Popular Woodworking Editors' Blog

Saturday we ended the Baltimore Card Table class at Kelly Mehler’s School of Woodworking in Berea, Ky. Much to my disappointment, no one finished the table completely. That’s not an indictment against the guys in the class, but more of an indication of my expectations, lofty as they might have been. I guess I should have gotten a clue when one of the participants asked me Tuesday afternoon if I worked at this pace in my shop.
 
In my first blog from Berea (click here), we had assembled the brick-laid table bases and had the legs tapered. By the second entry on Wednesday (read it here), we were into the veneer of the base fronts and working toward the string inlay. As you may remember from that entry, I expected there would no problem completing the work on the table by the end of class. Oops!

So on Thursday we began the string work on the legs and aprons, and created the double-knuckle jointed, swing-leg assembly. Things were moving along. I expected we could complete the stringing in a half-day on Friday, then begin the edge banding and string-inlay work on the top, then wrap up the work on Saturday before departing for home.

By noon on Friday, without the apron and leg stringing completed (that could easily be finished up at home), we moved on to the top. It took longer than I thought it would to create the veneer edge band, get it glued to the top and trimmed so we could begin routing for the string. By this point we were into Saturday. Bummer. My hopes of completion were quickly fading.

Before the guys began departing at around 2:30 in the afternoon, most everyone had the string areas cut and a majority of the base and leg stringing complete. No one had assembled his table (that’s the photo I planned to open this entry with), but everything was cut and ready to install except the tabletop string material. And nobody had routed the swing legs to wrap around the back edge of the apron. Unfortunately, that will have to be finished at home, too.

A class observation (besides my distorted sense of what could be accomplished in a six-day class): Woodworkers who are not regularly in the shop 40–60 hours per week are likely to fade as the week progresses (I resemble that remark these days). Everyone came into the class psyched and ready to bust out a table. But I noticed the pace slowing at an earlier time with each passing day. In fact, there were a couple guys who returned to the hotel to nap before dinner on Thursday. And on Saturday, before leaving for home, a few guys asked that I rout the string channel for the top’s edge – they were too tired and had information overload.

I don’t want it to sound like I drove the guys to the brink. It wasn’t a military boot camp. These are a great group of woodworkers and we had tons of banter during the week. We discussed issues surrounding the table and looked for better methods to resolve those issues. We made decisions based on a consensus of opinion and I’ll bet everyone discovered a few new techniques and different methods of work to take back to his shop and use on future projects. And as always, I learned a few things from the class that I’ll take back to my shop and use.

It has been decided that this class will run again at Kelly Mehler’s School of Woodworking in 2010. So if you’re looking for a challenging class and a fun week where you’ll get scads of woodworking information, check out the school’s 2010 schedule. Or contact the school at Kelly@kellymehler.com. We will adjust the work and strive to complete the tables during the six days allotted.

— Glen D. Huey

Tuesday, August 04, 2009 9:14:41 AM (Eastern Daylight Time, UTC-04:00)    Comments [2] 

You’re perhaps familiar with the “I Can Do That” column in Popular Woodworking, wherein we design and build a simple yet handsome piece using mostly dimensional lumber (though we’ve ripped a short piece a time or two with a jigsaw) and a simple (but good) set of tools.

There’s a free PDF manual on the web page that shows and tells how to use all the tools in the ICDT kit. And, most of the plans and instructions we’ve published in the ICDT column are also free on the site. The goal is to help beginning woodworkers make something they’ll be proud to show off for years to come – not something that will be kicked to the curb (as were the many L-bracket bookshelves I built lo these many years ago) once their skills and toolkits grow.

Currently in the toolkit we have a sliding compound miter saw, a circular saw and a jigsaw among the power saw selections. We’re thinking of adding a benchtop table saw so that longer rip cuts are possible. That would allow us to expand the types of projects we offer – without breaking the wood budget. Six 1" x 1" x 36" pieces aren't cheap – but a 1x8 that can be ripped quickly on the table saw into six pieces is far more affordable.

