodworkers who purchase a 6" jointer and quickly find that an 8" would have been more useful. Why not simply begin with an 8" machine? Also, look into a helical or spiral cutterhead. (To read my two-part helical cutterhead blog click here for Part One and here for Part Two.) Take a look at a G0490X. The shipping savings on this machine? $149.50.

The last, but not the least, machine needed to anchor your shop is a good planer. The second part of proper milling is to plane the board to parallel thicknesses. You can’t go wrong with a 15" planer. Grizzly offers the G0453 planer. Freight savings on this machine is $149.50.

So if you don't already have a table saw, jointer and planer, these are good machines – and total freight savings are $395.50. I’ll bet you can find a way to turn those savings into more tools. And move quickly. This is a limited-time offer with no ending date mentioned.

— Glen D. Huey

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• Like tools? We do! Read our latest tool coverage HERE.
• Learn a new woodworking technique today. Click HERE.
• Check out our selection of half-price woodworking books HERE.
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Wednesday, February 04, 2009 3:08:04 PM (Eastern Standard Time, UTC-05:00)  #  Comments [1] 
# Tuesday, February 03, 2009
Wisdom In Books

I started playing with CAD (Computer Aided Design) before I was an editor. I think it was an extension of doodling in my schoolbooks. The programs keep getting better and easier to operate, with an exponential increase in capabilities each generation. What’s not to like? Well, the expense can get a little steep … so I decided it was time to check out Google SketchUp. Free 3-D CAD software? Cool!  

I downloaded the program a number of months ago, but hadn’t really been able to spend any time getting used to the system. It came time recently to design a new kitchen table for the family and I was happy it would give me a chance to get comfortable with SketchUp.

I didn’t get too far into the design when I ran into a problem. Creating the individual shapes was extremely easy. But every time I tried to move a piece I’d created, it became an Escher vista. I was missing something important. Then I remembered Drafting and Design for Woodworkers (a book I helped edit not too long ago, and good buy at $29.99). I knew author Bob Lang had walked his audience through the SketchUp program, and I figured he’d have the answer right in the book on my shelf, 10' away.




And there it was on the illustration on page 81. My Escher leg was on the page. In two-minutes of reading I found the reference to the “Grouping” function – that was the elusive command. Excellent, the table drawing could continue.


I do like having my woodworking reference library handy. The Internet is great for finding a lot of information, but my books are more a comfortable reminder that I already had the answer. I just need to prod my own memory. Thanks, Bob!

David Thiel, Popular Woodworking Books Editor





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Tuesday, February 03, 2009 10:28:26 AM (Eastern Standard Time, UTC-05:00)  #  Comments [1] 
Popular Woodworking Now a Part of 'Wood Talk Online'

Popular Woodworking magazine is now a sponsor of the popular "Wood Talk Online" podcast, which is hosted by Marc Spagnuolo and Matt Vanderlist.

Starting on Feb. 10, you can tune in to "Wood Talk Online" and hear tips and interviews from the editors of the magazine in addition to the regular program, which covers furniture, tools, techniques and woodworking news.

What's a podcast? Essentially, it's like a radio or television program transmitted over the Internet. You can listen to it on your computer or even download it to your iPod so you can listen to it in the shop or in the car. If you'd like a taste of the show, you can listen to any of the 49 shows so far simply by clicking here.

Marc, also known as The Wood Whisperer, and Matt, of Matt's Basement Workshop, keep the show lively, interesting and funny. It's a bit like NPR's "Car Talk" for woodworking.

On next week's show, you can hear Glen Huey interview Chuck Bender, an amazing Pennsylvania craftsman and the founder of the Acanthus Workshop school of woodworking. Chuck's portfolio is absolutely jaw-dropping and huge. If you're interested in early American furniture, you should definitely browse the small sample of his work at his site and tune in next week to find out how he got started in woodworking.

Also, Chuck's work will be featured in the April 2008 issue of Popular Woodworking where he writes about carving a Spanish foot.

We'll also be supplying tips and tricks from our workshop that will be broadcast on the show. You can watch and listen to the show live at 8:30 p.m. (EST) on Tuesday, Feb. 10, by clicking here. (There's even an online chat room that runs during the show where listeners can comment on the show.)

And if you can't tune in next week, you can still download the show (it's all free), by visiting "WoodTalkOnline.com."

