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 Tuesday, May 05, 2009
Meet Don Williams at Woodworking in America
Don Williams is a conservator, educator, scholar and all-around inquisitive guy (and also the owner of more than 40 sets of suspenders). He is co-author of the book "Saving Stuff," with Louisa Jaggar, and has worked on some of the most interesting pieces in our "Nation's Attic," in private and public collections, and in historic buildings.
He's a seasoned teacher on a vast array of topics including woodworking, furniture conservation and wood finishing, and has published research on ancient coating materials as well as modern finishes, has developed finishes of his own invention, and has been published in national woodworking magazines. Don has also found time to write a mystery novel (still awaiting the right publisher) as well as several mystery stories – one of which involves a modern furniture restorer who discovers world-changing secrets hidden in an antique cabinet (I want to read
it!).
Don's career in various woodworking trades began in 1972, when he was a truck driver and repairman for an interior design firm. He's worked as a foundry patternmaker, and in the restoration trade on everything from clocks
and piano cases to classic European furniture and decorative arts. Don attended the University of Delaware to pursue a degree in museum conservation, where he got hands-on experience with one of the premier furniture collections in the United States, at Winterthur. He estimates he's seen tens of thousands of antique furniture examples in his years
of work.
Don has conducted dozens of short courses and seminars across the country on historic furniture, materials and techniques. At Woodworking
in America: Furniture Construction & Design,
Don will be sharing his expert knowledge of the sea change in joinery that occurred during the 19th-century, when furniture construction moved from all hand tools to modern machinery. The transition abruptly changed the way furniture was built, how it looked, and the people who built it. And, Don will be hosting two question-and-answer sessions, where you can ask him about 19th-century joinery, finishing, his suspenders, mystery writing and more.
— Megan Fitzpatrick
Read other entries by Megan Fitzpatrick
Tuesday, May 05, 2009 9:36:15 AM (Eastern Daylight Time, UTC-04:00)
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Woodworking in America: Furniture Construction & Design

Many woodworkers think that the ability to design a beautiful piece of furniture from scratch is a God-given talent. Either you have the knack or you should just make knock-offs.
I'm here to tell you that idea is crazy talk.
While there are some people for whom design comes naturally, I insist that anyone can learn to design well-proportioned, inspiring pieces that are built to last generations. Building things that endure is not just about using the right joinery – it's also creating a form that transcends the shackles of contemporary taste so that it will never be kicked to the curb.
Like any woodworking skill, your eye for design needs to be developed so it can flow through your hands, onto the page and into the wood. And that's why we created the Woodworking in America: Furniture Construction & Design conference.
This three-day event in St. Charles, Ill., will bring together the very best minds on furniture design and construction. And through a carefully orchestrated series of lectures, question-and-answer sessions and hands-on training, you will make serious advances in your ability to create furniture that looks good now, will look good in 100 years and is stout enough to endure everyday use.
The program, which runs from Aug. 14 to 16, is divided into three parts:
• Mastering the mechanics of the design process • Gaining a deep understanding of the predominant American furniture styles • Learning to create the right joinery, mouldings and details to execute your designs.
Mechanics During the last few years, Google SketchUp has changed the world of designing furniture. This free 3D drafting program works on virtually any computer and can be mastered by anyone willing to learn the ropes.
During the three days in St. Charles, we'll show you how Google SketchUp can be used for designing all kinds of furniture, and how you can harness its astonishing power to create designs that can be quickly modified. In addition to interactive lectures, we'll have an open SketchUp laboratory where you can bring your laptop and get hands-on instruction and advice from SketchUp wizards who are also dyed-in-the-wool woodworkers.
And with the help of Jim Tolpin – author of the seminal "Measure Twice, Cut Once" – you'll learn how to take those designs and execute them in a power-tool or hand-tool shop.
Furniture Styles & Details
Though there are many furniture styles, woodworkers tend to build in early American, Shaker, Arts & Crafts and Contemporary styles. So we gathered the foremost experts on the last four centuries of furniture styles to deepen your understanding of them.
