April 2007 Volume 18 No. 4 Fransçois Blanchet Harpsichord a novice approach to guitar making U IL D E G OF TH W IRE OO SH D P W O M R

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Founded 1990 www.gnhw.org The Newsletter of the Guild of New Hampshire Woodworkers

woodturning chisels you can make • zen & the art of woodworking • housed dovetails clean rails & stiles • bevel edged bench chisels • indoor air quality square peg in a round hole • hats off to the guild

photos by Jim Seroskie

Apr 7 BIG Apr 14 Small Meetings … New Date – p3 Apr 21 Guild Meeting … Nottingham, NH – p3 May 12 Period Furniture May 26 GSWT Jun 2 BIG Jun 16 Summer Trip Jul 28 GSWT Aug 4-12 NH Craftsmen’s Fair Sept 22 Annual Meeting

Harvey Best details how he restored a badly damaged antique Georgian Oak Table Restoration president’s message by Dave Anderson 

Change is the Only Constant

ike most other things in life, the member to take on the job of Sunapee to view the wares Lonly constant in the Guild is change. Wood Week Coordinator. Wendy being displayed This will be your second issue ofThe Old Mullett has accepted the job and I’m and sold by the Saw that has increased in size from 32 sure that all of you will be hearing from juried members to 36 pages. Just think, only a few years her over the next few months. Wendy of the League. ago our newsletter was 8-10 pages, all brings to the job years of experience During this event, the Guild staffs a black and white and occasionally had an in coordinating trade shows for the 20 foot by 40 foot tent. The event is insert with some pictures. Things have old Digital Equipment Corp. To our chance to interact with the public, sure come a long way to today’s full describe her professional background as showcase our skills, recruit new members, color mini-magazine. serendipitous to the Guild’s need is a bit and put ourselves in the public eye. Brian Sargent has submitted of an understatement. We sell raffle tickets for prizes made his resignation as Small Meetings I was slightly taken aback a few and donated by our members. This is our Coordinator citing other demands on months ago during a discussion about most important fund raiser for the Guild his time and his belief that there is a Sunapee with one of our members. We scholarship fund. Guild representatives need for someone with a fresh approach were talking about why so few members sell the tickets, answer questions about and ideas. I would like to publicly thank volunteer and his response was a request the Guild and act as ambassadors to Brian for the five years he has served for an explanation of – “What exactly is the public. Elsewhere in the tent, there as the person who makes the October Sunapee?” For those of you who don’t are normally two to three lathes with and March meeting work. If any guild know or aren’t really sure, what follows members demonstrating both faceplate member is interested in getting involved is an explanation. and spindle turning all day – each day. with coordinating and helping to chose Each year starting on the first In other sections of the tent, carvers will the topics for our small meetings, they Saturday in August and running for be working, someone might be making should either email, call, or approach nine days, the League of NH Craftsmen a dovetailed box, a Nantucket basket me at a meeting. This is an opportunity holds its annual craft fair on the grounds might be woven or a piece of furniture to have a voice in what programs are of Mount Sunapee State Park at the ski could be taking shape. offered in the future. area. This event draws between 20,000 The variety of skills displayed over the A few weeks ago, I was gratified and 30,000 people from all over New nine days is broad and limited only by to have a response to my appeal for a England and other areas of the country Continued on Page 13

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President Dave Anderson 603-887-6267 [email protected] • Vice President David Frechette 802-633-2561 [email protected] Scholarship Committee Secretary Greg Benulis 978-314-5815 [email protected] Selection Committee John McAlevey 207-372-6455 [email protected] Treasurer Peter James 603-435-8133 [email protected] Selection Committee Peter Breu 603-647-2327 [email protected] At Large Peter Breu 603-647-2327 [email protected] Selection Committee Jack Grube 603-432-4060 [email protected] At Large Jack Grube 603-432-4060 [email protected] Member Peter Bloch 603-526-6152 [email protected] At Large Jon Siegel 603-768-5882 [email protected] Member Bob Jarrett 978-456-3928 [email protected] At Large George Saridakis 978 549-1807 [email protected] — Please send all applications to John McAlevey, Selection Committee Chair At Large Bob LaCivita 603-942-1240 [email protected] At Large Andy Young 603-672-9558 [email protected] Volunteer Positions At Large Caleb Dietrich 603-556-1629 [email protected] Books Tony Immorlica 603-673-9629 [email protected] At Large John Whiteside 603-679-5443 [email protected] Membership DJ Delorie 603-463-5996 [email protected] Old Saw Editor Jim Seroskie 603-673-2123 [email protected] Old Saw Mailing Syd Lorandeau 603-542-5295 slorandeau@verizon. net Past President Roger Myers 603-773-9634 [email protected] Shirts/Hats Peter James 603-435-8133 [email protected] Programs Sal Morgani 603-772-1006 [email protected] Small Meetings Open Position Sunapee Fair Coordinator Wendy Mullett 603-332-1039 [email protected] SubGroups Sunapee Raffle Coordinator Jim Dimick 603-228-1131 [email protected] BIG Bob LaCivita 603-942-1240 [email protected] Video Librarian John Pitrone 603-894-5893 [email protected] GSWT Jon Siegel 603-768-5882 [email protected] Video Recording Peter Bloch 603-526-6152 [email protected] Period Furniture John Whiteside 603-679-5443 [email protected] Web Master DJ Delorie 603-463-5996 [email protected]