We reviewed benchtop table saws for the October 2009 issue (which will be arriving in subscriber mailboxes in a couple weeks), and we think the new saws are pretty darn good – especially for a beginner, or someone with a small shop (not to mention hand-tool users who need a table saw occasionally).

So what do you think? Does a benchtop table saw belong in the I Can Do That shop? Please cast your vote in our poll below.

— Megan Fitzpatrick

Tuesday, August 04, 2009 8:37:28 AM (Eastern Daylight Time, UTC-04:00)    Comments [23] 

I was curious, but not much, when my son started telling me about his visit to an old brush-making business here in Cincinnati that was closing its doors after 100 years. Two things stuck in my mind as he talked about how “cool” the old place was: First, that for many years the small business made the brushes for baseball’s National League umpires to sweep home plate and; second, there was some old woodworking machinery.

The building was changing hands and the contents were up for grabs. So we went to take a look and indeed, passing through the doors was like passing through a time warp. Dozens and dozens of various types of brushes were strewn throughout two floors of the building. But it was the shop area on the second floor that caught my eye in the dim light. There stood equipment for which I couldn’t fathom a purpose, mostly types of shears I guessed, used to trim and shape brush bristles. But at the far end of the room sat the woodworking equipment.

To my amazement, it seemed most of those machines were from the same era; my guess was the 1940s. I jotted the serial number from an old but apparently still operational Delta Unisaw that stood center stage. I hoped it would help date the machine. Later, a quick Google search landed my at the Vintage Woodworking Machinery web site that, sure enough, had the serial numbers organized by date of manufacture. Turns out this Unisaw was made in 1944, the fourth (or some would argue fifth) year of production.

Could I buy it? Do I want to buy it? What’s it worth? What would I do with it? After ruminating about this 65-year-old machine I concluded it would be fun to restore it and share the experience with our readers. The idea seemed especially intriguing given Delta’s recent introduction of the all-new Unisaw, the first major engineering and design changes in the tool’s storied history. And when done, we could do some side-by-side comparisons. So now all I had to do buy it at auction – which I did for less than $200.

What’s remarkable about this relic (aside from the obvious fact that it’s still around) is its likeness to all the Unisaws save for the new 2009 model. Take away a Beismeyer fence, the badges and motor, and it would be hard to tell this ’44 version from a ’04 version. Well, maybe this one looks a bit more used.

I’ve done some preliminary digging into this machine and will start chronicling my findings and sharing my experiences with you over the coming weeks. More than an interesting journey restoring an old – and much beloved – machine, I hope to learn and share with you some techniques that will help you keep your table saw and other machines in good operating order. My goal is to get this old beast close to what it was like new in 1944. I suspect we’ll set a new standard for the “how to tune up your table saw” article. Stay tuned!

— Steve Shanesy, publisher

Tuesday, August 04, 2009 7:51:08 AM (Eastern Daylight Time, UTC-04:00)    Comments [12] 

Ever since I designed and built my first passive-solar home near Atlanta in 1980, and, more recently, clients' homes that I have designed, I have been told that I was too “far ahead.” I was told, “We don’t build homes that way around here. Curb appeal only is what sells houses.” I was advised that homes had to be large to be good. Many of these suggestions were just the current trends or fads. But, what is real now? Our global warming and rising costs situation are not just passing — they are the future reality.

Building green should not be just the latest fad — it is a wise thing to do. At this phase of life of the American baby-boomers, I believe we have arrived at a crucial crossroads. We can choose to be smart or we can choose to leave a mess for our children.

"Building Today’s Green Home" will help you cut through the green-marketing hype and make smart choices that yield outstanding results. The eco-friendly sub categories – energy efficiency, sustainability, realistic home size, solar power and air quality – are thoroughly discussed in this book.