Jeffrey Greene – author of "American Furniture of the 18th Century" – will show you how you need to understand regional details to create period furniture that looks right. Robert Lang – author of several books on the Arts & Crafts style – will help you explore this misunderstood era and realize it's not all about dark oak and straight lines. Jerry Grant, curator of the Old Chatham Shaker Museum, will dispel the many myths about Shaker furniture and show you what it really looks like so you can build more authentic, better-looking pieces. And Oscar Fitzgerald, author of "Studio Furniture of the Renwick Gallery," will take you on an inspiring tour of contemporary furniture styles that will open your eyes to the work of the last 100 years.
Construction Good design is worthless without sound construction. So we brought together some incredible woodworkers who can tell you exactly what joints are appropriate and how to scale them.
For 18th-century furniture, Jeff Headley and Steve Hamilton from Mack S. Headley & Sons will explore authentic casework joints and mouldings, which they reproduce daily in their shop (they've even done work for the White House). Conservator Don Williams will explore the joinery of the 19th century and how it went from being cut entirely by hand to almost entirely by machine – and what means for your work.
For the Arts & Crafts era, we've brought on Jim Ipekjian, a professional woodworker from Pasadena, Calif., who has built hundreds of pieces in the Greene & Greene style. Jim has an unrivaled mastery of the incredible joinery of this era. And for the contemporary woodworker, we have enlisted Brian Boggs to help you unlock the secrets to composing your projects using wood grain – one of the defining aspects of modern design.
To top it all off, the keynote speaker will by Thomas Moser of Thos. Moser Cabinetmakers. Moser, one of the most successful designers and builders of contemporary furniture, will explain how he started as a home woodworker and became one of the premiere designers of the 20th and 21st centuries.
And if this is not enough, we also will have a Marketplace area filled with vendors selling the finest tools available now. This really is a weekend not to be missed.
The cost of the three-day conference is $375. You can read more details of the conference and register at woodworkinginamerica.com. I'll be there this summer, most likely sitting next to you and taking it all in.
— Christopher Schwarz
Read other entries by Christopher Schwarz
Tuesday, May 05, 2009 8:37:37 AM (Eastern Daylight Time, UTC-04:00)
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 Monday, May 04, 2009
A Good friend Retires

On my bench, always standing at the ready, is an old friend that needs to be coaxed into retirement. My mallet has served me for many years, but I noticed a while back that its age was beginning to show.
I turned this mallet when I was 15 or 16 years old. That was some 35 years back. The mallet kept its original shape and showed no signs of wear for many years. But throughout those early years, it was inexperienced and was not called into duty very often. It was only after I decided to hand cut all my dovetails that my mallet saw steady action. It was my reliable sidekick during my learning phase and became a trusted friend as my skills increased.
It’s not that this re-purposed baseball bat couldn’t do the work any more. I could pick it up and whack out any dovetails whenever necessary. But I noticed that my friend was losing weight and that I was swinging harder with each thwack. (I noticed that in my shoulder and wrist.) I was absorbing more to compensate for my mallet's shortcomings. As more and more glancing blows were delivered, I felt that the time had come.
This is not the first time I pressed my mallet into semi-retirement or had to do the job with a stand-in. I was woodworking with a friend at his place when we began a dovetail discussion. In order to demonstrate my point, I needed to cut a couple dovetails. He had a mallet, but I didn’t. And he wouldn’t let me use his mallet (big boy games you know). So I picked up an old baluster, then whacked out a set of dovetails much to his surprise. I’ve also used a square piece of stock while In a pinch and without my tools.
 I did acquire a new mallet a while back and it worked great. The only difference was the new guy was a bit square. Sure, it was balanced correctly. It was, and continues to be, durable. But I discovered that I changed my methods when using my square mallet. I no longer spun the mallet in my hand as I drew back for the next blow. I continuously beat on the same face. It was just a matter of time before the square mallet would begin to show signs of battle. This new mallet worked and it did so without being flashy. In the end, that lack of flash may have been its demise.
 I was mesmerized when a round mallet came into the Popular Woodworking shop from Blue Spruce Toolworks. This mallet was infused with acrylic and offered a lifetime of service.