The Guild of New Hampshire Woodworkers – Bringing together the diverse interests of the New Hampshire woodworking community. “The Old Saw” is published five times per year. To join the Guild, go towww.gnhw.org and click on “Membership “ to download an application form. announcements 

st April 21 , 2007 – 9:30 am From Concord Route 4 East, to route 152 East, approximately 5 April Guild Meeting miles on the left. From Exeter at Renaissance Strings workshop in Nottingham, NH Route 101 West to exit 7 onto route he next Guild meeting will instruments like violins are made? If you have, then 125 North, to be held on April 21st at you don’t want to miss this meeting. route 152 West, TRenaissance Strings, the workshop Jim Robertson has been a woodworker by trade approximately 5 of Jim Robertson in Nottingham. for over 20 years. He started his violin making studies miles on the right. The regular session will be from in 1995. Formal training began in 1999 at the Violin From Manchester 9:30 am to 12:00 pm followed by Craftsman Institute under Master Violin Maker Route 101 East to exit 5, go right one hour for lunch. Jim will then Karl Roy. Jim is the assistant to Karl at the Violin onto route 102, take a left onto give his presentation from 1:00 pm Craftsmanship Institute, and dedicates the remainder route 27. Take the next right to 3:00 pm. Please remember to of his time to making and repairing bowed instruments. onto route 156 to the end where bring your own chair and lunch. In his spare time, he holds demonstrations on violin it merges with route 152, then We will have a special short making at schools and violin camps, and fiddles with approximately 1 mile on right. demo by one of our members at the Strathspey and Reel Society of New Hampshire. From Portsmouth 9:30 am so be sure to be there on Renaissance Strings is located in Nottingham, NH Route 4 West to route 125 South, time. near Rt 4 and Rt 125. It is located at 181 Stage Road, to route 152 West, approximately Main Presentation – Have Nottingham, NH, in the big barn at the corner of 5 miles on right. you ever wondered how fine Gile Road and Rt 152 (Stage Road). – Sal Morgani

th April 14 , 2007 Guild Luthiers New Special Interest Subgroup

Small Meetings Rescheduled new subgroup of the Snow storm pushes back Goose Bay Lumber Tour–9am to 11am AGuild is being formed, to March meetings to April 14th Max number of attendees is 30. The meeting will be at Goose be announced at the April 21 Bay Lumber on Rt 4, Chichester, NH. Guild meeting, with the first ue to the Nor’easter that Carl and Liddia will be giving a tour of their facility, which will organizational meeting to be hit New Hampshire March include the small vacuum kiln, log yard and lumber facility. scheduled then. We are looking D16, the three small meetings Carl will demonstrate their saw mill – weather permitting. This at the May time frame for the scheduled for March 17 have been is a chance to learn something about what happens to a tree organizational meeting. rescheduled for April 14. after it is cut down and how it is processed. The group’s focus will be lutherie, These meetings will follow the Curved Side Grain Inlays–1pm to 3pm the making of stringed instruments. same format of past year’s small Max number of attendees is 10. The meeting will be at John There is a large community of meeting venue. Instead of one Whiteside’s home shop in Fremont, NH. luthiers in the area. NH Furniture large meeting, there will be three John Whiteside has been making furniture part time for the Master Terry Moore has agreed meetings at different locations past 20 years. He is currently taking classes for guitar making to be our mentor and honorary during the day. and has offered to share what he has learned. John will demo chairman. Details of focus and The Guild’s small meeting how to make a jig to do curved decorative inlays and the pro- organization will be worked out at format has met with much success. cess of making the inlays. Come and see John’s 24x32 shop that the May meeting. This is open to all We hope you are able to take he built himself and increase your knowledge of inlay work. – beginner, amateur, and professional advantage of seeing other shops alike. Plus, given the nature of the where the venue is focused to How to Make a Cabriole Leg–9am to 11am group, part of each meeting will be individual interests. Max number of attendees is 15. The meeting will be at the devoted to jamming! You must register as there is Homestead School in Newmarket, NH. If you are interested, contact often limited shop space in each Dan Faia is a graduate of the North Bennett St. School. Dan John Whiteside, 603-679-5443 or workshop. Just contact me at balances his time between making furniture and teaching. Dan [email protected]. When 603-483-1330 or preferably by email will show how to select the wood and then lay out and cut out you call, please have some idea at [email protected]. a cabriole leg. This is a great opportunity to learn from one of of preferred meeting dates and – Brian Sargent North Bennett Street’s top teachers! times. Write to [email protected] with your questions 

