Highland Staff

Oct 052012
 

I am reading three books right now. The first is Larry Haun’s memoir “A Carpenter’s Life — as told by houses”, published by The Taunton Press. It covers the arc of his life through the houses he lived in and houses he built during a lifetime as a carpenter. Haun would probably come in third behind Joseph of Nazareth and Tom Silva of “This Old House” if people were asked to name their favorite carpenter. He is especially well known in my personal circles as the guy who wrote the standard in the field for Habitat for Humanity on building houses. His book is a very personal memoir with a great deal of his own philosophy of life incorporated into it. I particularly like his ideas on efficiency in construction and how to speed up the process of building a house. On the other hand, I found a bit of a disconnect between his life in building large numbers of tract homes and his ideas on saving the environment. I do enjoy his homespun style and I have used his books on construction for many years. Haun passed away last year.

Mouldings in Practice

The second book I am reading is from Lost Art Press, Chris Schwarz’ delightful new specialty publishing company. “Mouldings in Practice” is written by Matthew Sheldon Bickford, he of the popular blog “Musings from Big Pink.” The book is fascinating and is not as much about tools and hand work as it is about freeing up your mind and your work. The author starts out by pointing out that most of us either buy mouldings ready made or by finding a router bit at the store that matches the shape we need and running our stock through the router table. When we do either of these things, we are severely limited in the shapes we can make or use. And if you want to change a profile you have to go back to the store and buy another bit or find another profile. With just a few moulding planes, you can make a virtually unlimited number of shapes and match any shape you see. Subtle changes in shapes and profiles are easily accomplished. Didn’t you ever wonder how they used to do it before electricity and hand held routers? I know I did. I couldn’t help but laugh when someone suggested that the initial reaction to this book by most people is “Oh crap, now I want to buy those stupid planes.” It is so obvious and so simple and so flexible that anybody above beginning woodworker will look at this and jump on it. This book is highly recommended, not just for the woodworking but for the new approach to your woodworking life.

The third book has nothing to do with woodworking, but since I am scheduled for a class at John Campbell Folk School on split bamboo fly rod making, I wanted to re-read “A River Runs Through It” by Norman Maclean, the essential classic on fly fishing. Many people have seen the movie made from the book a few years back, but as is often the case, the movie cannot provide a full appreciation of the skill of the author. Whatever writing skill I have was gained by practice and by reading, and I am not sure that writing can be learned anyway. As the old saying goes, “Either you got it or you ain’t”. This guy had all the skills and when you sit and read a sentence over and over and ponder the injustice of why he can do that and you can’t, then you appreciate real genius. I will offer some insights on bamboo fly rod making and the John C. Campbell Folk School in North Carolina in a few days.

Winter is coming. Better get these books so you will have something to read when the nights get cold and long.

Oct 042012
 

Now that the top is cut to final dimension, I’ll set it aside and start work on the base.  I’ve got some great crotch walnut for the main section of the leg.

I like to keep things symmetrical and consistent for the whole table, but I also want to use the existing grain pattern where I can.  So, I use a piece of glass and trace the grain curve and check it against all 4 cuts (two outside per leg) and take a sort of average or check where it will fall.

Drawing the curve of the grain

Drawing the curve of the grain

Once happy, I trace that onto a piece of 1/2″ or 1/4″ MDF to make a template. First, rough it out on the bandsaw, staying just outside of the line.

The bandsaw roughs out the template curve

The bandsaw roughs out the template curve

I use a spindle sander to cut right up to the line.

A spindle sander cleans up the edge

A spindle sander cleans up the edge

The sander leaves “divets” all along the edge. I go back and clean those up with either some rasps first or skip straight to a flexible sanding pad.

A flexible sanding pad gets a consistent, smooth curve

A flexible sanding pad gets a consistent, smooth curve

I’ll use this same template to make all 4 cuts. The top and bottom edge are kept square so I can use them for reference edges.

Oct 022012
 

This table design has a 2′ leaf at either end.  Now that I have the whole top glued up (10.5′ long!) – it’s time to rip off the two leaves.

I use my Festool TS55 and rail to correctly line up where the cut will go. I have only one shot at this – so although the rail has never slipped on me, I add two rail clamps to secure it.

Festool TS55 ready to cut off the end

Festool TS55 ready to cut off the end

I’ve never had tearout using the TS55 + rail, but I also add a line of blue tape down the cut line and a new splinter guard just to be sure. Here we go!

