Another Dovetailed Candle Box

Now that Christmas is over, I can publish some pictures that were marked "Classified" by Santa's Workshop. I'm working my way slowly through a pile of box parts that I milled a few years ago, and I completed the third of these in time to send home with my parents. Every box teaches me something new, and gives me a chance to practice what I learned on the previous box. I'm happy to say the successes on this one were greater than the failures.

On the last box, finished about two years ago, I discovered how easily I could overshoot the correct lid size. On that box I had to invent and insert bushings to keep the lid from rattling around too much. It turns out that cutting polycarbonate with a jigsaw is difficult to do. I don't remember the final solution, but I did eventually create two guide bushings that fit in the slots of the box and solved the majority of the problem. You can see one of them clearly in the left slot of the picture below.

So this time through I carefully sneaked up on the correct width, and when I planed the bevels, I was again careful not to get too overeager. The result was a lid that slides nicely, but (at least in the winter) will not fall out when the box is turned sideways. I'm hoping I didn't leave it too snug, or it will become one with the box for the summer. We won't know until then.

On the last box, I also had trouble with the finger pull, which I planned to make triangular. I found to my chagrin that the finished pull appeared off center because I carved the pull before applying the bevels (which were off center). I had to fix the problem by modifying the pull, which turned out to be interesting and beautiful, but much more worry and work than I had originally planned:

Somehow I managed to perform these tasks in the correct order this time, and was extremely careful in carving out the pull. There was a moment when I almost panicked, because in "touching up" I managed to lengthen one corner of the triangle, but I managed to bring it back in balance by keeping my cool and carefully extending the other corner:

Lessons learned on this one:

• Leave the sides slightly proud so they can be made absolutely flush with the side rails after assembly (one corner was slightly below where I wanted it, and subtracting material is more easily done than adding it).
• Don't balance things to dry on the same surface you are using as a work table. There was a repair job involved, but I'm happy to say that steaming can work wonders and only someone who knows what they're looking for will discover exactly where all the damage was done.
  
• Scraping is a good thing on figured cherry. My eyes saw tear out after the balancing act that had been invisible before I started looking critically. I learned that I can get the scraper to cut shavings instead of sawdust—that never happened before—and I cleared up most of the tear out. I noticed some very slight remainders when it was too late to correct: my finishing preparations will be even better next time.
• Learn to cut to a line (see my last post). These dovetails were respectable, but had several problems, including a couple spots that had to be wedged to hid the gap (M&D: can you find the two wedges? It's a lot like playing "Where's Waldo" even for me, and I put the wedges in...) Next time I hope to cut closer to the line, and on the waste side.
• The bottom corners were not as snug as I wanted them, and I hope to figure out why there was a slight gap. That said, they still look good:
  

That's all for tonight. Tomorrow I'm on my way to Rockler to buy a $200 6" Delta jointer that is usually $400.

Christmas 2008: What to Get a Woodworker

Every year I post my thoughts on what a woodworker might like to receive. My previous gift posts have additional ideas and can be found here:

• Christmas 2006 (Part 1)
• Christmas 2006 (Part 2)
• Christmas 2007

I have not checked this year's list to see whether I've repeated myself, but you can be sure that if I've said it more than once, it will be appreciated. Here is this year's list of gift ideas, divided into rough categories. Some are expensive, some are inexpensive, all are useful.

This year's list doesn't stick with just flashy or unusual objects. Some of the items are mundane but useful. These aren't just filler; they will be much used in the shop and can make great stocking stuffers.

Cutting and Shaping

Jigsaw
This flexible tool provides much of the flexibility of both a scroll saw and a band saw. I think of it as the ultimate freehand power tool.

Jointmaker Pro
While I admire Bridge City tools for their beauty and innovation, I usually think they are pricey and optional. With that said, I think the Jointmaker Pro truly delivers the value of its price, and that nothing else on the market can do what it does. It introduces a real innovation that even power tool users can appreciate.

If your woodworker does fine work, especially on a small scale, no other tool can provide the speed and reliability of this tool. It opens up a world of possibilities for speed and flexibility in woodworking.

The name tells only part of the story, because the tool can also be used to make extremely precise sculptural effects and tiny parts.

Router Bits
Another almost limitless source of gift ideas. A router needs bits to function, and the more bits, the more can be done with the router. If you want something that looks like more than a stocking stuffer and your woodworker doesn't have one, consider a good router table.

Router Plane
Yes, it's a hand tool, but even power tool users can appreciate one of these. Often when a dado or rabbet is cut there is clean up to be done on the joint. The Router plane set to the correct depth makes short work of it.