Table Saw Blades – Is a performance and longer life. A cheap increasingly finer grits up to at least Q combination blade the best blade will cost time in sanding and will 1500 grit. My preference in sandpaper choice as a table saw blade or would most likely dull faster. Cheaper blades over 1000 grit is Meguire’s Uni-Grit. dedicated rip, crosscut and solid also usually have smaller teeth which Wet sanding is followed by buffing. surface blades make more sense? cannot be sharpened as many times. I usually start with a lambs wool head – Anon and 3M Finess-it and follow with a Jon Siegel replies: No one likes changing synthetic head (more heat) and polish. Brooks Tanner replies: Combination blades. Manufacturers play on this fact, A highly figured grain, however, will not blades that I am familiar with usually and advertise that their “combination” or stay completely flat. give a poor cut and are usually relegated “multi purpose” blades work well in every As the humidity cycles, you will to carpentry, not cabinet or furniture situation. Don’t believe it! Dedicated see the grain movement in a glancing work. They do have a purpose on the blades work best. Many woodworkers view. Often this movement is sufficient construction site, and I actually have tell me they have trouble ripping thick enough to be easily felt as you run your one in my Skill saw. A general-purpose stock, but they don’t own a rip blade. hand across the surface. blade, however, is a different matter all On a rip blade, every tooth is the same, I have had one particular piece together. A good general-purpose blade perfectly flat (square) on the top, and that was made to replicate the figure is the #1 blade used in my shop. But there are a small number of teeth on the and finish of a set of speakers that has additional blades should be added for blade. remained completely flat. This was specific work. The primary blades in my finished with polyester, the same as the shop are as follows: Bob LaCivita replies: I think having resin used with fiberglass. There is no dedicated rip and crosscut blades is the infiltration or loss of water content. The 1 Forest 40 tooth Woodworker II, ATB better way to go in an idle world. I have piece is also in a humidity controlled (alternate tooth bevel), thin kerf. General worked in shops that use this system environment. This is a mirror finish, but Purpose. I use this for a majority of my and the amount of time lost makes it has a plastic look and feel. solid wood cuts. Rips are clean and almost inefficient. I use Forrest combination If the question was not intended to too clean for a glue joint. Little clean up is blades and they work well. If you have be a finish question, but instead is a necessary for a finish edge. On cross cuts, time, rip and crosscut blades is great. If sanding question. Figured wood may be pores are left open and are not crushed, as not, go with a high quality combination tooled dead flat (sanded, scraped etc.) they should be. The negative is that feed blade. but is dead fat only until the humidity rates are slower than a dedicated rip. But changes. the cut is finer and time is saved in sanding. Smoothing Highly Figured 2 Royce 80 tooth Melamine, high ATB, thin Q Wood – What is the best way Sticker Stain – Can “sticker kerf. This is used for veneer covered sheet to smooth highly figured wood (e.g. Q stain” which has just happened goods. High tooth count together with very bird’s eye maple) to a mirror finish? (within 24 hours) be removed? I had pointy teeth minimize splintering and tear – John Whiteside wet walnut touch steel overnight out of the veneer and also leaves a smooth and had blue stain. Has the stain finish cut. Brooks Tanner replies: Figured wood penetrated deeply? Could it be 3 Wood Crafter 40 tooth, ATB, 0.125 kerf. Used is finished to mirror finish by using bleached out? – Peter Breu for solid wood cuts in thick stock (6/4 +). A the same methods as with non-figured. thicker blade will take and dissipate more Basically finish is added in multiple Bob LaCivita replies: Sticker stain is the heat and also will not distort as readily coats and is then wet sanded flat result of acids and minerals leaching out under high load. This blade also has a larger exposing any depressions as shiny spots. of wood sticks (stickers) placed between gullet below the tooth for removal of a Additional coats are added, followed by layers of drying wood before drying or larger amount of chips. wet sanding. This is repeated until the while drying (air dried). 4 CMT 24 tooth, FTG (flat tooth grind), thin entire surface is completely filled with You have a stain from metal. kerf. Rips are faster and noise is lower than finish and no defects can be seen. Depending on how deep it penetrated. with the Woodworker II. Cut quality is It should be noted that the finish You can sand, scrape or plane it out. If the acceptable, but not quite a nice as with a 40 thickness is still quite thin since a board is not to thickness, you can run it tooth. majority of the finish has been sanded through a planer. I would avoid bleaching off. because you might end up with a bigger Good quality blades will give better Wet sanding is now performed with problem. I would sand it with 220. lose yourself in time

minutes later is strong. But after I did the first wipe down, the color was still there and a smoothness- to-the-touch emerged that surprised me. I didn’t want to apply a second coat for fear of losing that smooth feel on the first coat. Six coats later, with wet sanding between, only enhanced the results. by Bob Oswald The last coat was applied like talcum powder to a baby. I decided to wipe it on so thin, and the Art of Woodworking so thoroughly, to rub it out even as it was still wet. ave you ever read creative, not disposed to of mind for several reasons. It had all the properties I a really good structure. I did not want to make a could have hoped for. I can book where The concept further states mistake that would ruin a only say that time passed you look up and that when you are in that loss piece of wood. Everything and I didn’t realize where it wonder where the last hour of time mode, you are using was grain matched and to went. And the project and went? The same can happen the right half. And if you can fail with one part would be the finish is the best I have in your woodworking. It call on the right half more to go all the way back to the ever done. When I look back never used to happen to me on demand, you can achieve beginning. And the finish, on this project, I find nothing but it’s starting to. It’s related more focus, more inner color balance, presentation, that I would do differently. to being too goal oriented. peace. Jumping to the end of no visible flaws were all That’s an incredible feeling. As they say in other walks, the story, I’m here to tell you, critical factors. I did have a That is woodworking! enjoy the journey, don’t worry against all opponents, that it few little problems along the The project took easily about the destination. And is absolutely true. way and was fortunate to be twice as long as was in woodworking, I believe I started to read this able to recover them. ‘necessary’. But the results that the secret is to enjoy book and the exercises they It was not a conscious are ten times better than I every step. Do each step like take you through are simple decision to be focused. It would have done in half the it is the most important one but you are guided in a way just happened. And when time. in the project. Be almost that encourages you to do I finished about two weeks And in the great balance afraid to be finished. the exercise well, not quickly. later, I knew that this is what of nature, I have subsequently On a slow day at a trade About half way through woodworking is all about. To tested my dovetail skills on a show years ago, I picked up the book a few days later, I lose yourself in a project, to four little recipe boxes. I was a book at the a local college realized that I was losing lose yourself to time, to be in a hurry to see the results, bookstore called Drawing on that sense of time while delighted with the results. and the results show it. Two the Right Side of the Brain. I doing those exercises. I am most proud of the are garbage. I’ll salvage them was learning to draw then Recently, I committed finish. Too many of us skate and store something in them. and I had heard the book to a project that stretched through that phase, hating It will remind me each time I mentioned many times. The my skills. The nature of the it. I loved every minute of it. look at them what being in a concept is that the brain has project required it to be as That first coat is true magic. hurry is worth. Two are better two functioning sections. perfect as possible and it The color first comes to life. but far from acceptable. The left half is organized, caused me to focus like I It glistens. You don’t miss Focus, enjoy, learn, methodical and time keeping. never had before. And this a spot anywhere. And the appreciate, lose yourself in The right half is abstract, project put me in that frame reluctance to wipe it off ten time. taking control of your own metallurgy Woodturning by Jon Siegel Chisels You Can Make