— Christopher Schwarz


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• Like tools? We do! Read our latest tool coverage HERE.
• Looking for free project plans? We have hundreds. Click HERE.
• Learn a new woodworking technique today. Click HERE.
• Want more videos? See all our free videos HERE.
• Check out our selection of half-price woodworking books HERE.
• Get 8 years of Popular Woodworking on one CD. Click HERE.


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Tuesday, February 03, 2009 8:27:05 AM (Eastern Standard Time, UTC-05:00)  #  Comments [4] 
# Monday, February 02, 2009
Riving Knives-Everything Old is New Again
We love our Powermatic 66 table saw. It has occupied a central space in our shop for a long, long time and I doubt that we will ever part with it. It has almost everything we like to see in a table saw, except for one feature. The single lack is a riving knife, a form of splitter that is common in European machines but only now becoming standard equipment on saws in the American market. We've been writing about the virtues of riving knives for a couple years, and at our Woodworking in America Conference last November, we stumbled on a reminder that it isn't a new idea at all, and it's origins are as American as the Bacon Explosion. What we saw down in Berea, Kentucky was this:



That's a 1950s or 1960s vintage Oliver table saw, still in daily service in the Woodcraft shop at Berea College. The cantilevered, counter-balanced guard is standard equipment on this old saw, as is the riving knife behind the blade. I've seen a lot of these old saws, and they are exceptionally nice. I became curious about how early riving knives were available, so I did some poking around at one of my favorite websites Old Woodworking Machines.com. One of the great features of this site is original manufacturer's literature about vintage machinery.


That's an Oliver saw from 1949, and in addition to the riving knife, this behemoth also features a sliding table to the left of the blade. One more innovation that's been around for at about 90 years. The OWWM site has the catalog in PDF format. I decided to keep digging and found this saw from 1920:

This is from the days when the table of the saw tilted, not the arbor and blade. The riving knife pictured is above the blade so it couldn't be used for non-through cuts. But it does feature a sliding table, and a sensible overhead guard. OWWM also has the catalog for this saw available online. It's worth the read to discover what tools were like almost a century ago.

So new ideas aren't always new, and the sources aren't always what the media says they are. It's good to see things come around again.

Many thanks to Old Woodworking Machines.com for making this information available.

--Robert W. Lang


Looking for More Free Woodworking Information?
• Sign up for our newsletters to get free plans, techniques and reviews HERE.
• Like tools? We do! Read our latest tool coverage HERE.
• Looking for free project plans? We have hundreds. Click HERE.
• Learn a new woodworking technique today. Click HERE.
• Want more videos? See all our free videos HERE.
• Check out our selection of half-price woodworking books HERE.
• Get 8 years of Popular Woodworking on one CD. Click HERE.

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Monday, February 02, 2009 11:49:39 AM (Eastern Standard Time, UTC-05:00)  #  Comments [0] 
# Tuesday, January 27, 2009
Building a Bed, Part One


About a year and a half back, my spouse informed me that it was time for a new mattress. "Why?" I asked. There were no lumps. There were no valleys at the center of the bed. No rips. No tears. In fact, we were both sleeping fine.

Much to my surprise, I was told we needed new bedding because our mattress was 20 years old. That’s it. The mattress …… was old. Heaven help our cats. Now at 16 years old, the boys only have four years until their magic number is up. And my number has come and gone more than twice.

I held off as long as I could, but time finally caught up with me. A new mattress and box spring arrived. It would be nice to simply switch out the new setup with the old, but my wife figured this would be a great time to upgrade in size as well – out went the queen and in came the king. Out, too, went our pencil-post bed frame.

I wasn't too sad to change out the frame because the posts were an early experiment with glued-up materials. Each post showed a distinct bend if the canopy frame wasn’t in place. (Don’t join 8/4 stock with 4/4 stock, then cut a pencil-post design.)

I have the material at hand. I’m using 12/4 for the posts, 8/4 for my rails and 5/4 for the remaining parts of the headboard and footboard. The panels are 1/2" cherry-veneer plywood.

I thought it would be interesting to build this project on the blog. I’m not sure how many entries there will be. Hey, I’m not sure if something new will happen on even a weekly basis. (One thing I’ve found since I’ve been on staff at Popular Woodworking magazine is a respect for woodworkers who have regular jobs. My production has greatly suffered from the days of old when I worked 60 hours per week building furniture.) But you get to keep track and watch my progress.

