Busy Month

Its been over a month since I last posted, and I got out in the shop some.  I made a table for my friend's new house.  After building my hall table a few years ago I realized that (rectangular) tables are pretty simple structures.  A top, an apron, and legs, 8 mortise and tenon joints, and a way to attach the top, typically using screws to allow for some movement.  To make this table a little more interesting I decided to splay the legs at 5 degrees.  While this isn't a lot, it does change the some construction details, and was a good exercise in thinking outside of square.  Since this was built using reclaimed wood, I also decided to start with rough concept in my head, but let the wood dictate the design and dimensions as it is built.  This build went pretty fast so I once again didn't take many pictures.

Dry fit with some scraps for the top and shelf.

The table was requested to be a medium brown, and glossy, so I used the same finish I used on the bookshelves, WB dye, shellac, a glaze, then topcoats of shellac, and a coat of wax. 

After the dye and stain, ready for shellac.

Finished and ready for delivery

Quartersawn top

Overall this build when smoothly, and it was fun to design it as I built it.  I also broke into some of pear I acquired when my friend took down a tree.  I used some of the thinner pieces to make an 11-grooved box a la Roy Underhill.  This is a fun little box that is primarily made with a plow plane, in my case a rebranded Stanley 45.  it went surprisingly smooth although it is very easy to blowout when cutting the grooves for the splines, so I will probably use a backing board in the future.  The pear has some really nice figure, which was a good trial of my high angle blades for my low angle jack.  I was really pleased with the results until I put a coat of shellac on, and then the "end grain" really stands out as it disrupts the reflection.  I guess I'll have to sand next time.

11 Groove box out of Pear

The next projects will be a bit of a departure.  One is a still a Stickley piece, #800 Sideboard however it will have drawers and will be out of cherry.  The other two are a Shaker rocking chair and foot rest (cherry or maple), and a crib/bed (cherry).  The rocking chair requires me to make a bed extension and steady rest for my lathe, and also some steam bending.  The crib involves lots of slats, and some nice curves on the top rails, as well as some hopefully inventive, strong, and knockdown hardware solutions.  Hopefully I can get them done in 7 months, and remember to take some pictures.

3 Bookshelves Completed

I gave both sets of parents a tilt top table this year.  One as parts  for my Dad's birthday.  The other (completed) as a Christmas gift to the in-laws (a 2013 project I forgot last post).  Since we were going to Salt Lake City for Thanksgiving I decided to save on shipping, and pack the table in my luggage.  Luckily all the parts are small, and only the three legs need to be glued, and not necessarily clamped since they are sliding dovetails.  So I packed the parts, some glue, and a screwdriver.  20 minutes of work, and a couple hours to dry, and the table was complete.

Cherry Tilt-Top at the in-laws

The bookshelves for my sisters while portable, would not fit in luggage, and since each set( 2 uprights, 4 shelves, 8 pegs) weighs about 35 lbs, that doesn't leave much room for protection from baggage handlers or clothes.  On top of that they weren't finished when my family had to leave.    They each got a slightly modified version of my A&C finish that I used on our dining table.  Preraise the grain then sand with 220.  Apply a waterbased dye, then a seal coat of Seal-a-cell or shellac.  On top of the seal coat is an oil stain, I prefer using a gel stain, but the liquid stain works well too.  Here is where I switched it up a bit, in the past I have used Arm-R-Seal with great success, but with so many surfaces, and now that I own a compressor I wanted to try spraying.  These shelves got 3 coats of Zinnser Sealcoat.  Once cured for a couple days I applied a furniture wax with synthetic steel wool.

Spraying Carly's shelves

Completed Shelves

To ship them I used some 2-ply corrugated cardboard I saved from replacing the fridge, and some 1/2" insulating foam and constructed a fairly rigid box that didn't allow the shelves to move at all.  They seemed to make it just fine, and Carly already has hers setup.

With the girls bookshelves finished and out of the shop it was time to get back to my bookshelf.  After finessing the joinery it was time to fit the wedges and then chamfer all the edges

Ready for sanding, finish, and cookbooks

After that its on to sanding, and finishing.  I am using the finishing schedule as above.

After the first coat of dye

Completed bookshelf

Already full of cookbooks

Dutch Tool Chest

Back in November I took the Dutch Tool Chest course with Chris Schwarz at the wortheffort school in San Marcos, TX.  It was a much needed break from work, lots of fun, and resulted in a tool chest.  The Dutch Tool Chest is a unique design that results in decent tool storage, no horizontal surface to use as storage preventing the opening of the chest, and is quite easy to build.  It can hold essentially all the 50 or so hand tools needed to build just about anything, though fully loaded its not easy to move by yourself.  The class was  full two days, which resulted in a completed carcase, with just the front and top remaining, along with the insides.  This class is well suited for people just getting into hand tools, wanting to learn to cut dovetails, and dados by hand, and end up with a useful project.  For more experienced woodworkers it was a great refresher on all the good habits you've replaced with lazy bad ones.

wortheffort, with Brady intently chopping dovetail waste in the foreground

About to start fitting the back

I got a few important things out of this weekend.  It was a great confidence booster, that many of the skills/techniques i developed through making mistakes and deciphering overly opinionated forums, really were some of the best ways to work.  I also learned that I can put in 2 full days (9+ hours) in the shop, and that I was just lazy all the previous weekends.  I also had a chance to work alongside others, which is rare in the solitary world of garage/basement woodworking.  That was quite enjoyable and a great way to catch mistakes before you make them, or at least while you can still fix them.  In fact one of the best things was that I was able to go with a friend of mine, Brady, who has also recently been updating his blog at KirkwoodWorking.  Saturday evening, we all went for drinks after which Chris Schwarz gave a nice talk on the evolution of workbenches followed by a Q&A session.