With "Building Today’s Green Home," you can start your journey to either building your own home or use it as an aid in selecting a smarter and greener future residence.

And, my wife, Nancy, and my daughter Kristina, would like someone else to hear all this technical homebuilding jargon. They have heard this stuff for years — now it’s someone else’s turn!

David Thiel's comment about not having "house lust" until he visited the Walnut house (from a real woodworker with known shop lust!) down here in Georgia, sums up what a lot of folks say. Seeing a green home in person is the best way to catch green fever.

Wood used inside your home can serve several purposes such as timber trusses that are strong enough to support various types of sustainable roofing materials, including concrete shingles, the trusses span the width of the entire house opening up the area to any number of floor plans and of course, there’s the warmth of the exposed natural wood.

Art Smith
author, "Building Today's Green Home"

Monday, August 03, 2009 3:05:21 PM (Eastern Daylight Time, UTC-04:00)    Comments [0] 

With a six-day class at Kelly Mehler’s School of Woodworking, Wednesday means we’ve just ended the third day – the hump day. Photos may not adequately show the progress, but it is huge. And everyone is on track to wrap things up on Saturday.

Since we began the class, the guys have tapered the table legs, built up the brick front apron and separated the apron from the bricked assembly (shown in the photo at left) are the remains of the first day's efforts. Afterward they attached the back apron to the bricking. That connection is no small feat. Due to the fragility of the bricks, the dovetails that join the back apron to the front are most difficult. More than one brick-laid apron developed an issue as the dovetail sockets were cut. One thing the guys have learned is how to overcome problems – and that is a great lesson to learn.

After the apron was complete and the medial stretcher installed, it was on to routing a wide dado as part of the bridle-joint-joined front legs. A couple guys wondered why we took the time to create this joint until after the leg slid in position and the added strength was discovered. These nine card tables will not show signs of racking in the future.

We ended the day by installing the front veneer. Most everyone had the veneer trimmed before Kelly and his wife Teri arrived back at the shop with trays of sandwiches and other goodies. What else would 10 woodworkers do but sit around talking shop and enjoying the good eats?

And what’s an instructor to do while all the handwork is being done? It’s no hammock, but life is good.

— Glen D. Huey

Wednesday, July 29, 2009 9:52:22 PM (Eastern Daylight Time, UTC-04:00)    Comments [0] 

If you’ve been playing along at home, you’ll know that this is week number three – of the last four – that I’ve been on the road. Four weeks ago was the infamous “hammock” debacle, then two days after returning to the Popular Woodworking offices, I found myself on the way to Las Vegas to cover the AWFS show (I have two more entries to write about from the show, but those will probably have to wait until next week). And this week, after a full five days in the office, I’m in Berea, Ky., (where the first Woodworking in America conference was held), teaching at Kelly Mehler’s School of Woodworking.

My better half is not sure I reside at the same address any more. And if I didn’t continue to send in blogs, the PW office might forget I'm still on staff (I am still of staff aren’t I, Chris?)

So to make sure my co-workers are aware I'm still kicking, and to provide you with an inside view of a woodworking class at Kelly Mehler’s, here goes:

The project this week is the Baltimore Card Table published in Popular Woodworking’s June 2005 issue. We began Monday morning at 8:30 and in less than an hour, we were making dust. (That’s the way a class should be, get busy and have fun.)

The task for the class today was to "brick" the table apron and to taper the legs. The bricking portion of the table is slow going because each brick must be buttered with hide glue and positioned on a template. Then, as each row is finished, a router is used to shape the front.

Everyone did a great job because by 5 p.m. all the class participants had the legs tapered and the bricking complete – except for one straggler. If you can’t quite make out the fellow in the back of the bench room still working on his table after hours, it’s Kelly Mehler himself. He doesn’t work on his class projects until all his school duties are complete – then he has the chance to catch up with the rest of the class. (Actually, he was cleaning up his bench and his table apron is complete.)