Shown at the top is a rendition of the headboard of our about-to-be-begun bed. I've posted a SketchUp file (click here to download) of the headboard if you care to take a look and offer criticism – and please, if you have any better ideas, let me hear them quickly. I have to get started as soon as possible. My customer is rather impatient sleeping on a mattress that’s resting on a steel frame.

— Glen D. Huey


Looking for More Free Woodworking Information?
• Sign up for our newsletters to get free plans, techniques and reviews HERE.
• Looking for free project plans? We have hundreds. Click HERE.
• Learn a new woodworking technique today. Click HERE.
• Check out our selection of half-price woodworking books HERE.
• Get 8 years of Popular Woodworking on one CD. Click HERE.


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Tuesday, January 27, 2009 12:02:00 PM (Eastern Standard Time, UTC-05:00)  #  Comments [9] 
Complete Your Collection -- Popular Woodworking 2008 CD Now Available

This past year has featured some of our staff's favorite projects. Senior Editor Robert W. Lang's walked us through his 21st-century Workbench and Senior Editor Glen D. Huey showcased a handsome



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Tuesday, January 27, 2009 10:59:28 AM (Eastern Standard Time, UTC-05:00)  #  Comments [0] 
Want to Start Your Own Cabinetmaking Shop? Here’s How
After I running my own cabinetmaking shop for about three years, I happened upon a copy of Jim Tolpin’s "Working at Wood." At the time I was struggling to keep my business going. I’m not a great salesman or accountant. My system was basic: One shoebox (really, a size nine boot box) for incoming bills and the lid of the box for bills paid. My paperwork was done on notebook paper. Not exactly a professional approach. But, my customers were understanding of my office organization because they liked my work, so the fact that I was using Redwing boot filing cabinets didn’t bother them too much.

Tolpin’s book was exactly what I needed. I copied the style of the quotaion form and bought a receipt book like the one he pictured. The bonus was the copious information about setting up a shop and the process of flowing work through the shop. I had the proper tools and equipment, I knew how to build cabinets and furniture, but I had a small shop. Sometimes the work got ahead of me and I found myself stacking and re-stacking cut piles of parts. I like small shops, so it was important that I learn how to work in one. Jim showed me how to do that.

The path of our lives will sometimes lead us in directions we would never have planned. I had my own cabinetmaking shop for more than five years. But the product going out the door didn’t have a big return for me profit-wise, so I closed the doors and went back to work in a large production shop. Then, about 10 years ago, I was offered the opportunity to edit woodworking books. I knew woodworking, and I had a college degree (albeit in music composition), which meant that I could build and read. So I was hired by F+W.

Here’s where my life made some unexpected turns. I got to know several woodworking authors, one of them being Tolpin. I told him that I had bought his "Working at Wood" book back in 1990 and he thanked me. I thanked him for writing the book as it had helped me get my shop organized. At this time, his book "Working at Wood" had been out for about five years and was selling well. I asked if he had the rights to the book and if he would like to redo it in color, add some material and in general, spruce up the look of the book. He thought that would be just fine, so he proceeded to add some chapters, rewrote the rest, took color photos to replace the black-and-white photos and we had all the illustrations redrawn in color. Oh yeah, we retitled the book — "Jim Tolpin’s Guide to Becoming a Professional Cabinetmaker." We thought it more clearly stated what the book was about.

Jim Tolpin’s Guide to Becoming a Professional Cabinetmaker is your complete guide to choosing a location for your shop, getting the right tools, setting up shop, building shop fixtures, designing cabinets, how to flow the work through your shop, how to assemble, finish and install cabinets, how to structure your business, how to market, design and price your work and most important of all; how to sustain your business.

It's on sale for 50 percent off in our store right now. Just $12.50. Click here.

— Jim Stack



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Tuesday, January 27, 2009 10:14:23 AM (Eastern Standard Time, UTC-05:00)  #  Comments [1] 
# Wednesday, January 21, 2009
Philadelphia Furniture Workshop Open House
Get out your red marker, and circle Jan. 30 and 31 on your calendar. If you can get to Philadelphia that Friday or Saturday, there is a free event you won't want to miss at the Philadelphia Furniture Workshop. The cover of our February issue features Mario Rodriguez and inside is a story about his approach to making a quality drawer. This isn't another story about cutting dovetails, it is about all the other elements that go into making a first-class drawer for a fine piece of furniture.



