I took today easy. It was warm enough to work in the shop, but sometimes it is nice to take it easy.
This morning I headed to the Griswold Flea Market. I had time between the boys leaving to go to their mother’s house and when I had to be at Ben’s soccer game (which they lost 5-0, so they are getting better).
I found a 3/8″ socket chisel for $1. It was in good shape, just missing a handle. I also picked up another 1/2″ socket chisel (with handle) for $5.
This afternoon I broke out the waterstones and had a sharpening session. It took no more than 10-minutes to flatten the back and sharpen the new chisels. I also took the opportunity to grind one of my previous flea market finds (a 1/2″ chisel) into a dovetail chisel. I ground a bevel on the sides of the chisel to allow me to clean out dovetails.
This evening I turned a handle for the socket chisel. I cut a small piece of red oak, and turned it on the lathe. I need to take a class on turning. I suck. However, sandpaper can correct a lot of things. I applied paste wax and hammered the handle into the socket. A perfect fit.
I finished the first nightstand this week. Okay, I completed everything except the finish. I’m planning on building the second table and then applying finish to both.
Overall, the table turned out okay. It isn’t perfect, but looks nice. The drawer is still a touch tight, so I may plane the sides a touch thinner before applying the finish.
This is a pretty basic piece of furniture. The four legs are square, with a slight taper starting 6-inches from the top. The aprons and stretchers are connected using mortises and tenons. The top was constructed from thee pieces of oak, and attached using screws.
The drawer is made from solid oak. The box is constructed with dovetails. They are hand-cut dovetails, and it was my first attempt at making a drawer, so the dovetails aren’t perfect. The bottom is made from two pieces of oak that I resawed (by hand – they were too wide for the bandsaw) to 3/8″ thick.
What am I happy with on this build:
The wood is clear and the case looks nice. It is built from quartersawn red oak that I had cut from a tree that was taken down in Ledyard two years ago. I have an entire section of the tree cut into boards, so I have enough wood to make a full matching bedroom set.
The solid drawer bottoms – I debated using plywood, but I like the feel of the solid bottom. The panel is aligned so that the wood will expand and contract from front to back (and shouldn’t bind the drawer in the summer)
Most of the joinery is pretty clean. Not perfect, but it is getting better.
The drawer front is a good fit. I’m hoping that there is enough gap that the drawer won’t bind in the summer, but it is quartersawn and shouldn’t move too much.
What will I do differently on the next build:
I messed up the mortise for the bottom rail. It isn’t inset enough (the front of the mortise is lined up with the front of the rail). There is a slight gap and no front shoulder on the corresponding tenon. I’ll need to set the mortise back 1/8″ on the next build
I will try routing the mortises on the router table. I don’t have the best mortise chisel for 1/4″ mortises. I think the router table may be quicker to get all the mortises finished. But I am not sure if I can get the full depth of mortise on the router table. The current mortises are 1″ deep.
I’ll be more careful on the thickness of the spacers to guide the drawer. On this project they were a little too thick which requires me to plane the sides of the drawers a little thinner (and leaves a little larger gap around the drawers than I wanted).
I need to be more careful making sure that the drawer front and sides are flush on the bottom.
I would like to have the dovetails be cleaner right off the saw. I know that just comes with practice.
The half-blind dovetails were tough to get clean.
I need a better bench to cut joinery on.
I need a better way to hold the piece down when I’m cleaning out the dovetails.
I never properly sharpened my skew chisels. That (and the previous comment) made for a bigger pain cleaning out the half-blind dovetails than they should have been. A dovetail chisel would be a nice addition to the toolbox.
Nightstand after glue-up. The top is just resting on the base. An initial coat of shellac has been applied to the table.
I’m making progress on the night stand. I took some vacation time yesterday afternoon to meet the boys off the bus. I was able to get the first table glued before I took Ben to basketball camp. It isn’t perfect, but I feel pretty good about the construction.
Today I applied shellac to the base and top. I wound up making the top a little narrower (I had planned 20″ wide and wound up with 18″ wide). When I put the top on the base, it seemed a bit wide. Susanna agreed with me, and it took 30 seconds to run the top across the table saw and remove the 2-inches.
