Progress

It’s hard to recognize your own progress over a short period of time. But if you wind up able to see a comparison over a longer stretch, it can feel pretty significant.

Stained Glass Chair

'Stained Glass' Chair

I’ve been making an older chair design this week; one that dates back about 20 years. I still like the design, although eventually I’d like to devote some time to updating it. Right now, I’m just making some subtle changes to both construction and design as I proceed. This chair used to be one I considered really difficult to do. Not any more. Later designs have called for greater mastery of many more challenging techniques. And so this is a refreshing change.

That’s one of the big advantages of always pushing forward, and not staying too comfortable in your work. Taking on new challenges adds to your level of experience, your skill-set, and your confidence.  If, on the other hand, you always stay comfortably within your capabilities, you’ll simply remain wherever you are.

Next project, find (or design) something you don’t quite know how to do, then figure out how to do it. Seek out help if you need it. But push yourself. You might have trouble (I certainly have). You might even mess things up the first time. But you’ll learn. And you’ll be a much better woodworker because of it.

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Arch Table

I recently finished up an article for Popular Woodworking on my Arch Table, a piece I’ve been making for at least 20 years. It’s a something of a signature piece for me; perhaps because it’s part of my logo (thanks to my graphic designer), but more importantly, because it was one of the first pieces I did using flowing and branching curves, and a lot of my work since then has grown out of this piece.

The Arch Table in cherry

Megan at Popular Woodworking asked me to do the article about two weeks after I had shipped one out to a customer in Florida, so I had to make a new one. And now I’ve got a beautiful table sitting around looking for a buyer. It’s not exactly the same as the one on my web site (but is the same as the one shown here) but it’s available for $2795 (plus tax and/or shipping). That’s $200 off the standard price for this version, and $500 less than the version on the web site. Let me know if you’re interested.

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New Workshop Schedule

I’ve finally gotten things together and posted the fall/early winter workshop schedule. I’m excited to announce four new classes this session: Mortise and Tenon Joinery by Hand, a workshop on making the ‘Magic’ Tenoning Jig and its companion Mortise Jig, A Chippendale Chair class, and a Joinery with Curves workshop. You can see the complete listings here.

I hope you’ll be able to join us!

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Lie-Nielsen Weekend Workshop

The weekend after Las Vegas was more or less the exact opposite experience: teaching a workshop on mortise and tenon joints by hand at Lie-Nielsen in rural Maine. Hand tool heaven. It was great to get a tour of the Toolworks, get to know Thomas Lie-Nielsen and a bunch of the great people who work there a little better, and to teach a room full of very enthusiastic hand tool woodworkers.

Here are some photos of the weekend, graciously provided by Lie-Nielsen:

Sawing the cheeks must have been going well....

LN workshop 2

....and the shoulders, too.

LN workshop 3

LN workshop 4

LN workshop 5

LN workshop 6

Thanks to everyone at Lie-Nielsen, and to all of the students who were there!

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Whew!

There’s no place like home! I’ve been traveling an awful lot over the last six weeks: first a family vacation, then a trip with my son to his freshman orientation at college, then out to the AWFS Conference in Las Vegas to present two seminars, and finally off to Lie-Nielsen Toolworks to give a weekend workshop on mortise and tenon joints. A great time at each of these events, but all that moving around does take its toll. So it’s finally time to dig back in to the work at hand; furniture to make, lots of articles to write, and lots of photographs to shoot for those articles. Oh yes, and a new book project, which is scheduled to be published next fall by Popular Woodworking! More on that another time….

There wasn’t a whole lot of woodworking relevance on our family trip, but one thing stood out: the dining table at the rather bizarre place we stayed was actually a classic old Roubo-style workbench.

A Roubo Dining Table?

You can see where the threaded hole for the leg vise was plugged, and there’s some evidence of a crochet as well. Made a great dining table (other than the stretchers, which did get in the way). That will certainly go on the list of options for a new table design. This one only had through-tenons, but I like the idea of the through-tenon and dovetail joint even better.

AWFS in Las Vegas was great fun, and the seminars were well attended and enthusiastically received. The show itself was a wild experience. Attendance was not the greatest, which wasn’t really a surprise given the state of the economy, and I’m clearly not exactly the target market for a show like that. But cabinetmakers were in heaven amongst the endless sea of CNC (!). I loved watching an Onsrud 5-axis CNC router machine a sphere inside a cube (loose, but still captured).

http://www.cronsrud.com/video/5axis/pages/sphere_inside_cube.php

This was extremely impressive work, but it would be hard for me to justify something like that in my one-man shop. I also liked some of the Grex air tools, Lamello’s INVIS fasteners (that are indeed invisible once assembled, and tighten up with a rotating magnetic tool! – they’re not new, but they’re still pretty amazing), and a variety of other small tools.

Mostly, I enjoyed meeting people.

