Its Never Too Late For Woodworking

Get Woodworking Week may be over, but don’t tell John.John is an 80 year old Korean war veteran who I’ve come to know because he wants to learn woodworking. While you’d be right to ask yourself why a one-eyed octogenarian who needs a walker is interested in learning a craft he currently knows nothing about, his reasoning turns out to be the same as many of us. John want’s to learn to woodwork because he needs a table for his computer and can’t find the right one commercially.John and I spent the afternoon in my shop where we discussed the basic table he plans to build and the method of building it. We went from hand cut mortise and tenons to routed floating tenons to pocket screws.

This joint is OK.

I know that while steering someone from a hand cut mortise and tenon to a pocket screw may be blasphemous to some, I was happy to do it.

This joint works too.

It’s not that I want John to be a power tool woodworker who only uses steel fasteners. It’s that I want John to be a woodworker. As he’s never built anything, I think jumping right into a table build with eight (8) hand cut mortise and tenons would be enough to turn anyone achoice in frustration. I stressed to John that as much as he’s eager to learn and practice joinery, it was also important to actually building something. The satisfaction and pride of actually building a pocket hole joined table will certainly nurture his love of woodworking more than the frustration of a table that won’t assemble because of miscut tenons.

Just be sure it ends in something like this.

I say this often because I feel it’s important. It is not about how you build something. It’s about that you do building something. Start small and simply. Let your first few projects succeed. Then, once you’ve learned the basics let your interest take you to any style of joinery method you choose.

Or like this. The important thing is to just build.

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Ghetto WorkCenter Boom Arm Part V The Second Video

This second Ghetto WorkCenter video shows the completed WorkCenter. After making the saw tray and boom arm I kept going and moved on to make a tool holder. As I documented in my last post, I made the Tool Holder by coping the V design of the Festool Tool Holders. I made mine of wood and it mounts on the Ghetto WorkCenter. Now I can hang two tools on the WorkCenter while keeping the saw off the ground and the hose out of the choice.

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Bessey Snip Review

A few weeks ago Danette from Bessey mentioned on twitter that she was looking for testers for some new sheet metal tools they’re introducing. I spoke with her about the sheet metal fabrication we do at work and how I like to mix sheet metal into my projects when I can. She was nice enough to send me a set of their new snips for testing.

The new Bessey snips lined up next to my existing snips.
The Besseys are on the right of each pair. Theyre the one that look German.

Out of the box, the snips look great and come with a healthy coat of oil, which ensures that they’re rust free. The handles are well sized and the cutting heads appear to be well machined with micro serrations on some of the blades. This gives a reassuring zipper like feel when cutting.I tested the snips out on some copper, aluminum and steel sheet metal scraps we had in our metal shop. I also gave them to Rich, our lead metal mechanic, for a week of use in the field.We found that in practice the long, straight snips work fantastically. The cut smoothly and straight with an easy mechanical action provided by the snip’s built in mechanical advantage. The Bessey straights are the best straights that I’ve ever used.The right and left offset snips are also good performers, though not quite up to the standard established by the straights. While they cut smoothly and the same mechanical action is evident, I found that the heads of the right and left offset were a bit too big. While I was able to make tight radiused cuts, I could only do so after prying open the metal to allow the head to fit in. In thick materials, this would make using the snips quite difficult.

Bessey to the left, MidWest to the right.
The difference may not look like much, but it does matter in thick materials or tight curves.

In these photos, you can see the difference in head size between the Bessey and an equivalent snip from MidWest Tool & Cutlery (the current snips I have in my tool bag and have been satisfied using). The smaller head means the metal doesn’t need to be bent open as much to allow the snip in.Regardless of head size, the Bessey’s cut quickly and cleanly. I will certainly continue to use them for all but the tightest curved cuts.My mechanic, Rich, was impressed enough that he’s looking to buy a pair for himself. I think think that says all there is to say about the Bessey snips. If you work with sheet metal, they’re definitely worth trying out.

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Ghetto WorkCenter Boom Arm Part IV The Tool Holder

As I was finishing up the boom arm for the Ghetto WorkCenter, it dawned on me that I could also hand a tool holder on it.Festool includes tool holders as part of the WorkCenter. They also sell individual ones that fit on their CT vacuums. I have one of the individual ones. Unfortunately, my CT22 is too old to fit it. I have mine set into a block of wood that I clamp to my bench and BenchMark table. My ultimate plan is to use the Festool Tool Holder as a model to make a cabinet to hold all my sanders. For now, it served as a model to make a Tool Holder to fit on my Saw Tray.

This is how it began.

I began with the same piece of ½” baltic birch Ive made the rest of the Ghetto WorkCenter out of. I began by tracing the V shape of the tool holder onto the plywood. I used a forstner bit to make the rounded bottom of the V. Then I cut out the rest on the bandsaw. My bandsaw cuts weren’t exactly straight, so I used my rasp to flatten them out.

The Vs, fresh off the bandsaw.