apparatus, or formulas which Figure 3 – Grinding a Flute. The are available to the modern round nose grinding wheel is metallurgist. Instead they were guided only by trial used to grind the flute into the and error. Yet they were able steel rod. Grind to a depth that is to make astonishing tools, swords, armor, and cutlery just a little more than half way. of every description. This is because heat treatment is can buy from any machine essentially a simple process shop supplier. I prefer this which requires only two type of steel, because it is things… consistent, easy to harden, and very low cost. • Control the amount of carbon in the iron thus making “steel”. Heat Treatment Much mystery has been • Apply heat and cold to manipulate attached to heat treatment the crystals in the iron. because it has a long and somewhat clouded history. Fortunately, the first part The discovery of how to is taken care of for us. Tool convert iron into steel and steel (which is a blended its heat treatment (Anatolia, mixture of iron and carbon, 1200 BC) is what made plus a few other additives) iron superior to bronze and is made in many varieties by ushered in the Iron Age. The steel manufacturers, and can result of this is that today be ordered from any machine 95% of all metal products are shop or industrial supply made from iron. company. “Carbon tool steel” Centuries ago, those is the direct descendant of nyone can make in your own shop. You can early smiths did not have those earliest types of steel woodturning chisels use pre-hardened high speed the advantage of micro discovered thousands of Aby following these steel (tool bit stock). This photographs, testing years ago. instructions. In doing was covered in an excellent so, you are not trying to article by Bob Rosand approximate a standard in American Woodturner, factory-made chisel. Instead Summer 2001. I do not use you are creating a “hard tip” this type of material because tool. In many ways, this is it is available only in a better than a factory chisel. limited number of sizes and The cutting edge is extremely it is expensive. Or you could hard and durable, while the use files, springs, saw blades, shank is tough and strong. etc., and this is covered by A gouge made with a short John Lucas in American flute is much more rigid than Woodturner, Spring 2001. one with the flute running But in this article, I will the whole length – Figure 1. explain how to make chisels There are many out of high carbon tool steel, approaches to making chisels such as drill rod, which you Figure 1 – A collection of carving and turning chisels made by the author. photos by Patrice Martin & Jon Siegel 

Heat Treatment Made Easy wrote two excellent books with lots of hardening transformation has taken When the steel is heated to the good information on hardening and place as planned. red-hot temperature of 1450 degrees F, tempering with simple equipment. How can you test the hardness the crystal structure changes. If then They are The Making of Tools (ISBN without a $5,000 testing machine? The allowed to cool slowly, it goes back to its 0-442-29360-7) and The Modern most common method used by general original form. But if it is cooled quickly Blacksmith (ISBN 0-442-29363-1). mechanics is the file test. Simply use an (hundreds of degrees per second), that Although woodturning chisels are ordinary file on the workpiece. If the is, quenched in liquid, it will become different from sculpting chisels, these file “bites” and scratches the steel and set into a new crystalline form and thus books are a great starting point. there are some shiny filings produced become hard. This process is called However, now I purchase new (no matter how small), then the steel hardening and it works best if the steel tool steel to make my chisels. It didn’t is not hardened. If on the other hand, has around 0.9% carbon. take long before I realized that I had the file slides over the workpiece as if After the hardening, the piece may invested too much labor in the forging the file had no teeth, then the steel is be too hard and brittle to be safely and grinding of the tools, only to have hardened. Note that this action will used. It is possible to take away some them fail later because of imperfections ruin the file. It is best to keep a few (controlled) amount of the hardness in (cracks), or in the heat treatment throwaway files on hand for this test. the second part of the heat treatment process. I realized that compared to process called tempering, which is this labor, the cost of new tool steel is Shaping the Chisels softening. minimal. Grinding the bevel on some chisels, Some authors refer to the whole heat such as skews and scrapers is a simple treating process as tempering, and this Which Steel to Buy operation. The only additional thing is confusing. Hardening and tempering Steel that is near one percent you will need to make your own chisels are separate processes within the heat carbon and is specially formulated to is a very course grinding wheel. treatment. be hardened is called “tool steel”. You should not attempt to use the Before hardening, the steel can be Basic carbon tool steel comes to same grinding wheel for shaping the easily cut with a hack saw or machined, two varieties – a type to be quenched in steel as you use for routine sharpening. but after applying the heat treatment water W-1, and a type to be quenched These are distinctly different processes, described here, carbon tool steel can in oil O-1. The latter type O-1 is and require different tools. For shaping attain great hardness, which, if you somewhat more expensive, but is less steel, I recommend a 24 to 40 grit want to get technical, is in the 60s on likely to crack in the quenching process. wheel. This will allow you to shape the the Rockwell C scale. In other words, Also O-1 comes in rectangular shapes point of a rough blank in a few minutes in the fully hardened state (called as well as round, while W-1 usually with a minimum of heat build up. Martensite) it cannot be filed, sawn, comes only in rounds (referred to as or scratched by any steel tool. It is not “drill rod”). W-1 is still my favorite Making Gouges machinable, and can only be worked for making turning chisels, because Grinding the flute into a gouge is with abrasives. I make both skews and gouges from more complicated than making skews One of the most amazing things round stock, which is very inexpensive. or scrapers. It requires the use of a about this hardening process is that For example, one piece of 3/8˝ drill rod grinding wheel with a convex radius it is reversible. By simply heating the (36 inches long) cost $3.15, and is long which matches the shape of the flute. steel as before (to 1450 F), but cooling enough to make four chisels. That’s it slowly, the steel is made soft again. $0.79 per chisel! That is the opposite of hardening, and is called annealing. Fast cooling makes Sources for Tool Steel it hard, and slow cooling makes it soft. MSC Industrial Supply Co. This process can be reversed a number 800-645-7270 www.mscdirect.com of times if necessary until eventually ENCO the carbon evaporates from the surface. 800-873-3626 www.use-enco.com

Using Known When you receive your tool steel, Tool Steel vs Unknown Scrap Steel you may want to take a small piece At one time, I thought it was clever through the hardening process just for to beat the system and make tools out practice and then test it to see if the of free pieces of high-carbon steel – springs, axles, etc. I had been influenced Figure 2 – Dressing the Wheel. The diamond by Alexander Weygers, a wood dressing tool is used to form the grinding sculptor who took up blacksmithing in order to make better chisels. He wheel to a round nose. 