Mario has been woodworking, teaching woodworking and writing about woodworking for a long time, and now teaches with Alan Turner at PFW, a unique school in a great old building. On the last Friday and Saturday of January, the workshop doors will open for an open house. In addition to Mario and Alan, there will be many other woodworkers and vendors on hand to demonstrate tools and techniques, answer questions and talk about power and hand tool woodworking.



Among those on hand Saturday will be Adam Cherubini who writes our popular Arts & Mysteries column. Adam was one of the highlights of our recent Woodworking in America conference and is one of the most knowledgeable and personable guys you would ever want to meet. He'll be demonstrating hand tool techniques, and discussing stock preparation with hand tools.



Also on hand will be another walking, talking library of woodworking knowledge, Joel Moskowitz, founder and owner of Tools for Working Wood. Joel will be demonstrating freehand grinding and sharpening, as well as showing his line of Gramercy tools. We use the Gramercy holdfasts on a daily basis in our shop, and the dovetail saw can be found on almost any bench.

This is just the tip of the iceberg, for a complete list of demonstrators and vendors, click here. Connecting with experienced, knowledgeable people is a great way to give your woodworking a boost, and this group in this setting will be an event to remember.

For more information about the Philadelphia Furniture Workshop open house
CLICK HERE.

--Robert W. Lang

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Wednesday, January 21, 2009 3:52:34 PM (Eastern Standard Time, UTC-05:00)  #  Comments [1] 
# Monday, January 19, 2009
Bob's Bench-6 Months Down the Road
Of all the projects I've built in the four and a half years I've been with Popular Woodworking, the 21st Century Workbench has been my favorite, and it's been a favorite with readers as well. I've received many e-mails from readers who are building there own version, or getting ready to build one. It's been discussed on online forums and the SketchUp model is among the most popular in our collection on Google's 3D Warehouse.



I thought it would be a good idea to answer the most often asked questions, and report on how the bench is faring after six months in the shop. The number one question is "What would you do differently now that you've used it for a while"? The answer to that one is "I would have built it 15 or 20 years ago". The honeymoon isn't over and this bench has improved my woodworking and my attitude about the way I work. I was used to working on makeshift benches and often resorted to less than ideal ways of holding work, like holding down a cabinet door flat on the bench with one hand while I planed its edges with the other. Those days are thankfully gone.



I designed in a lot of methods to hold work securely, and almost every time I work on the bench I learn another trick or two. The ability to remove the tool trays in the center of the bench has proven more useful than I thought and I can quickly secure my work to the top or front of the bench using hold-downs, holdfasts or clamps. The only annoying issue that has come up is a bit of shrinkage in the top and legs. The dog holes are now slightly small, and the brass bench dogs started sticking when the heat came on this fall. Mike Wenzloff shared a cool trick with me, and the dogs are now a bit smaller.



One area of concern among readers is the mounting of the blocks that hold the screws for the Veritas twin-screw vise. These blocks are more than two-inches thick and are simply glued to the bottom of the bench top. The concern is that the pressure exerted by the vise will break the glue joint. As the project neared completion, Chris Schwarz expressed this same notion to me, and suggested that I bolt the two pieces of wood together. I'm convinced it will be OK, the edges were well prepared, the joint was clamped overnight and it was about a week before the vise was mounted. My thinking is that the joint is as strong as the wood itself, and I wouldn't be concerned about the vise splitting a piece of solid wood the same size.

So far, so good, and if the blocks ever do fail, I will bolt them back on and take the boss out to lunch, while I eat some crow pad thai. If you missed the original article, you can buy the back issue, or find it on the new 2008 back issue CD. There is also a short video about using the bench here. And last but not least, there is a 60-minute long DVD that follows the construction of the bench. On the DVD are a PDF version of the original article, a set of detailed construction drawings, and a copy of the SketchUp model. You can get the DVD by clicking here and if you have any questions or comments, you can leave a comment here on the blog, or you can reach me by E-mail.

--Robert W. Lang

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Monday, January 19, 2009 2:03:44 PM (Eastern Standard Time, UTC-05:00)  #  Comments [4] 
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