davepolaschek

Wood. Food. More.

I bought a little forge for the shop a couple years back. One of the things I'm short on in my shop is flat surfaces, so I decided to build a little table for the forge and associated tools to sit on (the anvil will hopefully get a stump).

I dug through the pile of wood, and found a chunk of 7/4 oak, already planed smooth (so 1½ inches thick), that's 6½ inches wide and 4 feet long. I decided a table top 16×18 inches or so would be about right, so I cut it into three pieces. Then I planed the edges so I could glue the three pieces together.

Three section table-top with battens resting on it

I cut a couple battens from another piece of oak, and decided I'd put them in with sliding dovetails. So I got out the circular saw and cut a few kerfs about ⅜ inch deep. The battens are about ¾ thick, so that seems right-ish.

The edges of the dados in the top are tapered by dint of going along the edges with a #79 side rabbet plane, held at an angle. The edges of the battens were planed with a jack plane to about the same angle.

gluing in the first batten

The first batten took some fiddle-farting around to get right, but the second went together more quickly, since I realized if I get the edges of the sliding dovetail socket close, it's much easier to make the batten match it than to try and tune the dado to match the batten.

both battens installed in table-top with clamps holding the top together

With that done, I glued the edges of the pieces for the top, put a dab of glue in the middle of each batten (the legs will be staked through the batten and top, so I don't want or need to glue in the battens), and clamped things together. In the next session, I'll flatten the top of the table, and start thinking about how tall I'd like it to be.


Contents #woodworking #ForgeTable

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Over time, wooden planes wear unevenly. Rookies to using them will tend to take a heavy cut at the start and end of a pass, which will tend to leave the bottom of the plane somewhat convex (which means no matter how you adjust it, the plane will be more aggressive than it should be). And just normal use will tend to make a plane slightly concave (which will mean no cut at all until the plane is set very aggressively, or unless you push down hard enough to flatten the plane out a bit).

In either case, the first thing you need to do is get the length of the plane flat. If everything else is right with the planes, you can use the hollow to flatten the round, and vice-versa. It's best to try and get the round close first, as this can be done with a bench plane if need be (you'll get a faceted bottom curve, but that's easily corrected).

If you have a convex plane, mount it in your bench vise, sole up, with the iron set in the plane, but retracted enough that it won't cut. Use the matched plane to take shallow cuts off the middle, planing from toe to heel. If the planes aren't matched, this will begin to match them.

If you have a concave plane, concentrate on the ends of the plane. It shouldn't take more than three or four passes unless your plane is way out of shape.

If you had corrected a round with a bench-plane, use the hollow and roll it slightly side to side to knock off the facets from that process to make a nice smooth curve.

After a few passes, retract the blade for the matched plane, set the wedge again, and wrap the bottom with some sandpaper (120 grit has been a good starting point for me) and sand to get the plane bottom correct.

The important thing is to set the blade in the plane body before adjusting it so the plane won't be warped from its normal use-state. This applies to both the plane you're reshaping as well as the plane you're using to reshape the other.

If the curve of the plane is off (they seldom are by much), simply rotating the other plane while leveling the length of the bottom will get you closer to correct, since the curves are circles.

Once you have one plane (probably the round) good, change them around, and mount the hollow in the vise, and flatten its length similarly, first with the plane, and then with sandpaper.

To check the curve on the plane (once the length is flat), I use an auger bit of the appropriate diameter to compare against the hollow. My good augers will give me a pretty good idea if the curve is wrong on the hollow. If it is, I will mark the high spots with a pencil, then use the matching round to plane off the high spots. Once the hollow is correct (according to the auger bit), I use it to make sure the round has the correct curve. Small adjustments here! It's highly unlikely the curve of the plane sole will be too far out of whack, unless you're changing it (which is more advanced than I'm covering here). More likely is a small ding in the sole that you can usually ignore unless it's too near the mouth.

With the wood correct on both planes, it's time to start sharpening the blades. I have a couple synthetic stones that I got from Razor Edge Systems which don't require lubricant. I keep them flat with a diamond plate, and the coarse stone works well for establishing bevels and making sure the back of a plane blade is flat. For the hollow blades, I use slip stones.