General

Blue Tape
This valuable addition to any shop makes an inexpensive stocking stuffer that will be used for everything from masking, clamping, to impromptu "ribbon" on brown-paper-wrapped shop-built gifts finished moments before delivery.

Cabinet Maker's Wrecking Bar
Actually not a wrecking bar, since the intent is to remove previously installed moldings without damaging them. If you get one of these, choose a brand with a very thin pry end, which allows the end to fit under the molding. I'm very satisfied with my Sharkgrip from Bakuma, which I bought through Sears. I've recently seen a Stanley version of the tool, but I thought the pry end looked too thick.

Rare Earth Magnets
Having a stock of rare earth magnets is inspirational. I use one to keep the chuck key at hand on my drill press, and others to turn hinges and tool bases into temporary bulletin boards. These also make a good closure option in small boxes and cabinets: they can either be visible, or hidden by a thin veneer.

Sandflex Blocks
Great for rust removal and maintenance. These are sometimes called rust erasers, because they work in the same way a pencil eraser does: by rubbing on the surface of the item to be sanded. They can also be used on wood.

Screw Extractors
For when a screw cams out. Everyone who works with screws eventually finds themselves in trouble with a damaged screw head. I need a set of these myself.

Toolbox
What do you give someone who has everything? Something to put it in. There's almost always a use for more tool storage.

Historical


Roman Woodworking by Roger B. Ulrich
This book takes a thorough look at roman woodworking, citing sources and including numerous pictures of primary source material. This will especially please the history buff and hand tool user.

Joining

Hammers
I love hammers, so I might be biased in this, but different sizes and shapes work better for different jobs. Holding a well-made hammer just makes me happy, especially if I know I have nails somewhere nearby.

Kreg Pocket Screw Jig
Good for building jigs, shop stands, yard furniture, prototypes (to avoid doing the real joints), and more. This type of joint is quick and effective.

Layout and Reference

6" Combination Square
Woodworkers need trustworthy layout and referencing tools, and different jobs need different sizes. I prefer the 6" combination square for most small work because there isn't as much of it to get in the way. If you get your woodworker layout and reference tools, don't economize. This is one area where cheap, aluminum, "good enough" knockoffs are definately not good enough. Choose an all steel (preferably hardened steel) from a reputable maker like Starrett or Brown & Sharpe. They are much more expensive than the combo squares sold at Home Depot and Lowes, but they will be acurate and (barring terrible abuse) stay accurate.

Marking Knife
Used to layout joints, especially hand cut dovetails. This can be a beautiful gift that will be used for countless marking tasks in the shop

Pencils
For the marking tasks not done with a knife. Any kind of pencil will do, though carpenter's pencils (the square kind) are too bulky for some applications.

Straight Edge
Fine woodworkers need to know if their prepped wood is flat. Especially if your woodworker uses hand tools, a good straightedge will be appreciated (even if there are several in the workshop already).

Planning

"Doors & Drawers" by Andy Rae
A great new book, released just this year. This book looks at both doors and drawers in an extremely broad and practical way. Andy includes construction detail for all styles of drawer, from the high art solid-wood dovetailed construction to the highly practical rabbetted false-front plywood drawer. Whatever you are building, this book will help you select the appropriate drawer and door designs.

Scratch Pads
A gift that will be used for drawing out rough plans, noting measurements, planning the steps of a particularly complex procedure, telephone numbers, hardware shopping lists and more. Lee Valley offers some very nice scratch pads that have a grid, which helps keep drawings to scale.

"Working Alone" by John Carroll
A carpentry reference that is useful for both homeowners and one-man home builders.

Reference

"Understanding Wood" by Bruce Hoadley
A full reference for how wood behaves and why. An excellent companion to the U.S. Forest Service guide.

"Understanding Wood Finishing" by Bob Flexner
Everyone has to apply finish, and nothing ruins a well made project as quickly as poorly applied finish.

"Wood as an Engineering Material" by the U.S. Forest Service
The full text is available online at no cost, but it is so valuable as a reference it ought to be part of any serious shop library.

Safety

Air Filtration
Like dust masks and respirators: woodworking kicks up a lot of fine particles. They aren't necessarily good for breathing, and they make a terrible mess when they settle.

Dust Masks / Respirators
If your woodworker is a power tool user (and especially if MDF is commonly used in the shop) this is a must. Tell them you love them by keeping them safe and healthy.