Tonight I glued in the cleats to attach the top as well as the runner for the drawer. Tomorrow I will attach the top and make sure the project is cleaned up and ready for the drawer to be built.
I’ll probably build the second table before building the drawers, but that is always open for change.
I also haven’t decided on a final finish for the tables. I may get some more water-based finish to spray on, or I may just use a wiping varnish. I’m leaning towards the spray finish – it will offer a little more protection than just the wipe on varnish. I have wiping varnish on hand, but I would have to go purchase more water-based finish to spray. Luckily, I don’t have to decide right away. The shellac will offer a little protection until I put a real finish on it, and they don’t need to be ready until Christmas anyway.
The top rail dovetailed into the leg. I could do a better job on the joint – hopefully the next one will be cleaner (good thing you can’t see this when the table is finished)
This week I found some time to work on the nightstands. I have material milled for both stands, but focused on putting together the first stand. Will came over for dinner on Tuesday night, and for the night on Wednesday, so I had a little less time than I had planned – but it is worth taking time from the workshop to spend with him. But I also did get workshop time both nights (a big thank you to Susanna for encouraging me to get out of the house and work on my projects).
I was able to get the carcase of the first table assembled. I still have to adjust one tenon and clean up two of the aprons prior to gluing up, but I should be able to glue up the carcase the next time I’m in the workshop.
The tables are made from red oak. I cut the mortises by drilling out the waste on the drill press and using a chisel to clean them out. I could use a good 1/4″ mortise chisel – that will be on my Christmas list (I’d love a 1/4″ English Mortise Chisel by Ray Ilse from toolsforworkingwood.com). The tenons were cut by hand. I did the first several using my dovetail saw – but the saw is for detail work and took forever to cut the tenons. The last two I cut using my carcase saw (an old backsaw sharpened by Matt Cianci – “The SawWright”). If you have any old handsaws that you need sharpened, I would highly recommend him. He is backlogged, and it takes 10-12 weeks, but a professionally sharpened handsaw is amazing to use.
Table carcase assembled
The next step is to glue up the table and add the cleats/runners. Then I have to finish milling, glue up and add the top. Finally, I will have to mill the lumber for the drawer and build the drawer. I’m still a little nervous about cutting the dovetails for the drawers.
I plan on trying to route out the mortises on the next table using a 1/4″ upcut spiral router bit I just purchased. I’ll let you know how that works out. I am not sure I can get the full 1″ depth of mortise on the router table. I may have to clean out the tenons with a chisel – so it may not save me much time on construction.
Today I continued milling lumber for the nightstands. I cut out pieces for the top and aprons. All the pieces were milled down to 1″ thick – when I am ready to use the pieces, I will mill them the rest of the way.
The lumber for the nightstands. I will mill the lumber for the drawers after the tables are built.
Next I marked out the mortises on the four legs. I double checked the placement. I only have one spare leg if I mess these up. I am using the drill press to remove most of the material for the mortises. The mortises are 1/4″ wide, 1″ deep, and 3 1/2″ long.
The leg after the drill press. The remainder of the wood in the mortise will be removed by chisel.
I was able to complete half of the large mortises on the legs tonight (for one of the tables). After cutting out the mortises, I will taper the legs on the bandsaw (using a hand plane to smooth the cut).
Completed mortise. I will cut the tenons on the table saw and individually fit them to the mortises.
Also, this is my 300th post on this blog in just under 3 years of writing.
Tonight I was able to start milling the lumber for the nightstands. I marked out the rough lumber for the legs and cut them to rough length (about an inch longer than the finished size of the legs). I do the rough cuts with a hand saw on my saw bench. I think it is much easier (and more pleasant) to use the hand saw to cut them to length.
After cutting the boards to length I began the milling process on the legs. The first step to milling the boards is to take a face of the board and make it flat. The boards don’t dry perfectly flat, but these boards are pretty close.