TS55 on the rail - also using blue tape to control tearout

TS55 on the rail - also using blue tape to control tearout

Four cuts later (two to cut off the leaves and two at the very ends), and I’ve got my final table top!

The table top with the leaves cut to size

The table top with the leaves cut to size

Oct 012012
 

The Lie-Nielsen #103 Standard-Angle Block Plane is the brother to the #102 Low-Angle Block Plane. The #103 plane has the iron bedded at 20 degrees, which along with the 25-degree bevel that comes on the iron, presents a 45-degree cutting angle to the wood (being a bevel-up plane). For those who aren’t hand-tool aficionados, this is the same cutting angle as standard bench planes. This angle is good for all-around work and even somewhat thicker shavings, compared to the Low-Angled planes, which excel at end grain and super fine cuts. The size of this block plane (5 1/4” long) fits so nicely in the hand, and is small enough to drop into a shop apron’s pocket, making it so easy to have within quick reach at all times. I love to use my small block plane in a number of ways, including edges of boards as well as smaller focused areas on the face of a board. The small block planes are easily a favorite of mine.

The body of the #103 is made from bronze, which has some distinct advantages. One of the advantages is how the extra mass of the bronze version is heavier than a like sized plane made from ductile cast iron. This extra mass makes it easier to keep the plane moving through the cut. Another important advantage, especially for those who live close to a body of water, is that bronze doesn’t rust. However, be sure to recognize that the A-2 cutting iron is still susceptible to rust, so make sure to apply a thin layer of Jojoba oil or Camellia oil to slow down the rust monster on your iron. Even though the bronze bodies will not rust, they can oxidize, which makes them less bright and shiny. Some people prefer the natural patina the bronze gains, as it ages, but for those who would rather retain the “bling” of the polished bronze, it just takes a little effort. A product called the Sunshine Polishing Cloth is available, and is regularly used by the Lie-Nielsen crew, on all of their bronze products. This cloth does a remarkable job of removing any oxidation, and restoring the original luster.

The #103 has an iron made of A-2 tool steel, hardened to Rockwell 60-62. This iron holds an edge for a very long time, but with A-2 , it is best not to hone the bevel at less than 30 degrees. The carbides in A-2 tool steel are fairly large, and when the angle is less than 30 degrees, the carbides at the edge of the iron don’t have enough support. I keep my honing on A-2 tool steel at 30 degrees or higher, and I’ve personally experienced great results.

As with most planes, I start honing the iron on a 1000-grit stone and finish with an 8000-grit. This will provide a shaving-sharp cutting edge. To accelerate the process, I usually hone at 5 degrees higher than the original bevel angle. (e.g. if the iron came with a 25 degree bevel, I hone at 30 degrees). This saves a great deal of time, as I’m only working a very thin sliver of metal at the cutting edge of the iron. When working the bevel of an iron direct from the factory, I can expect to take 5 strokes or less on the 1000-grit water stone. I feel the back of the iron to see if a burr is formed all the way across the cutting edge to determine if more attention is required. After I have a burr tip-to-tip, I move to the 8000-grit water stone. I usually take the same number of strokes on this stone as I did on the 1000-grit stone. To hone the back of the iron, I remove it from the honing guide, and using David Charlesworth’s ruler trick, place a thin 6” ruler on the surface of the 8000-grit water stone. The ruler should be at the edge opposite from where the cutting edge of the iron will be. Start with the cutting edge of the iron just slightly overhanging the edge of the water stone. With the iron riding on the ruler, pull the iron back until the cutting edge is about a 1/2” or so onto the stone, then push it forward so its just off the edge of the stone. This movement can be compared to a piston, pushing the iron forward so the cutting edge is just off of the stone, then pulling it back so it’s again about 1/2” on. Repeat this 8 to 10 times while moving slightly laterally with each stroke. Wipe the back of the iron off, with a towel or a paper towel, so you can check your progress. When you see a very narrow polished band, all the way across, at the cutting edge, you are finished. I can usually complete the total sharpening process in about 2 minutes, but just like anything else, speed and comfort with this process will come with practice. Check out a video of the sharpening process here. You can also find additional tips on sharpening, like what honing guides to use, adjustments for honing guides, how to make a jig to achieve consistent sharpening angles, and a whole lot more, on the Lie-Nielsen YouTube channel.