It is easy to round the edge of a oxide grinding wheels are better than Procedure grinding wheel to any radius desired the old fashioned gray wheels. They are 1 Cut the steel to length. Use a hack with a diamond dressing tool. Many softer, and as the surface breaks away, saw. Allow for one or two inches to woodworkers do not own diamond they continuously expose sharp grains of go into the handle. Lightly chamfer dressers because they incorrectly abrasive. Therefore they grind with less the cut edge on a grinder or belt. think they are expensive. In fact, small heat build up, and since they are “friable,” diamond dressing tools (1/4 carat) cost they are easy to shape with a dresser. I 2 Drive the steel into the handle. only about $6. If you own a grinding have found that the least expensive are Nothing could be easier than fitting wheel, then you should own a diamond 7˝ diameter wheels designed for surface a round rod into a handle. If your dressing tool. The tool consists of a grinding machines. They are available in chisel is made from flat stock round steel rod (about 6˝ long) with a 1/4˝ and 1/2˝ thickness for under $10. The however (for example a 1/4˝ x 3/4˝ diamond attached to one end. only catch is that they have a hole size skew chisel), you will have to make of 11/4˝. This means that you will have to a tang on the end which fits into Source for Diamond Dressers make a bushing to reduce the hole size the handle. If you have a way to hot ENCO to fit your grinder. Of course it is best to forge, this is the best. Another way 800-873-3626 www.use-enco.com go into the machine shop and make one is with a metal cutting band saw, out of metal, but perfectly good reducers but if you don’t have one, just grind To use the diamond dressing tool, can be made out of maple. the material away with a very coarse place it on the tool rest of your grinder wheel. and work it slowly the same way you What You Need for Making Chisels would use a small scraper to turn wood 1 Tool steel – either round rods or rectangular 3 Rough grind the point. Skews, flat – Figure 2. flat stock chisels, parting chisels, beading Always use a dust mask or a collector 2 Hack saw tools, etc. are easy to grind. Grinding because there will be a lot of abrasive 3 A very coarse grinding wheel for “roughing” the flute in a gouge however, takes dust produced. Be careful that only the the shapes some time – Figure 3. When diamond touches the grinding wheel 4 Several thin grinding wheels rough grinding the chisel at this and do not to let the wheel touch any stage, you do not have to worry 5 A diamond tool for dressing grinding wheels part of the metal rod or you may grind about overheating because the heat into round profile shape for grinding flutes away the metal which is holding the treatment comes later. Follow all diamond in place – the diamond will 6 Propane Torch (or two) – MAPP is better safety procedures for grinding wheels fall off. 7 Magnet and always use a guard even if one is not shown in the photos. 8 Water Wheels for Grinding Flutes 9 Motor oil In recent years, woodworkers have 10 Chisel handle – turn your own 4 Heat the steel to 1450 degrees F. discovered that white and pink aluminum You can tell when you have reached this temperature because a magnet will no longer stick to the steel. While heating the steel, touch the magnet in quick jabs. Do not let the magnet get hot or it will be ruined.

As you heat the steel, the first thing you notice is oxidizing of the surface and several colors are seen. These are the tempering colors, and are not important for now, as we pass through this temperature range (about 500 degrees F) on the way up to 1450 degrees F.

Figure 4 –Heating to the Hardening Temperature (1450 degrees F). Notice that the magnet and the quenching liquid are within inches of the torch. 

Figure 5 – Tempering Colors. The first tempering color to be seen is light straw, and this is sufficient for woodturning chisels.

To see the oxide coating, you must, before tempering, remove the black scale which formed in the hardening stage. Use an oilstone or some fine sandpaper At some point, you will see the 5 Quench in water or oil. As you until the surface is bright at least metal start to glow. The temperature take the chisel from the flame to on one side. of the first noticeable glow (blood the quench, do it instantly so there red) will vary depending on how is no time for it to cool off en route. You should stop at the first bright it is where you are working. Have the quench liquid within tempering color which is yellow In a darkened room, it will be inches of the location where you (440 degrees F). Subsequent about 1000 degrees F, but in bright are heating. As the chisel enters the colors correspond to these light, it could be 1200 or 1300 F. liquid, swish it vigorously in a temperatures – straw = 480, You should start checking with a circle. Continue the motion until brown = 510, purple = 540, blue magnet at this point. Do not let the cooling is complete – about 5 = 580. These represent greater the temperature drop as you do the seconds. Use either water or oil degrees of softening. Tempering magnet test. Keep the temperature according to the type of steel. beyond yellow or straw will reduce rising. The color gradually changes the edge holding properties of from dark red to cherry red – 6 Draw the temper. Tempering is the the chisel, but might be necessary Figure 4. When the first inch or so reheating of the chisel this time to for some chisels such as those for of the chisel is glowing evenly and a much lower temperature (300° mortising deep holes. the magnet does not stick at all, to 600° F) to remove some of the you are ready to quench the steel. hardness and brittleness. Not all 7 Finish grind. As with all carbon chisels need to be tempered. You steel tools, do not let the steel Steel above 3/8˝ diameter may be will lose some hardness in the get above the tempering color difficult to reach temperature with tempering. But chisels with very (yellow) during finish grinding an ordinary single propane torch acute edges need to be tempered to or the hardness will be lost. If – MAPP is better. Two torches prevent the edges from chipping. you let the steel get to the purple working together will handle up The right temperature is judged by or blue color, even for an instant, to 1/2˝ thick steel. Oxyacetylene, comparing the color of the oxide it is ruined, and will have to be however, is ideal for larger sizes. coating – Figure 5. rehardened. Therefore when you grind the tool, keep the point of the chisel cool by using light pressure, and cooling in water if necessary. If the chisel sizzles when it hits the water, it’s too hot!

I hope this article has helped to “demystify” heat treating and tool making for you. I have found there is nothing more satisfying than turning wood with chisels I made myself.

