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Rabu, 23 Maret 2016

Dads Benchtop Bench Part I

A few weeks ago, I wrote of how cool some Benchtop Benches are. After contemplating buying the Sjoberg Smart Vise for him, I instead opted to build a Jeff Miller style Benchtop Bench for my Dad for Fathers day.
Jeff Millers Benchtop Bench from FineWoodworking.com
As might be expected of me, I began by milling the legs out of Timerstrand. One of the nice things about Timberstrand is that they come almost perfectly flat. They’re also easy to mill. A few passes over the jointer and through the planer left them ready for joinery.
Timberstrand mills just fine.
Rather than use the traditional tenons that Miller used on his original, I used Dominos (no suprise to a regular reader. I glued the tops and bottoms to the legs. It was my intention to bolt the front and back stretchers as Miller did, using unglued Dominos rather than his staunch tenons. I say it was intention, because as with many good intentions, this fell to the choiceside once I had the Domino and glue in hand. The stretchers are not permanently glued to the legs.
Miller centered his stretchers on his legs, resulting in their being set back slightly from the face of the legs. As it was easier, I simply jointed my stretchers flush with the face of the legs.
The leg assemblies.
I glued the leg assembly in two (2) steps. First I glued the top and bottoms to the legs. Then I glued the leg assemblies to the stretchers. As soon as they were glued up, I put the whole thing on my table saw as a flat reference surface. There was some twist to bench base, so while the glue was still wet I added an extra clamp diagonally across them to try to pull the twist out.
The stretchers glues in and the diagonal clamp to minimize racking.
Once the leg assembly was in clamps, I began on the top and vise.
The top is made of the finger jointed mystery wood panels you can get from the home centers. I laminated four of the panels together (3/4” each to make a 3” slab) about a year ago as an experimental benchtop. The whole thing was about 6’ long and had an awful twist to it.
To make the benchtop bench top, I cut a 24” length off the end of the home center panel experiment. With a few passes through the planer, this smaller length flattened out quickly and ended up just under 3” thick.
The benchtop on the legs.
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Rabu, 16 Maret 2016

Dads Benchtop Bench Part III

With the vise nuts installed and the bench milled to accept the vise, it was time to work on the outer jaw.
The benchtop, ready for the vise.
Miller’s original features a 45° bevel on the top, outside face of the outer vise jaw. I’ve seen the bevel before on many Moxon Vises. It provides clearance to hold a saw and chisel at an angle. To cut my bevel, I eyed about how big I thought it should be, set my table saw to 45° and cut achoice.
Unfortunately, Once I put the vise jaw in place, I quickly realized that the big bevel I’d cut did not leave enough flat surface on the top for a bench dog hole. Rather than have the awkward hole which would have resulted, I flipped the front vise jaw around, and cut a much smaller bevel on the new top edge. This left the big bevel on the bottom, which I’ve grown to like the look of.
If Id left the big bevel on the top, I wouldnt have been able to drill (route) for dog.
To attach the vise I took the back jaw of the vise and set it upside down on my table saw. I also set the bench top upside down on my table saw. I used the saw as a reference surface to ensure that they were aligned, and then I clamped them together with parallel clamps. To fasten them, I simply used screws. I pre-drilled the holes and staggered the pattern to prevent splitting.
Fastening the rear vise jaw.
I installed the legs in a similar manner. I held them in place with parallel clamps and then screwed them to the top. Since the legs were slightly out of square, I was sure they were clamped extra tight to the top before I screwed them on.
Once I took the clamps off and flipped the bench over, I found that that screwing the legs to the perfectly flat 3” thick top was all it took to pull them into alignment. The feet sit perfectly flat on my tablesaw.
All that was left was to assembly the vise.Read More..

