The Birth of a Roubo...

This last Saturday a friend of ours was over doing some electrical work in the kitchen. My brothers and I had removed the old counter and tore down the tile backsplash the previous weekend. While the drywall was down, I wanted Mike to update the wiring to make sure all of the outlets were GFI and add some under-cabinet lighting.

Mike has one of those big trucks you love to drive around and every guy you pass stabs you with jealous daggers from his eyes. I like borrowing it when he is working on a project at our house.

This last weekend, I borrowed his truck to take a trip to Lowes. I needed to pick up some supplies for the work he was doing, but I also wanted to take advantage of the bed of his truck to haul a little bit of lumber home.

Two hours later, I returned, triumphant (and sore and tired...)! I had the lumber picked out for what I'm calling The Ten Board Roubo.

It starts with the hand-selecting of ten 12' long 2x12 southern yellow pine boards. Let me tell you, hand-selecting 12' long boards by yourself isn't exactly easy. If you ever start on a bench-building project in the future, I would suggest bringing a friend along to help move lumber during the selection process. Those suckers are heavy and unwieldy.

Once I got them home, I cross-cut them to somewhat smaller dimensions before I stickered them in the corner of the garage. The top is going to be 8' long, so I decided to cut them all into 8' and 4' sections.

It isn't much to look at so far, but it is a start... and it makes my garage smell good!

The mahogany board sitting on top of the stack is not part of the bench but another project I also started (er... picked up again?) this weekend. I'll have some progress on that project at a later date.

Total price for the bench lumber came out at about $150. I'd love to be able to spend the time and money on wooden screws for a face vice and pick up a shiny wagon vice for the end, but I have a baby due in less than 10 weeks, so both are at a bit of a premium right now. I'll settle with using the two record vices I picked up last year (a #52) and three years ago (a #52 1/2). As long as I recess the inner jaws and make some nice big chops for them, I'll be happy.

Decorative Wood Inlay Book Review

Decorative Wood Inlay
By Zachary Taylor

At some point in your woodworking endeavors, you'll find yourself doing inlay of some sort. It might be intentional, such as the addition of stringing to table legs or banding to the lid of a box, or it might be to cover up a mistake, like when I had to inlay an escutcheon into the front of a box to cover up an error I made cutting the key hole. Whatever the reason, it never hurts to have a book handy to get you through these times. Decorative Wood Inlay is the first book I reach for when I want a refresher to get me prepared for my next inlay venture.

Zachary Taylor is a woodworker from England who comes complete with the dry, wry humor we tend to associate with our brethren from across the pond. His writing style is clear and concise and easy to follow, but also very “British”. While wordsmiths will find joy in such sentences as, “The stroke is completed with the same attitude of the blade to the hone,” others might have trouble digesting the English nuance. In this case, he means the blade should be in the same position on the sharpening stone when it ends as when it began.

The book is organized in an easy-to-follow format, beginning with a brief history of inlay and ending with, as he so aptly puts it, “the finish”. Some of the chapters are a bit sparse, like the history (he does call it “brief”) and the last two chapters on adhesives and finishes. In his defense, however, I would point out that a book written on inlaying wood in a decorative manner should mostly cover the process of inlaying wood and not focus on the most basic mechanics of woodworking.

The first few chapters are useful to the beginning woodworker who already knows they want to incorporate inlay of some sort in many of their pieces. Chapter 2 covers the tools and equipment one might find useful while Chapter 3 discusses what Mr. Taylor deems to be important features for a shop setup. It is important to keep in mind that his ideal workshop is created with his kind of work in mind, so it certainly wouldn't work for someone who builds kitchen cabinets for a living.

The bulk of the book, of course, is spent discussing various types of inlay, covering several techniques for each type. Mr. Taylor first starts with one of the simplest types, corner banding. His first method uses a custom purfling tool made for him by Carl Holtey, one of Britain’s master plane makers. The second and third methods involve multi-tools (e.g. Dremel) and hand-made scratch-stocks.