After smoothing the sides with a rasp.

Once the V’s were rounded over with the router, it was just a matter of attaching the cleat and spacer so I could hang it on the saw tray.

Im loving my Bosch MRC23EVSK. It has great dust collection & visibility to boot.

The cleat on the left hooks the saw tray and the spacer on the right keeps in basically plumb.

Even with the ½” plywood, it’s working great so far.

She holds like a champ.

I’m not sure if I’ll add more accessories to the Ghetto WorkCenter, but for a little bit of plywood and some cheap fasteners, it’s proving to be a great addition to the shop.

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Ghetto WorkCenter Boom Arm Part II The Video

Earlier in the week, I began my series on my Ghetto WorkCenter Boom Arm. Its my homemade version of a boom arm and platform that fits on the systainers that fit on my vacuum.
I was hoping to finish the description about the Ghetto WorkCenter Boom Arm before I posted the video, but Im down with a cold, so heres the video (its an easy post to write). Ill get back to the construction in my Monday post.

Do you have a boom or hook to keep your vacuum hose out of the choice?

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Ghetto WorkCenter Boom Arm Part I The Platform

As my regular ready knows, I have a track saw. Specifically, it’s the Festool TS55. I’m not of the ilk that think a track saw is a table saw replacement, but I do love the saw and use it often.

A great place to put the TS55, provided it doesnt fall off.

Typically, when I use the TS55 it is to cut sheet goods which are laid out on my BenchMark portable work table. Though it supports sheet goods, dimensional lumber and allows lots of clamping, the open surface of the BenchMark prevent me from putting the saw down on it (plus then the saw would get in the choice of the work piece). Instead, I found myself putting the saw down on it’s systainer which was alchoices sitting atop my CT22 dust extractor and roughly the same height as the BenchMark.Using the TS55 Systainer as a table to rest the TS55 on between cuts proved very convenient, but I was alchoices very nervous of the saw slipping off. While the TS55 is many things, cheap isn’t one of them. Between the electrical cord, vacuum hose and the systainer being attached to a dust extractor on wheels, I figured it was only a matter of time before I tripped over one of the cords or knocked into the dust extractor. Either accident would send the TS55 straight into the concrete of my drivechoice.The fear of pulling or knocking the TS55 to it’s untimely death got me thinking of the Festool WorkCenter Organizer. It’s a neat organizer of shelves and pegboard and tool holders that Festool created to fit on top of their dust extractors. Though Ive not personally used one, the WorkCenter Organizer seems to be a very well designed accessory, based on Paul-Marcel’s review.

The Festool WCR 1000 Workcenter Organizer

Unfortunately, it’s also a nearly $400 accessory. This was not one of the Festool prices I feel is fully worth it. Rather than spend almost as much as a new TS55, I opted to make my own version.The first step would be to make a platform with a raised lip that would both fit snugly on a systainer and also prevent the TS55 (or any other tool on top) from sliding or falling off the side.Building the platform was simple. I started with a scrap of ½” baltic birch plywood. I laid it on top of the systainer and aligned two (2) sides. Then I marked the other two (2) side locations with pencil. I cut the platform out using the TS55.

The platform is just the same size as the systainer (or so I thought)

To make the lip, I cut out stips of ½” baltic birch on the table saw. I used a stop rule to mark out ½” along the length of the strips. Then, using that line as a reference I clamped them to the platform and screwed them in with #8 stainless steel flat head screws. The stainless was necessary, but I like the aesthetics of it.Once the platform was assembled, I tried it out to discover that it was just a hair too small lengthwise. Rather than start over, I simply unscrewed the lip from one end and shimmed with blue tape. After a few test fittings I had it shimmed just enough to hug the top of the systainer snuggly.

Snuggly fit and no choice to slide off

The TS55 fits in the platform wonderfully, and now the only choice I’ll manage to damage the TS55 is if I’m clumsy enough to knock the whole dust extractor / platform / TS55 stack over.Satisfied with the platform, I began to plot out the boom arm.

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A House In The Trees Part XIII

Over the past two (2) weekends Ive been able to get back out to the tree house. Though Ive only been able to get half-days in, I have managed to just about finish the sheathing.

The tree house, as it stood before the last two weekends work.

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This video shows the sheathing of the gable ends, and all the frustration that entailed.

This shorter video shows an easier day of protecting the roof and sheathing the clearstory wall.

The next step will be to install the clearstory windows. The next two (2) weekends are just about spoken for, but hopefully Ill sneak in some window time too.

The sample Kalwall panels Im making the clearstory windows from.

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My Own Treehouse of Horror

This weekend I managed to get some solid, yet frustrating work done on the tree house.

The Treehouse.

Before winter set in I was able to get most of the sheathing done. All except for the gable ends. So, thats where I began.

This first side was a piece of cake.

The first side, the front, went easily. A few quick measurements and a track saw make quick work of accurate cuts, even when a single piece of sheathing tucks beneath both roof angles resulting in a complicated shape.