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Kamis, 10 Maret 2016

Dads Benchtop Bench Part II

Once I had finished the legs and had milled the top, I made the twin screw vise out of a big hunk of oak Kari Hultman gave me. It was about 10/4 to begin with, and after all of it’s milling, the vise was still a heavy 8/4. This was a bit thicker than Miller’s plans from Fine Woodworking, but I figured giving up 1/2 of vise capacity wasn’t worth the extra work of planing off 1/4” from each jaw.
Assembling the legs to the top.
The milled vise jaws.
With the vise jaws milled, I then set out to drill the vise screw holes and make the mortises to countersink the vise screw nuts. I used Miller’s side to side spacing to determine the screw location, making sure that they were clear of the legs before committing (I had made the width of my legs slightly wider than Miller’s. The screws are simply centered, top to bottom.
With the vise screw locations marked on one (1) of the jaws, I set them on top of each other on my drill press. I used an 1/8” bit to drill through the entire upper jaw and about half the lower jaw (I ran out of bit length). These 1/8” holes served as center guides for the larger bits I would use to make clearance for the vise screw (about 5/8”) and the vise screw nut (about 1-1/4”).
Drilling the pilot holes for the vise screws.
After checking that the vise screws fit in their holes, I set the vise screw nuts in their holes. I traced around their flanges and pulled them out.
Then I used my DeWalt DWP611 with an 1/8” upcut spiral bit to route out for the screw flanges. To set the depth, I set the router on my bench and brought the bit down to the bench. Then I loosened the depth guide and slid the flange between the top and the turret. I then tightened the stop and pulled the flange out. By lowering the router until the stop hit the turret, I had set the depth exactly as deep as the flange.
Plenty of clearance.
I then simply routed free hand. To ensure that the flanges fit, I made sure to go outside the lines which were drawn tight.
Too proud.
When I installed the vise screw nuts, I found that they fit perfectly within the routed out areas. I also found that they stuck out proud of the inside face of the vise jaw. I had to remove them and cut off the excess with a grinder in order to fit them properly.
Being shamed into fitting.
With the vise nuts installed, I assembled the vise by inserting the vise screws through the front jaw into the rear jaw and snugging them up. Then I laid the vise in place, letting the screw threads rest on the underside of the benchtop. I marked the screw locations with a pencil and took out the DWP611 again.
I actually routed the nut clearance first.
I used the router freehand to remove a clearance hole for the screw threads and I relieved a small amount on the edge to give just a little extra clearance for the back of the vise nuts.
Ready to receive the screw.
With the benchtop milled to accept the vise, I went back to complete the front jaw.
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Rabu, 09 Maret 2016

The MWA Gets By With A Little Help From Our Friends At Woodtalk Show

Wood Talk did the Modern Woodworkers Association a big favor by helping to promote the MWA teams for the Fine Woodworking Live Build Off.
Yep, these guys want the online community to rock.
I trust that if youre following the +Modern Woodworkers Association you already know who the Wood Talk guys are. If not, be sure to check them out. Youll be glad you did.
In their most recent episode, #141 - Quality Control Is Boring!, Marc mentioned our build off.
Like us, they want to demonstrate how thriving the online woodworking community is. Were looking to show everyone by assembling a number of four (4) person teams for the Fine Woodworking Live Build Off. Our goal is to not only have online woodworkers win, but to have them play a major role in the build off so that everyone in attendance at Fine Woodworking Live learns of the community and the fun we have.
If youll be at Fine Woodworking Live on Friday Night, August 9th, please joing us for the build off. You can sign up below. Youll make some furniture, meet some friends and have some fun.
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Selasa, 16 Februari 2016

Dads Benchtop Bench Part IV

Im almost done with the story of the Benchtop Bench. Before I get to the final trial of the vise, heres my video which describes the completed bench.
I apologize for the portrait video format. I rested my phone on my miter saw to take the video, and it didnt occur to me until I was watching what Id recorded that it should have been laid in landscape mode.
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Dads Benchtop Bench Part V