After getting the first face flat, I will turn the boards on the side and get one edge square (90-degrees) to the flat face. Flattening a face and squaring an edge is done on the jointer. If the boards were wider than the jointer, I would have to flatten a face using a hand plane – but I’m not sure I’m ready for that (and luckily I didn’t pull out any lumber for this project that is wider than the jointer (8-inches).
The second step is to mill the boards to thickness. However, the rough boards are almost 3-inches square, and the final dimensions will be under 2-inches thick. I am concerned that the boards may cup slightly when I remove that much lumber. So, tonight I just milled the boards to 2-inches square. I will let the boards sit for a couple of days and then re-flatten and square them before planning them to the final thickness. I use the planer to get the boards to the desired thickness. If these boards were flat (instead of square for the legs), I would then rip them to width on the table saw. I just get these square using the planer.
Tomorrow I will start milling the boards for the top and aprons. It is nice to work with clear, dry lumber. The last couple of outside projects used wet oak and maple which is terrible to mill.
A group of the lets after the initial milling. I will mill up 9 legs (4 per table, plus one spare)My shop assistant.
Although the workshop reorganization isn’t totally complete – the workshop is looking pretty good. And since, I don’t want to only spend time cleaning and organizing the shop, I started the next woodworking project today. And yes, part of it is because it is more fun to start projects than finish them. But I plan on trying to keep putting away and sorting out the workshop as I build this project.
I am starting to build two nightstands for the boys (one each to start with). I started with a classic shaker side table plan from Fine Woodworking, and modified the design. The tables will be a little narrower than was in the magazine.
The fist step was to take the plan and make a story stick with the appropriate measurements. That way I don’t have to use a tape measure and risk cutting things to the wrong size. I just have to take the story stick and mark out each part. The story stick was a scrap piece of oak I had in the workshop.
Marking out the boards – making sure to remove an inch or two at the ends of each rough board. This is some 2″ square boards for the legs
The two tables will be made from red oak. If they turn out nice, I will make another pair out of cherry for our bedroom. After marking out the dimensions, I made an estimate of how much wood I would need and headed out to the barn to pick out wood. I am using a tree that I had cut into boards a couple of years ago. The lumber is beautiful. It is clear and the boards are thick (probably 1 1/4″ thick each for the thin boards) – so it should be no problem getting nice wood for the project. There is enough lumber from that tree to make several more matching pieces of furniture for the boys.
Of course the lumber was on the bottom of the stack in the garage. I had to unstack the pile, pull the lumber I needed out, and then re-stack the pile. I think Tucker was the only one that enjoyed that part of the project – I uncovered a mouse nest which is endless fun for a beagle to dig through.
After getting the lumber out I started marking out the boards. The next step is to cut the boards to rough size. This will allow me to easily mill the boards (it sucks to try to mill a 10-foot long board), and I can plan out the nicest looking pieces for the most visible parts.
A couple of things that will be a challenge for this project:
Each table will have a drawer. I haven’t built drawers before, and will plan on hand dovetailing the drawers.
I will attempt to resaw the sides of the drawers (they only need to be 1/2-inch thick). If I can’t do the cut on the bandsaw, I will try to resaw by hand. It is a waste to use the planer to take a 5/4 board down to 1/2-inch thick.
The legs will be tapered. I haven’t figured out how I will taper them yet. The magazine shows a jig for the tablesaw. I’m thinking I will either taper them on the jointer or use the bandsaw (followed by a hand plane).
A couple passes of a hand plane expose the nice straight grain in these boards.
Today wa a chore day. The boys had friends over and, for the most part, spent the day playing rather than fighting. I spent time organizing the garage as well as the wood pile under the workshop. The chilly morning encouraged me to install all but two of the storm windows.
After morning chores, I spent time picking up and organizing the workshop. I have most of the bigger power tools where I want them (or at least where I think I want them). I have as much of the floor put down as I have lumber for right now. Now it is time to clean up and find a home for everything. It helps me keep somewhat organized if everything has a place. Not that I always put things back in their places. Actually, it is a challenge to keep any space organized. But having a home for everything helps.