Even though the mallet was sent to editor Christopher Schwarz, I borrowed it from his bench while he was away and gave it a quick try on the dovetailed bracket feet for a couple blanket chests – our October cover project. I immediately coveted this tool.
When I found out a new mallet could be ordered in a variety of colors, I quickly placed my order for a red body with that striking black handle. It was the true definition of flashy. When my mallet arrived, it was a bit less than the brillant red I had envisioned – Schwarz called it pink in a Woodworking Magazine blog entry (click here). To me, it has the word "flashy" written all over it.
I’ve had opportunity to put my new friend to the test and so far I’ve been more than pleased. Whacking steel-banded chisels has added a few small blemishes, but I don’t expect this mallet to show any significant signs of wear for some time to come.
What are you using for a mallet? Better yet, what have you used? Have you gone the way of a baluster or something else? Leave a comment so we can create a list.
— Glen D. Huey
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. • 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. Read other entries by Glen D. Huey
Monday, May 04, 2009 3:45:21 PM (Eastern Daylight Time, UTC-04:00)
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 Friday, May 01, 2009
And the Caption Winner Is...

A few weeks ago, we had a "Caption the Photo" contest, for which we received nigh-on 200 entries – so many, in fact, that out server kept timing out when I tried to view them in Firefox (Safari solved the problem).
So, I culled through them and picked my top-10 favorites, then had everyone else pick his or her top two from my list. My favorite was from Ric: ".... so what are you waiting for? There are lots of woodworkers waiting to chat with you! Come on and join the party, dial 1-900-....."
However I'm sad to report, Ric, that you and I must have a skewed (ha!) sense of humor. The grand-prize winner, based on a semi-democratic vote, is Trevor: "Hello, Jack? You Know those 1,500 bowls we needed by tomorrow? Yeah, that was a typo, we only need 15...Jack? Jack? Hello?..."
So Trevor, as soon as I track down your address, I'll be sending you your prize: Our new "The Best of Shops & Workbenches" CD,
which has 62 of our favorite articles on building benches, setting up
your shop and filling it with the jigs you need. (You can see a
slideshow of the contents of our $15 CD here.)
— Megan Fitzpatrick
• Get 8 years of Popular Woodworking on one CD. Click
HERE. • Looking for free
project plans? We have hundreds. Click HERE. Read other entries by Megan Fitzpatrick
Friday, May 01, 2009 11:23:30 AM (Eastern Daylight Time, UTC-04:00)
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 Thursday, April 30, 2009
A Heavy Load and a Long Road to Haul

A few of us have been kvetching lately about tired, aching feet after a long day in our concrete-floored shop. (Still, I'd rather have sore feet than a sore butt from sitting in front of the computer all day.)
Editor Chris Schwarz spent last weekend teaching at the Marc Adams School of Woodworking, and he was on his feet all day, for two days. But he had a nice mat to stand on, so while his fingers were raw from sharpening, his feet were happy. And I spent a number of years as a bartender (and can still mix a mean mint
julep), so I know what a difference a bar mat makes – especially when
traipsing around for hours in high heels (not that I often wear high
heels in the shop).
So, we decided to break down and buy six mats – one for each bench, and one each for the table saw and jointer. I searched the interwebs for stall mats, on a recommendation from Charles Davis, of The Wood Zealot's Workshop (a very funny blog, but not one for the easily offended). Charles claims they're the best anti-fatigue mats he's tried (which makes sense, since the average horse outweighs the average woodworker by at least a couple hundred pounds). You'd think stall mats would be easy to find this close to the Bluegrass state, but we had to drive about an hour east of Cincinnati to score some nice sturdy ones, made on-site out of recycled tires. And those suckers are heavy – 100 pounds each. And they're not very malleable. But, we managed to cram them into the back of my Subaru, then headed off to the relatively nearby lumberyard to pick up some 8/4 stock for an upcoming project.
But, we had three people in the car. So we made the youngest (and most malleable), Drew DePenning, associate editor for the web, sit in back atop the stack of mats and hang on to the stock; after all, it's only 28 miles, and these mats are supposed to be very comfortable!
I believe I need new brake pads and shock absorbers. And should a police officer see the picture below, um, it was all Chris's idea...