For a hollow or round, you want to do about 60% of the work on the back of the blade. This is pretty easy, since you're just making sure it's flat. Don't do “the ruler trick” or lift the tang of the blade, just make it flat on the stone.

For the bevel, I start with a known-good plane body (see above) and use a marking knife and layout fluid to paint the face of the blade, and then mark the correct curve on it. If the blade is WAY out of shape, I'll take it to the grinder and grind to that curve 90 degrees from the back, and then grind the bevel by hand, but I've only needed to do that on about one blade out of ten.

Other than that, it's just sharpening. Just make sure to establish the correct curve first, then worry about the bevel. And try not to use the same track on the stone every time so you have to flatten your stone more often. About 30 degrees will be fine for the bevel in almost all cases. If you have a hollow-ground bevel (from a grinder), you'll want to lift the tang of the blade just a hair while sharpening the bevel because that's the way the geometry works. Matt Bickford's book (see below) has pictures and an explanation.

Once the blade is sharp, use a strop to keep it touched up. I've got a set of hollows and rounds that I'm slowly getting back in service using these methods, and I haven't had to sharpen the blade on any of them a second time yet. But every time I use one, I'll give its blade a couple passes on the strop just to make sure the edge stays nice and sharp. And it gives me practice adjusting the blades so I get better at that.

And if you're serious about this, buy a copy of Matt Bickford's Mouldings in Practice and read chapter 14 of that book. It's a much better treatise on maintaining hollows and rounds from a guy who has a ton more experience at it than I do.

Edited to add: my buddy Kent found a three-video series for those who learn better from videos than from words.


Techniques Contents #woodworking #mouldingPlanes #maintenance #technique

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This is a collection of things I wrote about various #woodworking and #woodturning #technique I've figured out over the years. I don't claim to be an expert, but I've made enough mistakes that I'm not a complete beginner, either.

#technique #contents

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A while ago I picked up a bedan to add to my set of turning tools, and it's rapidly become one of my favorites, due to its versatility and ease of sharpening (I touch it up on the same stones I use for my smaller chisels, which aren't as flat as the ones for the big chisels and plane-blades – that's probably another blog at some point).

Anyway, back to the bedan. I've mostly been using it as a heavy scraper, which it does pretty well. But that sharp edge doesn't have to be presented as a scraper. It can also be used in a peeling cut to rough a spindle in a big hurry, or, as I practiced today, to do planing cuts like a skew on steroids. (If you don't know what the various cuts are, go read Simplifying the Skew now. It'll clear things up.

So, I started practicing planing cuts. The huge bevel of a bedan means that riding the bevel is pretty idiot-proof. Even I can see and feel that big bevel rubbing on the piece I'm turning. The only trick is not catching the side and inadvertently using it as a scraper, which will push the bedan into the piece, causing a bigger catch with the edge… bad juju. But the tool is so heavy, it'll just plow through the wood and remove a giant divot. No real worry about breaking a 3/8” square piece of tool steel with mere wood.

I ripped a chunk of SPF (spruce pine fir) construction tubafor into two squarish two-by-twos, and chucked it up. Put a live center in the tailstock to hold it straight. I've found when I'm trying a new technique, using a chuck on the headstock and a live center on the tailstock makes it almost impossible to have a catch that heaves the piece of wood around the room. Not totally impossible, but almost. Safety first, kids!

First ball turned with the bedan

My first ball went really well. Wow! This was using the same tool I had just used to rough the piece to round, and there was wood everywhere. And then to get a finish like this with the same tool… Wow!

The second one… well… I started having problems.

Second ball turned with the sedan, which had a bark inclusion

See that spiral on the left of the frame? That's a catch anyone learning the skew will recognize immediately. But it wasn't that bad or scary. It just bugged me. Wait! What's with my tool-rest? Or, it's full of notches from my six months of learning to turn, and sometimes having… boo boos.

Close-up of the tool rest on my lathe, showing divots in the edge

After addressing that with a flat bastard file, the rest felt a lot better and my bedan didn't catch in the divots causing problems with my practice.