Ear Plugs or Muffs
Those who use hand tools exclusively won't need these. For everyone else, give the gift of hearing. Using both forms of protection is most effective. I recommend against muffs that play music. As nice as they seem they will essentially replace the noise of the power tool with the noise of the radio, and because the tool is still loud (even through the muffs) the direct feed radio will be turned up louder than normal and feeding directly into the ears.

A related caution: don't use mp3 players or earplugs on a string in a power tool shop. The wire is a hazard that could get caught and either damage the ears, or pull the head into a machine.

Goggles
Eyes are good. Keep them intact. I like the kind of safety glasses that look like aviator's goggles for several reasons. First, they don't interfere with the muff style hearing protection. Second, they prevent chips from dropping behind them. It’s a good idea to have several pairs so they can be swapped out when one starts to steam up, and so they can be kept where they are most often used.

Protective Gloves
There's lots of nasty stuff in the shop. Don't let it touch skin.

Stock

Moisture Meter
Air dried lumber especially needs to be checked before use. If the wood is too wet, expect splitting, checking, cupping, winding, and shrinking as it dries.

Wood
Beautiful wood is always appreciated. You can never have too much of the raw materials, and a beautiful or unusual piece of wood often inspires a beautiful and unusual project.

Work Holding

Clamps
Norm Abrams famously said, "You can never have too many clamps". Enough said. Look for types or sizes that may not already be in the shop, or add to a type or size that is under represented. In addition to handscrews (which I mentioned separately) consider bar clamps, paralell clamps, c-clamps, pinch dogs, miter clamps, band clamps, etc.

Handscrews
Wow. These are such great and flexible clamps I give them their own topic. If there are no handscrews in the shop, get a pair of 8" or 10" handscrews. These provide flexibility that no other clamp can provide, and using several together can provide quick effective workholding solutions that would otherwise be difficult or time consuming to accomplish. More is better, so get at least two (preferably four or more). I would be happy to receive more handscrews any day, especially in sizes I don't already have.

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That's it for this year's Holiday Gift Guide. If you have additional suggestions, please leave a comment.

2008 Woodworker's Gift Ideas - Part 1

Every year I make a short list of gift suggestions, things I believe most woodworkers would enjoy receiving and that I know I would appreciate. If you're shopping for a woodworker, the good news is that there are so many different tools and utilities you'll likely never run out of things to give. But remember: quality matters in the shop. So if you have the choice between giving a bunch of throw away tools or one really marvelous tool, opt for the one.

Without further ado: 2008 Woodworker's Gift Ideas (Part 1)

1. A Marking Knife
   Especially if your woodworker does any handwork, a marking knife is a marvelous tool, and one that can be appreciated in multiples. Lee Valley offers very nice and affordable knives for this purpose, including beveled marking knives and an ultra-affordable, so-called woodworker's knife. Another affordable and excellent option is the Hock marking knife, which can be used as they are or with the addition of a handle. If you have a little bit more to spend, try looking at marking knives from Blue Spruce Toolworks or Superior Works.
2. A combination or engineer's square
   Precision woodworking requires a lot of layout, and a good square allows for careful checking of handwork, not just as a square, but also as a reference surface and a gauge. This is one tool you should not get from your local Home Depot or Lowes, since they generally carry cheep aluminum squares that are easily damaged by the inevitable hardships of being in the shop. If you can, go with a hardened steel version from a reputable maker like Starrett or Brown and Sharpe. The Starrett 12-inch combination square is a reliable choice for mid-sized work. It can also be handy to have a 6-inch combination square and a 4-inch double square.
3. Safety gear
   What can be more flattering than telling your friend or spouse that you like them just the way they are? Safety equipment can help keep them that way. My suggestions include a half-face respirator or a full-face respirator with filters appropriate to the job (you will need different filters depending on whether you are removing solvent fumes or small particles, for example). Another excellent safety option is for ear and eye protection.

That's it for this edition of gift ideas. I'll have more suggestions later.

Photo copyright and courtesy of kellyhafermann.

Gift Ideas for a Woodworker (Part 2)

My last list of gift ideas included mostly power tools, but I'm really a hand tool kind of guy. If you're looking to please me or any other hand tool lover, there are plenty of good options out there. Here are just a few:

Adria Tennon Saws
For tenon saws, you can hardly go wrong with one of Adria's hand made tools. I'm using a Stanley gents saw, but I sure would like one of these.

Yeung Chan Detail Chisels
When working fine joints, its a plus to have fine chisels. These are all fine tools, but the ones labelled C, D, and E are the ones for which you will have a hard time finding good substitutes.