— Megan Fitzpatrick p.s. A couple Cincinnati-area readers have asked where we got the mats: From the very nice people at Dandy Products in Goshen, Ohio, 513-625-3000.
 Read other entries by Megan Fitzpatrick
Thursday, April 30, 2009 6:34:35 PM (Eastern Daylight Time, UTC-04:00)
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 Wednesday, April 29, 2009
No Axe-wielding to See Here
A few days ago, I took a poll to see what should be done with my decades-old, ugly (but functional) L-bracket-built bookcases. Frankly, I'm surprised the chain-saw option wasn't more popular. But, Mother Nature won out...as did a friend across the street. I popped across to borrow some parm-reg cheese, and she mentioned she was looking for cheap bookcases. Done. I got a block of yummy cheese, and the bookcases have a new home. Now I'm off to make bruschetta.
— Megan Fitzpatrick
Read other entries by Megan Fitzpatrick
Wednesday, April 29, 2009 7:29:14 PM (Eastern Daylight Time, UTC-04:00)
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Channeling Danny Proulx's Ghost

When Danny Proulx was about a third done writing his book, "50 Shop-Made Jigs & Fixtures," he suddenly passed away. He was at a woodworking show in Ottawa, Ontario, doing what he loved to do best — teaching and talking woodworking.
Well, that left me in an interesting spot — I could cancel the book or somehow get it finished. It happened that Danny had one of his students from Algonquin College as an assistant shop worker. His name is Luc Rousseau. I called Luc and asked him if he'd be interested in finishing Danny's book. There was silence for a long time. Then he said, "I could possibly do it if I had some help."
After some discussion, Luc and I decided that we could finish the book, with the help of Danny's father-in-law, Jack Chaters (who was the cameraman at the time). So, I high-tailed it up to Russell, Ontario and met the guys.
As we (Luc, Jack and I) were standing in the middle of Danny's shop, pretty much in the dark (mentally, not physically. Danny had so much lighting in his shop you needed sun block and sunglasses to enter it.) about what to do next, that's when we felt it — Danny's ghost. Danny was a fairly big guy in this life and his ghost was equally formidable. We all stood there and it became clear where Danny wanted us to go. We went into his office and there, in the file cabinet, was his completed outline for this book!
After that, we simply filled in the blanks by building the jigs and fixtures he had already chosen. Luc was very much relieved and Jack started laughing. He said, "This doesn't surprise me in the least, Danny was so organized that he left nothing to chance — not even his own demise."
So, under the tutelage of Danny's ghost and a couple of good guys, we completed Danny's book.
— Jim Stack, senior editor of Popular Woodworking Books
Wednesday, April 29, 2009 1:43:18 PM (Eastern Daylight Time, UTC-04:00)
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 Tuesday, April 28, 2009
Bosch: Innovation and a New Technology

Recently the Bosch Power Tools and Accessories division of Robert Bosch Tool Corporation held an event held in Arlington Heights, Ill. Managing Editor Megan Fitzpatrick was in attendance and returned with scads of information – some we can share and some we cannot.
Megan wrote about Bosch’s first foray into pneumatics (read her entry here). The new "Full Force Technology" centers around an innovative tool design where patented air cambers in each tool utilize 100 percent of the air moving from the compressor to the nailers. With no air needed to return the driver to the “ready” position, Bosch’s pneumatic tools are 20 percent smaller and 10 percent more powerful, according to the company.
The innovation didn’t stop there. Bosch has taken the normal "hotdog" style tanks and stood them on end and at a slight angle. This is to increase balance and make transport easier. The company also added a patented "EZ Drain" system for simple front-access tank drainage.
While the focus of the event was to introduce a new line of pneumatics (and other tools, most of which are for construction and destruction), there was another very interesting discovery.
If you’re a fan of new technologies (and what woodworker isn’t) you might know about the new e-Coupled inductive charging system. I, myself, have not been at the forefront of this phenomenon.
This new e-Coupled technology is intelligent wireless power that uses inductive coupling to transfer energy from enabled surfaces to any compatible device. That means there is no need for power cords and battery chargers and there's no on or off switch. Your device has a coiled copper ring near the battery and another copper ring is in the wireless power source. The two rings communicate all the necessary information that allows the device to fully charge. Just sit the device on the e-Coupled platform to charge. For more information, visit this Leggett & Platt web site (click here).