Figure 6 – Drilling the Handle. After the drilling, the work is placed between centers, and the tailstock center fits the drilled hole. by Geoffrey Ames a super-slick trick to make a super-strong joint Housed Dovetails This article appeared in the Dec 2006 issue of Popular Woodworking and is reprinted with permission

Geoffrey builds 18th century period furniture and teaches at the Homestead Woodworking School

he housed dovetail joint is mechanically sound, historically correct for 18th century casework and a hallmark of fine craftsmanship. It provides an accurate means of locating drawer dividers and runners, and is quite useful when making shelves. If you can mill stock straight and square, control stock thickness, make dados and operate a router, you can make this joint. When assembling case pieces or shelves, you will have little need for glue, screws or nails. Dados alone have little mechanical strength, but with the addition of a dovetail socket and dovetail tenon, the joint is properly aligned and quite strong. This joint allows cases to be made without face frames. When the housed dovetail joint is used for shelving, the shelves are prevented from cupping because the shelves are Editor’s Note held flat in the straight, shallow dados. A number of GNHW members Much of my work replicates 18th-century case pieces have published material in the such as chests and highboys. For years, I made furniture by commercial press over the years. laying out the housed dovetail joinery, carefully handsawing, It is a measure of our good then chiseling the dovetail sockets. This slow and inefficient fortune to have access to these process tested my patience enough that I began my search for accomplished and articulate a quicker, more accurate method. professionals in our midst. I like to make the housed dovetail joint with a dado roughly Generally, The Old Saw policy is 1⁄8˝ deep. The dado is used to align and strengthen drawer to avoid reprinting such articles runners or shelves. By housing the shoulders of runners or in favor of original material or shelves, the joint doesn’t invite gaps like a half-blind dovetail occasional refreshed material joint, as seen in the drawing on the next page. from other non-commercial publications. Searching for a Solution However, when this article by As I tried out different methods, I built numerous sleds and GNHW member Geoff Ames was edge guides, but my only success required the use of a sled and brought to my attention, I found two matching routers – one fitted with a 3⁄4˝ O.D. straight bit, it to be compelling and one that 3 the other with a ⁄4˝-14° dovetail bit. fit well with a series of recent My search for a simple solution led me to milling all the and future articles on joinery. I dados prior to routing the dovetail sockets. But aligning the anticipate the use of commercial dovetail bit with the dado was not possible because a standard reprints to be infrequent; 3⁄4 1⁄8 however, I would appreciate ˝ guide bushing was too deep for the ˝-deep dado, and 3⁄4 any feedback you’d care to offer. the ˝ dovetail bit interfered with or would shear the guide – Jim Seroskie bushing. Then it occurred to me that what I really needed was photo by Al Parrish a shorter guide bushing. 5IF
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Combining a dado joint with a half-blind dovetail The 3⁄4˝ outside-diameter guide bushing must be reduced to yields a superior joint for casework. The weaknesses protrude less than 1⁄8˝. This allows the base of the router to of both joints are eliminated. lay flat on the workpiece.

The first step is to mill all of the dados Use the modified guide bushing and a Use the same guide bushing and a 3⁄4˝ to a depth of 1⁄8˝ with a 3⁄4˝-diameter 3⁄8˝ straight bit to prepare the socket dovetail bit to finish the dovetailed straight router bit. for cutting the dovetail. part of the joint.

Get a standard 3⁄4˝ O.D. A Simple Formula Porter-Cable router-guide To successfully make the bushing and reduce the housed dovetail joint, there protruding guide to slightly are a few milling, tooling and less than 1⁄8˝. You can cut the setup requirements. The dado excess off with a hacksaw, must be a minimum width and then file or grind the cut of 3⁄4˝ to allow a 3⁄4˝ guide edge smooth. bushing to ride into the dado Now you can set up your to create the dovetail socket. router with the modified The dados should be slightly guide bushing and a 3⁄4˝-14° more than the depth of your dovetail bit as seen in the modified guide bushing. photo at right. The bottom The stock thickness for the edge of the dovetail bit should drawer dividers or shelves protrude a bit less than 1⁄2˝ should be the same as the As you slide the router along the edge, the guide bushing and below the guide bushing for width of your dados. dovetail bit will enter the dado together. a total depth of about 5⁄8˝. After milling all the Be sure your stock is thick dados with a 3⁄4˝-diameter When you have pre-cut sequence of the cuts you enough to prevent routing straight router bit, set up all the sockets, switch your need to make. through your workpiece. I the router with the modified router setup to the dovetail The router is slid along recommend using 13⁄16˝ or 3⁄4˝ guide bushing and a 3⁄8˝- bit. Securely clamp your the face of the case side, from 7⁄8˝ stock for case sides. The diameter straight bit. Clearing workpiece to your bench, left to right. The dovetail bit drawing at the top of this out the socket with this bit lock your router bit depth, and the guide bushing locate page shows the proportions will reduce the amount of and turn on your router. the dado and enter the dado and appearance of the material the dovetail bit will The photos above show the at the same moment. Keep finished housed dovetail. have to remove. the router base firmly down 12

on the case side and carefully guide the router into and out of the socket without lifting the tool from the work. Slide the router up to your stop line then retract. If you turn off the router while it is in the socket the dovetail bit may be pulled down and ruin your work. Cleaning out the socket with a 3⁄8˝ bit prior to routing the dovetail socket helps prevent this. You’ll likely experience some tear-out where the router exits the socket. Make your workpiece about 1⁄8˝ wider than the finished dimension to allow for edge cleanup. Any tear-out is easily removed by a few passes over the jointer. On to the Matching Tenon This clamping jig lets me quickly make the tenons without adjusting the router setup. The work Of course the dovetail socket is clamped vertically below the Masonite guide. requires a matching dovetail tenon. With an easy solution to making the female part of the joint, I looked for an equally simple method to cut the dovetailed tenons on the end of the drawer divider or shelf.