Chris and I discussing the finer points of screw clocking

Unfortunately after that weekend it was back to long hours at work, and working on the upstairs floor before Christmas, so the tool chest sat mostly idle.  Eventually I found the time to finish the lid, and start the insides.

On Tuesday we had a rare "snow" day here in Houston, and I was able to finish up the interior bits of the chest.

The inside with tools.

Rip and crosscut panel saws on the lid

Bottom with small drawer

Finally I took some in progress shots of the small brass mallet rack in my tool chest.  I started with some scrap oak, and traced the shape of the mallet on the ends.  I am a big fan of quick and dirty waste removal, so I cut a couple slits down the length and split out the waste with a chisel.

Freshly sharpened rip panel saw

Using my new handscrews instead of my hands

Then I took a more refined approach, using #8-12 molding planes, and finally the mallet head wrapped in sandpaper.

Close to the line with planes

Cleaning up a few plane tracks

Now I just need to make a stand to raise it up a few feet, and probably some wheels, cause fully loaded its not something I enjoy lifting.

2013 Projects Part 2

The second half of the year consisted mostly of working, running, and flooring.  No one likes pictures or descriptions of cubicles or me drenched in sweat, so instead some pictures of flooring:

First three rows

A little further along

Floor complete

Eventually the upstairs was completed.  The stairs look a little longer has I had to make the bullnose out of solid hickory, then get the stain to match.

First Flight

Second flight and hall

The three astute readers may notice the appearance of a green chimney cupboard upstairs.  I finally finished the hand tool only chimney cupboard.  This project was actually a lot of fun, but I will not do it with BORG pine mystery-wood again, that was a mistake.

With the exception of the Dutch Tool Chest and  bookshelves in upcoming posts, that wraps up woodworking in 2013.

No woodworking this weekend

This weekend we finally were able to see the results of last 7 or so months of work.  Both Christy and I ran the Chevron Marathon on the 19th.  We both managed to run the whole time (not counting a a couple Gatorade/water stations, its just easier to drink when you slow down a little), and we also did a pretty good job of maintaining our split times.  Christy averaged 10:52 min/mile and finishing in 4:44:46, and I averaged a 9:04 min/mile and finished at 3:57:42.  Both meeting our goals of <5 hrs and <4 hrs respectively.  We are both sore (obviously) but feel great about our accomplishment.  This also frees up nights and weekends just a little.

Projects from 2013

Lots of people make resolutions around the first of the year.  I don't really like the whole resolution thing, as it never seems to stick.  One thing I do think about is all the projects I want to build, or complete since there are still a few lingering at various stages.  Soon enough the list of projects I want to build reaches some unobtainable number in 10 years let alone 1 year.  To make myself feel better I then have to make a list of all the projects I've completed, its not as long, but still impressive enough that the to-do list is less intimidating.  All this rambling is leading towards something....the list of project I completed in 2013:

By the end of 2012 I had finished my workbench and reorganized the shop.  To help accommodate the new layout I needed a new lathe stand:

Then started to make everything round:

Tap handle, chisel handle, and peppermill

Bottle bottle opener

Started to play with the mahogany again:

Spice Rack

Roorkhee Chair progress

Then decided to practice my dovetails:

Pine; ready to go

The beginning of 142 dovetails

Quick graduation gift (with a new toy....love the LA Jack)

Finally completed the Roorkhee chairs and bookcase in May

Christy, dutifully trying out the new chairs

Starting to load the bookcase

And then broke into the special walnut I brought down from Boise

Bookmatched crotch walnut for the top

Top Shaped and finished

Completed table

After that work got crazy, we started training for the marathon, oh and the ceiling fell down...and the floor got ripped up....

Just a minor leak causes a big hole Why not just replace the carpet while we're at it? So the project I had been avoiding, a hand tool only chimney cupboard, was pushed back a little further Thicknessing the back panel Kiska does not seem concerned about the delay Whew....that's probably enough for one post.  I will post the remaining 2013 projects in a few days.  I guess I did quite a few projects in 2013.  Hopefully 2014 is at least as productive

Holiday Vacation

Vacations are tricky for those with lots of hobbies and full time jobs.  On the one hand its a chance to travel/see family/relax/etc.  on the other, all you want to do is spend time on your hobbies.  I was lucky enough that this vacation I was able to do both.

My parents and youngest sister came down to celebrate Christmas with my wife and me.  This year the big gift went to my sisters, both receiving a fairly portable set of bookshelves.  For Libby the gift was some time in the shop making her own.

Both "received" their gifts(oak/picture of oak) a little early, even though the actual bookshelves still aren't done yet.  To streamline the process for Libby, I decided to build Carly's alongside (the fact that I was too busy with other project had nothing to to with it not getting done before the holidays).

Once again I didn't take many pictures along the way, but we made pretty good progress and actually got the dye and stain on the bookshelves before Libby had to go back to school.


 Of course things didn't go perfectly and someone ended up needed stitches.  Luckily it was not my little sister.  Remember to secure your work piece when paring your mortises.  The good news is I should be able to remember the date of my last tetanus shot a little easier...Christmas 2013.  We did use plenty of safe practices while sanding.

They flew back to Rochester, and I started finishing Carly's and even got to work a little on the bookcase I get to keep.  I am taking a very hybrid approach on this project, I drilled holes for the mortises, and removed most of the waste with a jigsaw.  Then went back and cleaned them up with chisels.  The plan is to get this dyed by the weekend so I can spray shellac on all three at once.