What does this have to do with Bosch Tools? Watch this video and you’ll see a number of Bosch woodworking tools mentioned. Bosch is the exclusive cordless power-tool partner for e-Coupled and is working with e-Coupled to develop something – something we cannot mention at this time, but you can see in the video.
This is totally cool stuff. What do you think?
— Glen D. Huey
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. Read other entries by Glen D. Huey
Tuesday, April 28, 2009 3:25:39 PM (Eastern Daylight Time, UTC-04:00)
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A Big Truck Showed Up at Our Door Today

As Editor Christopher Schwarz and I were leaving to get coffee at lunchtime today, a big panel truck pulled up to our loading dock – so we hightailed it to Chris's car. But Senior Editor Glen Huey has both our mobile numbers, so there was no escaping the unloading duties (to be fair, I didn't actually do any unloading; someone had to take pictures after all!).
In the truck were two huge crates from Lie-Nielsen – the first of multiple shipments for the upcoming Lie-Nielsen Toolworks' Travelin' Hand Tool Event, May 16 and 17 in our Cincinnati shop.
Admission is free. Hours are noon-6 p.m. Saturday and 10 a.m.-5 p.m. Sunday.
Experts from Lie-Nielsen will be on hand to demonstrate their tools. We'll be here to give shop tours and apologize for dangling modifiers. Members of the Society of American Period Furniture Makers (SAPFM) will be giving hand tool demos (click here for the demo schedule). And we'll be joined by John Economaki of Bridge City Tools, Ron Hock of Hock Tools, Kevin Drake of Glen-Drake Tool Works, Ron Brese of Brese Planes, Bob Zajicek of Czeck Edge Hand Tool and Jameel Abraham of Benchcrafted.
So make plans to join us on either or both days at 4700 E. Galbraith Road, Cincinnati, Ohio, 45236 (look for the F&W Publications sign out front...and the tool makers and users in the parking lot). And here's a link to a Google map of our location.
And the delivery fellow? We told him there were more crates to come. As he was leaving, he mentioned that a shipping competitor has great customer service. I believe there may be some heavy metal in those crates.
— Megan Fitzpatrick
Read other entries by Megan Fitzpatrick
Tuesday, April 28, 2009 2:51:46 PM (Eastern Daylight Time, UTC-04:00)
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How to Stop Bamboo From Exploding

It's a good thing that I keep a change of clothes at work. And that I don't wear leopard-print underwear.
OK, let's back up a minute.
This morning I'm finishing up work on the next I Can Do That project, and it requires about 1,000 bamboo skewers that are cut to 8-1/4" long. That 1,000 is not a typo.
We try to obey "the rules" of the I Can Do That column when we build these projects – the tools and materials must come from a home center. And so I wanted to find a way to cut these skewers using the tools in the I Can Do That tool kit. There is no band saw. Only a chop saw and a handsaw.
So I bound together 100 of the skewers tightly with blue tape and marked on the tape where I needed to cut the bunch. I set a stop on the miter saw and began the cut slowly. About three skewers later the entire bunch exploded, and I was glad that I'd visited the Little Editor's Room before beginning the operation.
So I took a bundle out to Senior Editor Glen D. Huey and asked him how he'd cut them.
"With a handsaw – hand tool boy," he said, cackling.
Then he said he'd do it with a band saw, which was my first choice as well. So I bound up another 100 skewers in tape and made the cut on the band saw with no problem.
Looks like we'll be recommending the readers use snips or a handsaw to trim these skewers – perhaps while watching Ingmar Bergman's "Scenes from a Marriage."
Oh, and about that leopard-print underwear comment above: My grandmother always said you should wear undergarments that would look fine in the emergency room when they cut your clothes off – a rule that my mother scandalously violated in her youth with hilarious consequence.
— Christopher Schwarz
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.
Read other entries by Christopher Schwarz
Tuesday, April 28, 2009 10:37:55 AM (Eastern Daylight Time, UTC-04:00)
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