Dovetail Tenon Clamping Jig

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GFODF I came up with this jig that uses is precarious and shaky at best.  the same 3⁄4˝ x 14° dovetail bit and An alternative is a horizontally router setup. mounted router, but my method The common method used to uses a simple and easy-to-make jig create dovetail tenons is to mount as seen above. the same dovetail bit used to rout When setting up the vertical the sockets in a router table and run dovetailing jig, make some trial c c the long narrow dividers vertically, passes on scrap the same thickness twice at each end. This method Continued on Page 13 African Padauk … by Caleb Dietrich 180 BF – All 16’ long &OR3ALE & of very fine quality. I have one piece 28˝ wide, one piece 26˝ Steps to wide, and three pieces 12˝ wide. Prefer to sell all together. $2700 for all or make offer. Clean Rails & Stiles Serious inquiries only, please. pre-plan for tear-out when you make your cut list Steve McPhee: 603-868-7091 Foley Belsaw Sharpeners … It is much safer than the dreaded climb here is a lot to consider when Two sharpeners both with stands. One is set cut and it allows you to set the fence on your creating a cut list for the parts up for sharpening hand saws. The other is Tof frame and panel doors. Perhaps shaper and leave it there. This assumes for circular blades. Both are 1/2 hp. the most important is to allow extra your machine can handle a full depth Harvey Provencher: 603-774-3331 overall width and length so they can cut and that tear out is the only reason be squared up once they are assembled. you would take a number of passes. Radial Arm Saw … This is especially true if they are inset I recently put this method to the Sears radial arm saw (12˝) with table and doors. That is, doors which are fitted test on eight Bird’s Eye Maple doors. enclosed tool storage cabinet. Setup has to their opening – which should be With sharp cutters, there was minimal integrated dust hood and collection by a perfectly square, right?. Depending on clean up afterwards. This works for Reliant 1hp dust collector. Price is $300 or how thorough your design process was, profiles too. I just made half a dozen best offer FOB Riverwoods at Exeter, NH. you will also have to add the length of 11/4˝ thick entry doors and used the Bill Fletcher: [email protected] tenons to your shoulder measurements same technique. Table Saw … and do various other calculations… After you try this technique making 10˝ Jet Table Saw JWTS-10JF. This saw • At this stage, you can also account doors, you‘ll surely find a number of has seen hobby use only. 4˝ dust port, 1.5 for tear-out by adding 1/16˝ to the other situations in which it will be HP – 115/220 single phase. Currently on width of all your rails and stiles. beneficial. Amazon for $629 plus shipping or ebay for Make this 1/8˝ if the piece will be photos by Caleb Dietrich $400 min bid, local pick-up. Email me if you machined on both sides as in the want pics. Asking $350. rails and stiles of a divided door. Syd Lorandeau: [email protected] • The extra width allows you to joint the parts after an initial pass through the shaper or router table. Take one pass over the jointer Presidents Message – continued at 1/16˝ if you are working with a who volunteers to work a particular straight grained wood. This will day. The guild also sponsors the clean up any tear out that may Best in Wood award given by the have occurred on the shaper. If you League to those items displayed in are working with a difficult wood, the Living With Crafts building. take two passes at 1/32˝. I can not over-emphasize how • Once you have a straight smooth safer than climb cutting important Sunapee is to our public edge on all your parts, pass them image and how important the through the shaper one more time First pass tear-out at full depth (above) funds raised by our raffle are to our for a light finish cut. This method followed by jointer & light second pass scholarship program. Our success is fast, and produces great results. clean up again at full depth (below) is totally dependent on having guild members step forward and volunteer to donate prizes, Housed Dovetails – continued demonstrate, and work as Guild as your workpiece so that the top of tenons can be made without changing representatives. the bit barely touches the top edge of the router setup. Wendy will soon be sending the board. Move the jig top in or out The stock used for the drawer out a guild wide email asking for to adjust the tenon thickness to match dividers and runners should be milled volunteers to work at Sunapee. the 3⁄4˝ width of the socket. to precisely the same thickness as the Jim Dimick will also be emailing The 1⁄8˝-thick Masonite on the top dados. This housed-dovetail system is you to ask you to donate an item of the jig is equal to the depth of the based on 3⁄4˝ tooling. Consequently, for the raffle. Try spending a day dado cut in the side of the case. With the dados, dividers, runners or shelves or two at Sunapee this year. You the base of the router on top of the should be uniform, flat and straight. will have a great time and will also Masonite, and the edge of the bushing Good stock preparation is absolutely be helping out your guild. – Work against the edge of the Masonite, the essential for good results. safely by Harvey Best Georgian Oak Table Restoration repairing a severely damaged 1800s style side table

to disassemble a joint and rebuild or fortify hidden structure. After considering the options and based on my past experience with furniture restoration, I accepted the challenge and took on the project. Once I had the table in my own shop and had the opportunity to examine the project, I realized that this amounts to “detective work”. It means looking for evidence of what the table looked like “before”, and assembling the missing parts to resemble a finished table accurate to the time and period. I also conferred with the owner to determine the extent of the restoration and the decision to work toward “option 3” and completely restore the leg and table to as close to the original state as possible. ou never know what you will take cracked and both boards moved easily away from a Period Furniture apart. The leg was fractured into three major Group Meeting. The discussions The owner of the table contacted the pieces. The first step was to use epoxy to range from design and technique to Period Furniture Group for advice on join and fill the fractures. The epoxy I how-to-do-it. whether the table could be restored and use is West System type 105 resin and There were eighteen members who could provide the highest quality type 206 hardener. Each metal container attending a recent meeting at John restoration work. After examination and uses a pump dispenser to meter the exact Whiteside’s shop in Fremont, NH. discussion of the project, the members ratio with a single stroke of each pump. General topics included new and in- concluded that at least three options I mix small batches of the slow-set process work, a safety topic is always were viable. epoxy and stir thoroughly. The mix is presented and the main topic for this brushed onto the fractured ends of the meeting was a discussion about guitar 1 Fashion a new leg and join it to leg pieces to be joined and allowed to soak making. But John added a bit of intrigue fragments sufficient to support table for into the fibers. I then mix powdered with a challenge to the Group. display purpose only. colorant and high density filler (West A furniture restoration project was 2 Fabricate a new leg of similar material, color #406) into the remaining mix, while put on display for review by the members and grain to match for display purpose only. stirring enough colorant to match the – an 1800s style side table of Georgian 3 Use the broken leg with the salvaged furniture tint. oak from Wales. It was a simple design fragments and reconstruct the leg using The high density filler thickens the of four legs supporting a single drawer epoxy and colorants to make the table epoxy and creates a strong bond. This with a flat oak table top. The rear left usable for light duty and for display. colored and thickened epoxy is then leg had been shattered in a shipping brushed over the previously “wetted” accident. Small wooden fragments were These options were complicated by fractured ends. Clamps are applied contained in a plastic bag. The three the existence of some decayed wood in and parts are aligned with cauls. This other legs were intact but their joinery the apron which supports the leg joints. is where squeeze-out and excess epoxy was loose. The table top glue joint was Decayed wood indicates the possibility is wiped away. Care is taken to clean that additional work may be necessary exposed surfaces. More time spent photos by Harvey Best 16