To set the iron for an even full-width shaving, back the spin wheel off until the iron is adjustable, but still keeping the iron under slight tension. Using the adjuster nut, wind the iron back into the body. I like to place a piece of white paper on my bench, so it’s easier to see the next step. While holding the plane over the paper, sight down the plane sole, so you can see when the iron starts to project. Turn the adjuster nut clockwise, and stop when you see a little black line showing through the mouth of the plane. This narrow black line is the front of the iron. Now that you see the iron, look to see if it is even across the plane. If not, light taps on the side of the iron, near the adjuster nut, will help even the iron in the mouth. Once you have the iron laterally positioned, again sight down the sole. Turn the adjuster nut counter-clockwise, while watching to see the black line disappear. Stop just after it leaves your sight. Now rotate the adjuster nut clockwise, just until you feel slight pressure, taking out any backlash. Depending on your eyesight, it’s possible you may have enough iron projecting to test your settings, without needing to advance the iron further. I know I’ve watched the iron as it “left my sight”, only to find I’d actually left it out by about .001”. To finalize and verify your setup, put a thin piece of wood in your vise on edge, and see how your plane behaves. Start by testing both the right and left sides of the iron, to see if the shavings are of equal thickness. If the iron doesn’t yet engage, turn the adjuster nut clockwise by a couple of minutes (thinking about the face of a clock) and test. Repeat this process until the iron is engaging the wood. This will prevent overshooting a fine shaving. The testing on both edges of the iron provides feedback relating to how even the iron is oriented in the mouth. If the shaving from each side isn’t equal, another light tap or two should resolve that issue. If both edges cut similarly, setting the overall thickness of the shaving is next, and ultimately a repeat of the above process of advancing incrementally. When you reach the thickness of shaving you want, re-apply the 1/4 turn of the spin wheel and see how the plane behaves. If the plane needs further adjustment, just follow the same procedures of releasing the spin wheel’s pressure on the iron, adjust, then re-apply the spin wheel. Once you get used to the process, it will feel like second nature.

I hope this helps answer any questions about this plane. Please let me know if you have any specific questions I may have missed.

Click to take a closer look at the Lie-Nielsen #103 Bronze Standard Angle Block Plane.

Click to see Highland Woodworking’s entire selection of Lie-Nielsen hand tools.


Lee Laird has enjoyed woodworking for over 20 years. He is retired from the U.S.P.S. and works for Lie-Nielsen Toolworks as a show staff member, demonstrating tools and training customers. You can email him at lee@lie-nielsen.com or follow him on Twitter at twitter.com/is9582

Sep 272012
 

The underside supports (aprons and batons) are there to help keep the top flat.  I added them with screws and liquid hide glue.

Center Table Underside Supports

Center Table Underside Supports

Unfortunately the batons couldn’t go straight across the full width because of table slides that need to pull out at each end.

Table Slides Attached

Table Slides Attached

I made table slides for the leaves using Accuride Heavy Duty drawer slides and attaching thick oak to each side (aprons and runners).

Homemade Table Slide

Homemade Table Slide

The leaves also got the underside support treatment.  You can see in the foreground the elongated holes to allow for wood movement.

Underside support of the table and leaf

Underside support of the table and leaf

Sep 252012
 

I had a recent post about using the Festool Domino as an alignment tool when edge-gluing boards.  Here’s another shot of how I use it – this time adding a narrow 2″ border piece.  The long grain edge joint doesn’t need any additional strength, but the dominoes help keep everything aligned as I put on the glue and clamps.

Festool Dominos installed and ready to glue

Festool Dominos installed and ready to glue

Note: The two dominoes spaced closely together are because I’m ripping a leaf off the end of the table at that location (right between them).

When I have narrow pieces to glue-up, I use BowClamps to help distribute clamping pressure.

BowClamps help to distribute pressure evenly

BowClamps help to distribute pressure evenly


Morton is a furniture designer + builder working in Harvard, MA.  He reviews tools for Highland Woodworking on YouTube.  You can also find him on Facebook, Twitter @morton, and his own YouTube channel.

Sep 202012
 

For long glue-ups or complicated ones, I like to use the Festool Domino to help align the edges.  This leaves me to concentrate on other things during that critical 5 minutes.  I simply use a pencil to mark lines across the two boards, although I could use the Cross Stops to space them.  The first one I make exact, and then oversize the holes from there.  Simple, fast, effective.

Festool Domino helps to align edges

Festool Domino helps to align edges

Festool Domino cuts a really nice mortise

Festool Domino cuts a really nice mortise


Morton is a furniture designer builder working in Harvard, MA.  He reviews tools for Highland Woodworking on YouTube.  You can also find him on Facebook, Twitter @morton, and his own YouTube channel.