Medium Shoulder Plane
Outside of the standard smoothing plane, this is one that will pull its share of duty. It allows the creation of a nicely consistant relieve in panel work, and fine tuning of rabbet and tennon joints.

Hitachi Drill and Drive
Not totally a hand tool, but super neat and useful. I first saw this in November, helping set up the 15th annual Medicine Wheel in Boston. The tool allows you to have countersink and screw driver on your drill at the same time and switch between them in about 1 second. At a Big Box store you can get just the insert and the holder for about $10. Online, it seems you can only get it in larger sets.

Scrub Plane
If your woodworker ever deals in rough cut timber, this can be a real blessing. It allows quick levelling of the stock, and if you have a 12" planer it can eliminate the need for large capacity (expensive) jointers: just flatten one side and start running the stock through the planer with the flat side down. With this method, a 4" jointer may be all you need.

Paring Chisels
Chisels are an all around "must have" for fine hand work. This is the set I have at home. It does the job, though there can be significant set up time involved in flattening the backs and getting them good and sharp...

Bow Saw Kit (or Bow Saw)
An all around tool that I look forward to having in my shop. Many people think of them as band saw replacements, but you can do so much more with them. I prefer the idea of a kit, because I want to make my bow saw, but I doubt your woodworker will complain if you get the completed saw. This one was rated as one of the best new tools, 2006, by Popular Woodworking.

That's it for now. Until next time, keep your tools sharp, and your fingers out of the way.

New Handplane from Knight Toolworks

I received a really nice gift this year: a fine new coffin smoothing plane from Knight Toolworks. Unlike many planes, this one comes fully tuned and ready to use without any adjustment. It even ships with the shavings inside to prove it. When I took it out of the box, I stopped long enough to read about its care and feeding (this is my first "woodie") and to take a picture.

Then I took it right down to the shop and put it to use on my current project. I did manage to jar the blade loose, which led to an impromptu session of "how do you adjust this thing?", but after a few rounds of tapping the strike plate, tapping the blade, tapping the frog, testing the cut, I got it right back in working order. And it stays adjusted much better than my Miller's Falls (which I'm still trying to get adjusted so my thumb can't force the blade out of true while I'm using it).

In the picture above, you can seed the box bottom I'm working on in the foreground and the coffin smoothing plane in the background. Those frothy shavings were all made by me after adjusting the plane and putting it back to work. It took me a little while to get used to the lighter body and different shape of the wooden plane, but there can be no doubt: this is now the nicest and most functional hand plane in my shop.

Gift Ideas for a Woodworker (Part 1)

So I'm a little bit late to help you with this year's Christmas shopping. Sorry. I'm going to keep this post short and sweet, but trust me: I would be glad to receive anything on this list, even if I already have it ;)

As gift giving occasions prompt me, I expect I'll create new installments. In the interest of full disclosure: if you follow a link to Amazon and purchase something while you are there, a little bit of your purchase helps keep this Web site up and running. All other link destinations are purely informational, so you can see what I'm talking about.

So without further ado: a (very) few gift ideas for you to mull over.

Veritas Ruler Stop
This is a nifty little gadget for under $15. This makes almost any metal ruler more useful, and will be appreciated by hand tool and power tool users alike.

Bosch Colt Router
A nice little palm-sized router that has been well reviewed by both Fine Woodworking and Popular Woodworking magazines. Flexible in ways that a larger router cannot be.

The Toolbox Book
The stuff of dreams for most woodworkers: a book that inspires making something for themselves and gives them a glimpse into the lives and shops of other woodworkers. I've browsed this one for hours.

Incra Miter Gauge
Alright, this is something I can't use right now because I don't have room for the power tools it goes with. But I've used one of these at my brother-in-law's shop. It is a great aid for keeping precise cuts on the table saw. Awesome.

Rikon Mini Lathe
This is a great value in a mini lathe: it has all metal parts (an important feature for the knobs that get torqued every time the machine gets used) and many features usually only available on full-sized lathes. Especially great for folks with a small shop that might not be able to dedicate lathe space.

SawStop Tablesaw
Okay, this is expensive. But can you adequately value the gift of fingers? A friend of mine lost several fingers to his table saw, and this would have saved him the trouble. An awesome safety advance that should be standard on all table saws (but isn't). But remember: most injuries on a table saw are caused by kickback. This saw also has an innovative anti-kickback knife that sits closer to the blade than any other I've seen.

That's it for this installment. Keep safe, and do good work.