Second ball turned with the bedan, looking rounder

A pine "curly" turned off using a planing cut

That second one is a bit of wood planed off near the end of the ball. That's one heavy “curly”.

More turned balls, showing a few bits of tear-out

A turned cylinder, looking fairly smooth

A turned shape, somewhat ball-like

Things weren't all sunshine and puppies, but I feel like I made some progress this morning.

Here's the one-shot explanation if you want to try it yourself. For a planing cut, similar to rolling a bead with a skew, you want the edge of the bedan somewhere around 70 degrees away from parallel to the piece. Keep the top edge of the bevel just clear of the piece, so it doesn't act like a scraper, and rotate the bedan to keep the bevel tracking down into the v-groove you cut before starting the ball.

The bedan, positioned as to begin a planing cut

That's about what I learned this morning. I've got five more chunks of tubafor to practice on over the next five days. I'll try to post again as I figure out more.

Edited to add: my afternoon practice piece went very well. I practiced planing cuts, as well as paring cuts and turned the following piece:

Another practice piece, with a few different shapes turned into it

I was proud enough of it that I finished it by sanding it, then applying my homemade friction finish (linseed oil and shellac).

The same practice piece, finished with an oil and shellac finish

Here's a closeup of where a knot made for some very tricky grain. The bedan cut through it pretty cleanly. Note that this is after less than 3 hours of practicing with the tool.

Close-up of a knot with "tricky" grain


Techniques Contents #woodworking #woodturning #technique

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Moving to Santa Fe, I've discovered that a lot of the handles on my wooden-handled tools have loosened up as the wood has dried out. Or in the case of things with ferrules, the ferrules will fall off because the wood shrunk.

There's a simple fix for the latter problem. I just punch a dimple in the ferrule using my Starrett automatic center punch and all is well.

Dimple in the ferrule of a rasp


Contents

#woodworking #tools

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Back in February 2022, Tony, the Gr8Hunter sent me a Keystone Iron City hand-cranked grinder he had scored in Pennsylvania. It was pretty rusty (but just surface rust – no pitting I could see) and would barely turn, so I completely disassembled it, soaked everything in Evaporust, chased the threads on all the nuts and bolts with taps and dies, applied a coat of linseed oil to the wooden handle, then reassembled everything, oiled the moving parts, and gave it a test drive. It worked great, but there was a deep (maybe 1/16 inch) groove worn in the wheel from something, so I trued that up and took out the gouge. Now I've got a nice grinder I can use for things I don't want to grind on the 3600 rpm electric grinders. As another one of my buddies says, Don't work faster than you can think!

I thought about repainting it, but it works fine, and I think I'd rather be using it than fussing with repainting it.

Side view of Keystone Iron City grinder

Hand cranked grinder thumbnail


Contents

#woodworking #tools

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Building drawer boxes, I'm working on small dovetails on relatively thin stock. I don't need a big square for marking lines, and given how cluttered my bench is at the moment, a small square seemed like a good thing to have.

I took a scrap of sycamore and planed it so the sides were flat and parallel.

Then I cut a slightly oversized dado in one of the pieces, glued a cross piece in, pegged it with a piece of bamboo skewer, and made sure it was actually square.

Small marking square

Marking a line on a scrap of plywood to test that the square is square

Flipping the square over and comparing to the line to verify that the square is square

Looks close enough for my needs. I'll clean it up and give it a coat of oil at some point, but for now, I'm back to marking and cutting dovetails.

With some shaping to make it more comfortable in the hand, and a couple coats of oil, it's looking pretty good to me.

Marking square, after finishing

After a year of use, this little tool is still always within reach. I did shorten the upright on it so I could mark dovetails on some box sides that were only about 2 inches wide, which meant only about 1½ inches stuck out of the vise when I was marking them. So now it's a much shorter T than previously, but it's still long enough to mark a pair of ¾ boards when I'm marking and gang-cutting tails.


Contents

#woodworking #tools

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Not all of my handy tools are commercial tools. Looking back, about half are shop-made tools to help me get something done. This is one of those.