With the bench built, all that was left was to screw in the two veneer press screws which held on the front vise jaw.
The completed benchtop bench.
While they fit fine, I unfortunately found that once I tightened them, the handles came off the screw shaft. It seemed that since they were meant to exert pressure between the vise nut and the end of the screw shaft, Shop Fox hadnt bothered to attach the handles with anything more than friction.
Nope. That handle wasnt meant to exert clamping pressure.
While the discovery of this issue after I thought I was done did give me pause, I thought about it for a night and by morning I’d come up with a solution.
The pins and drill bits. I only needed 2. I bought 4 just in case.
Locked and ready to drill.
I headed down to the hardware store and picked up some metal pins. After drilling through the handle and screw shaft with my drill press, the pins were easy to knock in with a hammer.
Locked and ready for action.
Once the handles were pinned on, the vise worked great.
Clamping like a champ.
I’m very happy with the choice the benchtop bench came out, and my Dad appreciated it as a father’s day gift.
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Sabtu, 13 Februari 2016

MWA Podcast 35 Bob Lang

MWA Podcast Episode 35 - Bob Lang of Popular Woodworking

MWA Podcast Episode 35 - Robert Lang (58:16)

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Selasa, 09 Februari 2016

The Woodchat Telephone Game Part I The Game

Chris, Matt and Scott, the three (3) woodworking super nerds who run +Woodchat,  the weekly woodworking discussion on Twitter and Google+ are currently in the middle of their telephone design game. In the words of +Chris Wong:
You know what the Telephone Game is, right?  One person starts by whispering a phrase into the next person’s ear and that person whispers what they heard to the next person and this continues down the line.  By the time the phrase passes through all the players, it is totally different. 
Wouldn’t it be fun to try something like that with furniture design?
They decided to find out.
Since May 29th they have been passing the design from participant to participant with each one having a week to make their changes to the previous design. I was lucky enough to be invited to participate and foolish enough to accept.
I tried to follow the structure of a Telephone Game and I only focused on the previous version (+Megan Fitzpatrick’s) when I was making my design. It proved to be a challenging and enjoyable process.
My Telephone Design Game design.
I’ll elaborate on how I came upon the design I did in a separate post. In the meantime, be sure to follow along every Wednesday at 10:00 Eastern to see that week’s contestant share and discuss his or her design. If you’re up to it, you can even sign up to participate. You’ll have fun if you do.
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Kamis, 04 Februari 2016

Woodchat Telephone Design Game Part II The Design

The Woodchat Telephone Design Game works like any telephone game. Each participant takes something from the previous participate, make intentional or unintentional changes and then passes it along to the next participant. Instead of using silly phrases, +Woodchat is using a furniture design.
The design started with this piece by +Chris Wong of Flair Woodworks.
Chris Wongs Telephone Design Game Design.
The design version before mine (design version #6) was by +Megan Fitzpatrick. This was her design.
Megan Fitzpatricks Telephone Design Game Design.
I really liked the center, lowered section of what I’ll call the desk surface (though to be true to the Telephone Design Game guidelines, it should only be called furniture). I felt this really complimented the curved legs and the cloud lifted stretchers.
My least favorite part of the previous design was the hard edge along the outside of the desk surface. I felt that the juxtaposition of this hard edge against the soft curves of the lowered center and stretchers left the piece unsettled. The outside edge was the first design component I changed.
Wanting to tie curves of the desk surface, legs and stretchers together, I eliminated the hard outside edge and instead worked to sculpted the top surface around and into the legs. I felt this brought a more harmonious composition to the design.
I carried that curve down the leg, following the same splay which was in the previous design. At the bottom of the legs I felt the cloud lifted stretchers tied in nicely. At the top the stretchers seemed awkward and unnecessary against my new curved and flared leg to top joint. I removed the top stretchers.
Next, I tried to flair the vertical ornamentation which ran between the stretchers in the previous design. I tried this a few times, and each time the flared transition into the stretcher was big and awkward. I finally decided to eliminate the the vertical ornamentation and leave the desk in what I felt was a cleaner state. Sometimes the absence of material is just as important to a design as the presence of material.
I’m happy with the choice the desk came out. While I didnt initially have too much attachment to the design, after discussing it on Woodchat last week it has grown on me. While I can’t say it’ll be soon, I think I’d like to make this desk some day.Read More..

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My Telephone Design Game Design.