He follows this process for each technique he discusses – how to perform the function with a variety of tools, going into enough detail with each method that they all seem comfortable and do-able. Throughout the next chapters, he outlines inlaying stringing, inlaying curved stringing, inlaying panels and motifs, and inlaying irregular shapes. Each technique he discusses builds upon the previous, finally ending with the high-end techniques of inlaying guitar rosettes and purfling.

Over the past seven years, I’ve amassed a nice little collection of woodworking books. Many of them are quite enjoyable and do get read from time to time. But this book gets pulled down from the shelf for reference and for reading pleasure more than almost any other. I think it would be a fine and inexpensive addition to any woodworker’s library.

Hand-Cut Dovetails With Frank Klausz, Wrap Up

On Friday, March 19th, six members of the guild met up with Frank Klausz for dinner at the Soulard Restaurant. The beer was tasty, the food was rich, and the conversation was daunting! Frank is anything but shy and his speak-your-mind approach to everything in life is refreshing, if not intimidating. If you ever get a chance to eat dinner with Frank, don’t pass it up.

The next morning, 15 guys showed up at the St. Louis Woodworking Academy, most unsure of what to expect, ready for two full days of hands-on instruction from Frank. Except to say we cut our pins first, I won’t bore you with the details of making hand-cut dovetails. If you want to learn how to do it the Frank Klausz way, then you should pick up his DVD on How To Make Hand-Cut Dovetails or you can find detailed descriptions of his technique in the September 2005 issue of Popular Woodworking magazine or in the book, Hand Tool Essentials, also published by Popular Woodworking.

I would be remiss, however, if I did not point out a compliment Frank mentioned several times during the class (and even once after the class when talking to Wayne Watson, the guild V.P.). The benches we used were not the best suited for hand tools. In most cases, we had two woodworkers to a bench and the one vice on each bench either didn’t work or was of such poor quality it was unusable. But after Frank demonstrated the technique for cutting dovetails, and gave us scrap wood to practice with, we all went back to our benches and figured out how to make it work. Not one person complained about not having a vice – people either shared what good vices we had or people made their own set-up with clamps. Frank was really impressed with our ingenuity and ability to adapt to the situation.

By the end of the first day, 15 people had 15 boxes (though they weren’t all quite the same size) assembled with hand-cut dovetails. We let them sit overnight to allow the glue time to fully cure. On day two, we leveled the sides, shaped the lids, and cut off the tops. Frank showed us how to add the hinges and lock and we ended the class by discussing his suggested finishing techniques.

Hey, those are some pretty good hand-cut dovetails!

I really enjoyed this hands-on class, much more so than any of the lecture classes I’ve attended over the years. Some people learn better by reading and listening and others learn by doing – apparently I’m one of the latter. Though I do see the reason for and a need for lecture classes in the future, I also look forward to the next hands-on class sponsored by the guild.

I don’t expect we’ll see any finished boxes in the April 2010 guild meeting, but I do expect to see a few in the Show and Tell portion of the May meeting!

(By the way, that first picture is Frank's box, not the box of anyone in the class. I took some pictures of it for inspiration.)

Cruel And Unusual Punishment?

One would think seeing such a display in an in-box would bring tears to the eyes of the average woodworker. I mean... an e-mail from Konrad Sauer could very likely mean some type of infill smoothing plane is in the works, right? And who doesn't want to hear from Chris Schwarz on a lazy Friday morning? Or any morning of the week, for that matter.

Alas, the Konrad and Chris in the in-box displayed above are not the plane-making and woodworking gurus you might be thinking of. In this case, Konrad is the Team Lead of a report-writing division and Chris is a member of a technical support team at the software company that keeps food on my table. And I work with these two quite often in my capacity as a software support specialist.

But up until this last week, I hadn't seen their names so close together. To be honest, as I stared at my in-box, wasting a few minutes of my day thinking about what I'd rather be doing, I did find a tear in my eye...

Getting Ready For Frank...

This weekend, I'll get to spend most of two days with one of my favorite master woodworkers - Frank Klausz.