I added a small “desk” in the corner. I’m not sure I’ll use it too often, but I like the look. It is just a deep shelf at desk height, nothing complicated. But it will give me a place to plan projects. At least in theory. I’m sure I’ll mostly plan projects sitting on the couch in the living room. I’ll also now have a place to put the chair when it isn’t in use.
I am nice and tired tonight. So are the boys. And the dogs. Back to work tomorrow. At least it is a short work week.
New desk height shelf in the corner of the workshop. Under the 10,000 woodworking books/magazines I have.
Back of the workshop with the new floor and walls.
I am rearranging the workshop. Again (or rather, still – if you read my post from last week). I am making slow progress on the project, but am getting to the point where the workshop is getting back to almost usable.
I have enough of the floor installed to have most of the heavy tools back where they belong. The next project is to go through the pile of way too much stuff that I moved from the back of the workshop to the front. Hopefully I can find homes for everything, and maybe even find a way to get rid of some of the stuff.
I am only insulating the bottom half of the walls. In public, I would say that I am only insulating the bottom to preserve the look of the old walls. But, just between you and me, I am pretty lazy. It would be a lot more work to do the upper half of the walls (all the electrical wiring is run on the upper half of the walls). Maybe next year if I am inspired to insulate the rest of the space. I’ll see how bad it is to heat this winter.
Cutting down the door to the workshop loft – the door needed an inch taken off the bottom to accommodate the new floor). Photo by Ben Curtis
The new layout certainly opens up space in the back of the workshop. I used to have the workbench out from the wall, which made it a little cramped between the workbench and the outfeed table of the table saw. I also had all the hand tools on the side wall, which meant always walking away from the bench to get tools I needed. The tools are all hanging (or will be hanging) on the back wall, over the workbench.
Maybe I’ll build a new outfeed table, and some nice shelves for all the woodworking books I have (that are sitting in a pile in the front of the workshop). I’ll see what I feel like attacking once the shop is cleaned up. Maybe I’ll just reorganize the shop again. It would be so easy to just turn into one of those people whose only connection to woodworking is reading magazines, rearranging the workshop, and periodically building shop furniture.
Ignore the pictures. The workshop is still a disaster. But an improving disaster. To keep the rest of the family busy, I arranged playdates for everyone. Will had Shane over. Ben had Slater over. Susanna got to babysit Michael. Targa and Tucker, well, life is just one big playdate for a dog. My playdate was with a bunch of air-dried pine 1×10’s and a hand saw (not to forget the cordless drill).
The gang hanging out for the day. I took a break from the joy of hand-sawing lumber long enough to snap the picture. I tried to get Tucker to take the picture, but he kept cutting everyone’s heads off, and getting the camera wet.
Taking a snack break with the boys while out bicycling earlier this month
I haven’t found much to blog about this month. It isn’t that I have been bored. I have been very busy. But I think I’m still working on getting used to the fall routine. I have to keep reminding myself that writing is a good way to focus on things at home. It gives me motivation to finish projects. It is certainly fun in an ADHD way to start projects. But it is no fun to only blog about starting projects. It is much more fun to write about finishing projects.
I decided to do a little more than just clean the workshop. I am doing a reorganization of the entire shop, and adding a new floor (just rough pine 1×10 boards on top of the existing floor). I moved my workbench to the back wall, under the window. I will move the table saw back a foot or two to allow for more room when cutting long boards. So far about 1/3 of the floor is installed. I’m also adding insulation around the bottom half of the walls. Pictures will follow when the workshop no longer looks like an example of typical ADHD organization (or a 10-year old’s room). Really, I will get it organized. It will just take some time.
I haven’t finished too many of the house projects that are still hanging out there. So, they are still sitting out there. But at least they aren’t in the way. I have been focusing on getting the workshop finished. I think the workshop had been enough of a mess after building the chicken coop, that I figured I might as well just do the walls and floor now. Nothing is as much fun as starting a new project. The trick is to finish them. Or at least mostly finish them. A workshop is never really finished.
Maybe this week I’ll find enough focus to finish the workshop and maybe even one of the smaller projects hanging out around the house. I’d be happy with just getting the workshop back to a usable space.