I've been wanting to film videos in the shop (not too much, but people seem to like them…) but never had enough hands. I took two pieces of scrap pine, and a couple wood screws, and made this. It did the job pretty well.

Phone holder from the front

Phone holder from the side

I just clamp it in one of my vises, or screw it to the bench, adjust the aim, then snap my camera into the case and film. Easy-peasy!


Contents

#woodworking #tools

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Yesterday I decided I wanted to make a bowl, so I went digging through the wood horde and found a chunk of elm that looked as though it might want to be a bowl.

Elm bowl, sitting on a slab of apple wood

I rough-turned it yesterday and soaked it pretty well with linseed oil. This morning, the oil had firmed up the spots in the grain that were giving me trouble (likely because I haven’t sharpened my bowl gouges in a while) and I got the bowl cleaned up and finished. I really like the way ulmiform grain looks when everything goes right.

side view of the elm bowl

I think it came out fairly well. Finished by sanding to 400 grit, then a coat of linseed oil, a couple coats of shellac, and finally a coat of paste wax.

bottom of elm bowl

#woodturning #woodworking #bowl

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A while ago I got a dowel maker. Got it up and running, and made a video of making a ¼ inch beech dowel.

Stanley #77 Dowel Maker

And here's a photo of the instruction sheet.

Stanley #77 Dowel Maker Instruction Sheet


Stanley No. 77

DOWEL AND ROD TURNING MACHINE

With this machine you can cut dowels when you are ready to use them, and cut them from the same material as the wood being worked.

It not only cuts dowels of various sizes and lengths to perfect dimensions, but with it you can form rods of practically any length.

One cutter head complete for making dowels or rods ⅜ inch in diameter is furnished with each machine.

Additional cutter heads with blades, sizes ¼, 5/16, 7/16, ½, 9/16, 5/8, 11/16 and ¾ inches can be furnished, if desired. The blades are adjustable so that the dowels or rods can be made for a tight or loose fit.

Directions for Use

Saw the stock square for the dowels or rods 1/8 inch larger than the diameter to be turned. Chamfer the end of the stock for an easy start. By means of the left hand clamp screw, secure the stock guide plate with the proper opening in line with the cutter head.

The cutter heads have a right hand thread and are screwed to the hollow spindle of the machine, allowing them to be easily attached or removed.

If a tight fitting dowel is desired, loosen the screw that holds the blade to the head and slide it back slightly. Make a trial cut.

For a loose fitting dowel reverse the operation, sliding the blade forward. Be sure to fasten the screw after the blade is adjusted.

When resharpening the blade be sure to preserve the original contour. We recommend honing in preference to grinding.

The extra power required for turning large rods is provided for by the adjustable crank which can be lengthened by shifting the locking position where it is attached to the speed gear.


I have cutters for the even sixteenths, which I think should cover my needs pretty well. Anything larger than that, I can make on the lathe. And if I should need one of the odd sixteenths, I can chuck a dowel of the next larger size in a drill and sand it down until it fits.

I also had a buddy ask how I have the cutters set up. Here are a couple pictures.

Top view of the cutting head for a Stanley 77

The left half of the blade is exposed over the edge of the cutter body. The right half isn't. Note that on mine, the blade can pivot a little, and it's very sensitive to pivoting, but it looks like years of sharpening has also made the edge of the blade kinda curved.

Front view of the cutting head for a Stanley 77

This one also shows just how little of the blade is protruding beyond the body of the cutter. I can back it off a hair and get an even better finish, but I suspect the real trick is that the blade is skewed a bit from a straight peeling cut, and that improves the finish, just as it would when using a skew on the lathe.

Set up like this, the dowels end up being about 1/128 inch oversized, but a quick wipe down the length of the dowel with some 60 grit sandpaper makes them fit the holes drilled by my auger bits perfectly. I would rather have the dowels slightly tight than too loose, since it's much easier to make them looser than tighter.

I also bought three brand new blades, and as the blades are identical across all the cutting heads, that should be a lifetime supply for me.


Contents

#woodworking #tools

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