I spent some time the past few evenings making sure all of the tools I'm bringing to class are tuned up and ready to work. This evening, following David Charlesworth's ruler-trick method of sharpening, using just a #1000 grit stone, a #8000 grit stone, an eclipse-style honing jig, and a thin metal ruler, I got my two block plane blades and my smoothing plane blade razor sharp.

I didn't even think to take any pictures of the process, but when I came up with an end-grain shaving from my low angle block plane, I thought I would photograph it for you. You can just make out some of the text in the middle of the shaving. Not too bad for end-grain.

Yeah, I think it's ready for Frank...

I'll spend some time each night the rest of this week warming up my sawing skills and making sure the rest of my tools are ready to go, as well.

Hand Tool Essentials Book Review

Hand Tool Essentials – Refine your power tool projects with hand tool techniques
From the Editors of Popular Woodworking Magazine

If you are a power tool woodworker interested in taking your woodworking to a new level, then this collection of articles, pulled from the covers of Popular Woodworking Magazine, is a great place to start. Chris Schwarz sets the pace for the rest of the collection in the first of seven chapters, with three introductory articles discussing the reasons for, providing the motivations to, and outlining the fiscal ease in which you can incorporate hand tools into a power tool shop.

Since most hand tools do not work well when dull, the second chapter is comprised of nine articles dedicated to helping you make your tools sharp. These articles focus on sharpening plane irons, chisels, scrapers, and draw knives and also cover some of the different sharpening techniques, like using the ruler trick or adding a camber to your plane blades.

Chapter 3 covers hand planes and is the subject with the most articles dedicated to it. There, you will find information on what different kinds of planes there are and when to use each one, how to restore a flea market find and how to tune a new one, and on using wooden planes, smoothing planes, and jack planes. The last article is a bit of eye candy, with some great photos and information on infill planes.

The next two chapters discuss the use of hand saws and chisels. In the chapter on saws, Frank Klausz gives us the final word on dovetails and Chris Schwarz discusses East vs. West. Another article goes into detail on the usefulness of the bench hook and how to make one. The chapter on chisels covers basic and advanced chisel techniques, restoring an old chisel, and modifying stock chisels to work better.

Do you know how to properly use an awl? Or what the difference is between a striking knife and a marking knife? Or how to glue up a table base without using clamps (I'll give you a hint – it involves drawboring)? These answers and more can be found in Chapter 6, which contains several articles on the other hand tools you might want in your shop.

The final chapter provides you with the perfect excuse for buying some hand tools – projects! Start off your bench obsession with the Roubo-style workbench. Then follow it up with a cabinet to store your planes, a sawbench for sawing boards using the proper form, and some miter shooting boards for making tight, precise joinery.

The articles are all well-written with crisp clean photos and clear captions. They are both concise and detailed and easily read one at a time or all in one sitting. Had I not won this book for planing the flattest board at a Chris Schwarz hand plane class earlier this year, I wouldn't hesitate to spend the retail price of $24.99 to add it to my permanent collection.

Getting a little feedback on feedback...

The topic of constructive criticism has come up several times in discussions with other woodworkers over the past few months. I was thinking about tackling the subject in a more thorough manner, but I wanted to get an idea of how people in the woodworking community in general felt about it.

(Plus, I'm also working on writing shorter, more interactive, blogs and I thought a survey might be a good first step...)

Constructive criticism, as I see it, is defined as using your (limited or extensive) knowledge gleaned from life experience, structured learning, or books to offer advice to another as to how they can improve upon something they've done. When providing this service to another, I think the focus should be on the word, "constructive." Nobody wants to hear you say their work is crap, but they might be open to suggestions as to where they could apply themselves a bit more in the future.

So what are your thoughts on the subject? When you present a project to others, be it family or friends or other woodworkers, do you want to only hear the good? Are you completely satisfied with where your woodworking skills are and do not feel any desire to improve them? Or would you be interested in hearing what might be improved as long as it is balanced with some positive comments? Or are you completely comfortable with someone else offering advice on improving your work?

If you would go to the home page of my blog and take 10 seconds to fill out the brief survey, I would most assuredly appreciate it!