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Saving Time

Green Hearing Protection

At least they're easy to see

One of the better time-saving choices I’ve made in my shop was to purchase a pair of fluorescent green Peltor hearing protectors. I admit that they’re pretty goofy looking, especially in combination with the bright pink P-100 filters on the 3M dust mask I often wear, but I’ve cut down drastically on the time I used to waste looking for my black ear muffs; the green is pretty easy to spot anywhere in a shop full of more natural colors. But yesterday, my system broke down just a bit. I had brought in a Granny Smith apple, and left it on my bench in the morning. For much of the day, I found myself heading over to the bright green apple when I was about to turn on a machine, instead of to my hearing protectors, which were usually hiding somewhere at the other end of the shop. I finally had to eat the apple just to stop wasting time. Or rather, to stop wasting time in that particular way.

Not exactly the same color, but close enough...

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Summer Talks and Classes

In addition to my regular schedule of classes in my shop this summer, I’m really looking forward to a couple of events on my calendar. First, I’ve got two presentations (on July 20th and 21st) in Las Vegas at the AWFS Convention: a talk on furniture design, and one on designing and making chairs. A week and a half later, I’ll be teaching mortise and tenon joinery with hand tools at Lie-Nielsen Toolworks in Warren, Maine. We’ll cover everything from the basics of chopping mortises and sawing tenons by hand, through more complex joinery involving haunched tenons, joinery with curved parts, twin mortise and tenon joints, etc. I’ve got some very interesting jigs I’ve recently developed that can make all of these joints quickly and accurately, without a power cord in sight.

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In Praise of Masking Tape

The other day, after I found myself reaching for my roll of blue masking tape for the fourth or fifth time, I realized just how useful and versatile the stuff is.

Blue Making Tape

One of a couple of rolls of blue masking tape I have in the shop

The realization came as I was putting a little piece of tape on my mortise chisel to ‘set’ the depth of cut – I continue chopping until the tape is at the surface, do a final clean out, and I’m done. A had used the tape as a drill bit depth ‘stop’ as well. Earlier I had used the tape as a shim (this tape is about .005”, the clear plastic packing tape I also use on occasion is about .001”) for micro-adjusting the position of a stop on a jig. This is by far the most common use I have for these tapes. A variation on that uses it to rout a groove that’s a little bit out of parallel with an edge. I’ll build up a tapered reference edge, by putting a series of incremental lengths of tape along a straight edge (for example, a 1” strip, a 3” strip, a 5”, 7” etc.) all starting at the same point, The result is a carefully defined tapered edge to run along the router or tablesaw fence or to hold a router fence against. Sure, I tape things together too. I commonly glue down splintered edges with the tape. I didn’t use the blue tape for initial taping up of veneer segments today, but only because I’m not doing any veneer work. I’ve even used pretty much for its intended purpose: to mask off joints when pre-finishing parts.

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Alternative Joinery

A couple of years ago, my wife asked me to take a look at one of her father’s chairs that had loosened up a little. I was not really looking forward to fixing a 30-year-old chair, especially one with little merit other than the fact that it was my father-in-law’s, but agreed to take a look at it and ‘see what I could do’. I brought it in to the shop and was startled to find that all four legs were attached with bolts running through the corner blocks to a threaded insert in the legs. The corner blocks were simply glued and screwed to the chair rails. This was fairly basic knock-down technology, but the chair had been in daily use for decades and it only needed a half turn with a wrench to tighten it up as good as new. A project I had dreaded turned into a significant lesson learned. I don’t use this approach on my regular chairs, but I find it a great method for putting together prototypes in a hurry, and in some unusual situations it has added some terrific reinforcement to otherwise difficult joints.

Attaching a leg with a bolt through the corner block

The leg isn't glued on, it's just bolted on through the corner block

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More Chair Joinery

Angled Mortise and Tenon Joinery

Angled Mortise and Tenon Joinery (sort of a cross section)

Harder to do by machine, although easier to do by hand is the angled mortise. The hard part of this joint is that the shoulders of the tenon are angled so they seat against the chair’s leg. The tenons are cut straight, just as for a normal, right-angled tenon. The mortise is cut at an angle. There are a couple of advantages to this. First, you don’t wind up with short grain on your tenons, as you might with a steeply angled tenon. The second advantage is less obvious, though no less important. With the mortises cut at an angle, the direction of the joint failure is not the same as the force that the joint sees; it’s at an angle. In other words, the chair back wants to move straight back under stress, but the joints don’t point straight back, and, in fact, point in two different directions. The same is true for the front of the chair. This makes it somewhat harder (although certainly not impossible) for the joint to fail.

The twin mortise and tenon joint

The twin mortise and tenon joint

There’s also the twin tenon, with twice the surface area of a regular tenon. There’s not often room for this joint, but when there is, it can be a very solid choice. 

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