This piece, it didnt fit so well on the 1st, 2nd or 3rd try.

Alas, on the second piece of the rear side (the 4th of 6 total) I measured correctly and then proceeded to cut the piece incorrectly, and then incorrectly again, and again. Finally on the fourth try, I got it right. It turned out, I was measuring using my 26" square. While the square is dead accurate, its important to reference the measurements on the correct side or else the measurements will be off by the width of the square blade.

Thats a lesson learned & a piece of T1-11 wasted. Hopefully its now back to accurate cutting.

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The Woodworking Shows Are Back!

This year the Woodworking Shows are under new ownership with renewed energy, enthusiasm and excitement.

Every year the Woodworking Shows visit my neck of the woods when they stop in Somerset, NJ. Ive attended almost every show there for the last decade. In that time the quality of the show has moved decidedly downhill, the number and quality of the vendors has shrunken and it has gone from a full day to a few hour affair.

2 years ago, Andy and I were able to hang out and talk chair making.

There was a highlight two (2) years ago when Andy Chidwick traveled with the show, giving lectures and generally spreading woodworking enthusiasm. Even then the atmosphere was less than exciting though.

This year, under their new management, the Woodworking Shows have rebounded and are well on the choice to their former glory. Andy is back teaching about design and his wonderful sculpted woodworking. Jim Heavey, Paul Sellers, Roland Johnson, The Crazy Canadian and others are packing the lecture spaces also. Woodworkers are excited to attend and partake.

Where else can you see a cool bench like this, other than the Woodworking Shows.

There seemed to also be more vendors this year, and the vendors seem to be of higher quality. Companies like Woodpeckers, Arbortech and Clear Vue Cyclones were worth attendance alone.

The sense that I, and that the other attendees I spoke with, had is that the shows are back. The energy, enthusiasm and excitement are returning. The fun day of woodworking education, tool test drives and comradery is here again.

If you see this trailer, go in and check it out.

If the Woodworking Shows can maintain this return to form, next year will be a must attend. Check their calendar and see when theyll be near you. Itll be a worthwhile day.

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Sabtu, 13 Februari 2016

Ghetto WorkCenter Boom Arm Part III The Boom Arm

As much as I love my TS55, I find keeping the vacuum hose clear of hangups to be the most challenging part of using it. Don’t get me wrong, I wouldn’t use the TS55 without the vacuum hose. It does a great job of capturing what I’d estimate to be about 85% of the dust.My old setup was to simply velcro the power cord to the vacuum hose. This meant there was effectively only one (1) tether being dragged by the saw, but in practice I have continually caught the hose on the side guards of my BenchMark Table, on the workpiece or on the track..

It cuts wonderfully, when the hose isnt getting caught.

My first attempt to remedy this issue was with the purchase of the Festool Guide Rail Deflector. The Guide Rail Deflector is a plastic piece that fits to the end of the Festool Guide Rail. It’s designed to prevent the hose and cord from getting caught up on the end of the guide rail. Unfortunately, it doesn’t keep the hose and cord on the rail, so they still fell to the side and caught on the BenchMark Table’s side guards and the piece being cut.The solution to keeping the hose out of the choice is a boom arm. I know from my previously built wall mounted boom arm, that they work wonderfully at keeping hoses and cords out of the choice. Unfortunately, the boom arm that Festool makes costs a bit over $300.00. For a short hose, a short extension cord and some steel tubing, that strikes me as much more than I’m willing to pay.

Looks as good a place as any to mount a boom arm.

Once I’d built the TS55 tray, it dawned on me that if I made a boom arm to fit on it I’d finally have my hose and cord out of the choice.

A simple boom arm.

I made the boom arm using scrap ½” baltic birch plywood. The pieces simply lap each other and are fastened with ¾” flat head screws. The arm attached to the support mast with small butt hinges. The hose is attached to the arm with small I-bolts, springs and plastic ties. Thanks to a suggestion by Chris Wong of Flair Woodworks, the hose will soon be attached via Wrap-N-Straps from Lee Valley.

The springs allow plenty of give in the hose.

To mount the boom arm to the saw tray, I attached a small hook to the back of the mast. It was notched so that it caught the side of the tray and prevented the boom mast from moving side to side. I then added a second hook that caught the inside of the lip on the tray. So that the mast would stand vertically, I added a spacer block at the bottom. It holds the bottom of the boom off the systainers the same ½” as the lip around the tray.

The initial hook allowed too much wobble.

While the initial hooks worked, I found that the mast and attached boom wobbled a bit more than I was comfortable with. I took off the initial second hook and replaced it with one the full width of the tray. Now the boom arm is rock solid.

The new hook is the full width of the tray for much more stability.

The completed boom arm holds the vacuum hose out of the choice during use. No more getting caught up half choice through a cut. It also mounts on and off the saw tray in moments.

The completed boom arm on the saw tray.

Now that my saw can no longer slide off the systainers, and the vacuum hose it up and out of the choice, what to do about the sanders?

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