On Tuesday, we’ll wrap up building the table base and hopefully have the veneer in place. And if everything goes as planned, we should be routing in the leg stringing.

Tuesday, July 28, 2009 8:59:09 AM (Eastern Daylight Time, UTC-04:00)    Comments [1] 

You’d think running Grizzly Industrial, the wood- and metal-working machinery company, would be enough to keep its owner, Shiraz Balolia busy. After all, he’s a “hands-on” guy who founded the business, and to this day he's involved with everything from machinery design to the company’s catalog design.  

And, he builds amazing guitars – you may have seen them in the print catalog or at one of the shows where Grizzly is exhibiting. Guitar making must be what Balolia does in his “spare” spare time.

For the past couple weeks Balolia has been competing in Bisley, England as Vice-Captain of the USA F-Class Open Rifle Team, where he finished in the top 10 of the Grand Aggregate (multiple shooting ranges) World F-Class Championship. His USA F-Class team took the gold medal.

Just what is F-Class shooting? F-Class is shot prone at distances of 300 to 1,200 yards. Competitors may use almost any caliber rifle, a scope, and a front and rear rest or bipod. That’s right up to 1,200 yards – well over 6/10ths of a mile. The “bulls-eye” target at these distances? Just 5" in diameter.

Balolia, age 57, has been shooting for more than 30 years and is just one of 24 shooters in the United States who is qualified as a National Rifle Association High Master marksman in the medium-range (500 yards) and long-range (1,200 yards) categories. He has documented his experiences during the recent competition on his blog.

What does it take to shoot at these distances? More than a steady hand, apparently. In a story about Balolia for “The Bellingham (Washington) Herald,” Doug Huddle wrote, “It is a world where the slight swelling of blood vessels from a shooter’s heartbeat at the moment a bullet exits the barrel can result in a monumental miss at the target end of the range.

“In his quest for the string of perfect shots, among those things under his control, Balolia strives to leave nothing to chance. And to overcome all the variables in the bullet’s intended path that can jibe its trajectory over which he has no control, Balolia focuses a Zen-like concentration.”

In addition to his recent success in England, Balolia is also the current Washington State Champion and holds several national records in F-Class. His rifle is a single-shot, bolt-action 6.5-284 caliber rifle built to his own specifications.

— Steve Shanesy

Photo courtesy of the US F-Class Open Rifle Team

Monday, July 27, 2009 7:15:01 PM (Eastern Daylight Time, UTC-04:00)    Comments [1] 

The cover on the August 2009 issue shows two walnut blanket chests stacked one on top of the other. I built the two chests at the same time, but to different dimensions. I kept notes on each and, of course, did my scratch-pad drawings on both as the building progressed.

As I worked, I struggled with which size chest I would write about in the accompanying article. Should it be the larger of the two? Or would it be better to run through the building of the smaller blanket chest? I selected the smaller chest due to its unique size, because that smaller size might fit better in more of our readers' homes. I had a 50 percent shot at getting the choice right. And I think I did OK because I haven’t been overwhelmed with woodworkers asking for plans for the larger chest – but I have received a few requests.

I posted a blog entry on how to scale furniture from drawings and other plans, or how to bypass the entire process by taking a drawing to a copy shop and having the piece enlarged. (That, however, should be a last resort due to the board thicknesses becoming enlarged as well.)

Because I was looking for a reason to use SketchUp and improve my skills with the free program (you better believe that I’ll be in the SketchUp seminar at Woodworking in America next month in St. Charles, Ill.) I thought I’d prepare a front and end elevation for those of you who want to have something more to work with. You can download a pdf of the file below (or access the SketchUp file here). Enjoy, but do take the time to learn how to scale from photos and drawings. And by all means, get a firm grip on Google SketchUp so you can use our entire library of SketchUp projects.

— Glen D. Huey

Monday, July 27, 2009 1:04:07 PM (Eastern Daylight Time, UTC-04:00)    Comments [6]