The remaining leg joints were soaked with white vinegar and followed with hide glue forced into each mortise/ tenon. I was able to inject some glue using a hypodermic type injector into joints that allowed movement. All leg joints were pipe-clamped and allowed to dry. Glue blocks were reinstalled on the underside of the table. Two new glue blocks were fabricated to replace those missing. The oak tabletop was composed of two oak boards, butt joined to form a surface 18˝ wide x 32˝ long. This joint had been repaired more than once based on the number of different types of glue cleaning now saves much grief after to match the shape of the splice. The still clinging to the edge. the epoxy has set. Clamping cauls and joint was epoxied with colorant and I cleaned off the residue from both blocks of wood are covered in wax paper high density filler as before. faces of the joint and applied hide glue. or plastic film to prevent bonding where But this joint was more complex Pipe clamps were used to draw the edge it was not intended. due to the ragged edges coming into together and left to dry. Glue blocks The third portion of the fractured leg alignment with the oak splice. The splice were reattached to the underside of the remained glued to the apron of the table. overlapped the fragile cross section of table. This completed the mechanical The old hide glue appeared original the mortise and bridged the fracture assembly of the table. in the joint and had to be softened between the upper and lower parts of to dissolve enough of the glue to the leg. I filled the mortise cavity with The finish on the table including disassemble the parts. I have found that modeling clay to prevent liquid epoxy the drawer with its two brass knobs warm white vinegar will work quickly to from filling the void. remained the final part of the restoration. soften dried hide glue if the joint can be After clamping and drying time, A thick coating of brown furniture wax saturated and kept moist. the clamps and cauls were removed had been applied over the entire surface and the clay was excavated from the of the table when it was shipped from Once the vinegar had done it’s work, the mortise cavity. At this stage the leg was Wales. I removed the wax with a cloth joint came apart. I discovered that the fully assembled and ready to be joined soaked in mineral spirits and carefully joint was a double mortise and tenon to the table. But the decayed tenons wiped all surfaces. The white cloth that came together at the leg mortise. on the pine apron would not make a became a dark brown rag. The heavy It was 45° mitered. The oak side apron strong joint. I decided to make a new wax had concealed a hand rubbed was in perfect shape but the rear apron double tenon apron joint and join it shellac finish that appeared worn. The made of pine was seriously decayed. The to the existing apron. The new tenons finish needed a light clean up. I chose a tenons disintegrated as I pulled the were cut into an old dense grained, hard light shellac “polish.” joint apart. Corner blocks mounted on pine board salvaged from a previous Using blond shellac flakes, I dissolved the underside of the apron were also restoration project. The tenons were a one pound cut in alcohol. I took a wad removed with the joinery. All parts were shaped to a tight fit in the mortise cavity. of cotton and folded it into a palm-sized set aside to dry for a week. The new “repair” apron was trimmed and piece of old cotton shirt. I poured drops Following drying and clamping time, dowelled into the existing apron. of alcohol on the cotton and rolled the the leg was ready for the next step of I should clarify that the reason I was material into a pad. Then I dipped the assembly. The mortised leg fragment able to manipulate and work around the pad into a shallow dish of shellac and removed from the table apron could apron/leg joint was that the tabletop proceeded to wipe the table surface. The now be joined to the previously epoxied was loose and had broken away from the rapid evaporation and light padding of leg. The mortised leg fragment was glue blocks. Apparently, the shipping the surface brought up the sheen and 75% intact but was not strong enough damage included the cracked glue joint glow of the old finish. I let the finish without “grafting” solid wood into the in the tabletop and loose joints at the dry for a few days and applied a light joint. I chose a splice of straight-grained three remaining leg joints. I chose to coating of Liberon furniture wax. The oak to closely match the existing wood work on the worst leg first. wax was buffed off and the table was grain. The splice measured approximately The leg was now re-joined to the completed – call the customer! 5/8˝ square by 5˝ long and was chamfered apron and clamped in alignment with 45° on each end. I chiseled a matching the three other legs. The glue was a dado in the corner of the leg fragment liquid hide glue made by Titebond. by Dave Anderson Choosing a Bevel Edged Bench Chisel

cared for should be expected to last us and quite often at very attractive prices. our lifetime. You can even buy from suppliers in both Choosing a bench chisel requires some Europe and the UK, though shipping thought, hopefully a chance to test out takes time and adds extra expense. various brands, and a decision about I have chosen, for the sake of how much you are willing to spend. brevity and clarity, to cover only new In this tool category, there is literally tools currently in production. Antique something for everyone. All chisels tools would themselves, double or must meet some basic criteria for you to treble the length of this short article. work effectively. The steel used must be The opinions expressed here are my hard enough to hold an edge without own and some folks will undoubtedly chipping or folding, and it must hold disagree with my opinions. The best this edge for a reasonable time between advice I can give is to make every effort sharpening. to try before you buy. Most chisels are between a Rockwell The quality range available today Rc 58 and 62. Japanese chisels, which I ranges from the abysmal stuff at the

photos by Jim Seroskie by photos won’t cover here, are typically harder home center to exceptional. At the and run between a Rc 62-64. low end of the adequate scale are the n most shops, the single most The next requirement is that the back Marples/Irwin Blue Chip chisels. They used hand tools are the bevel side of the chisel be flat or reasonably generally are a good value for the Iedged bench chisels. They are the flat so that it can register when you want money and work well after a good bit of choppers of mortises, the trimmers of to pare, and so that when sharpening, back flattening and some honing. Their tenon shoulders, the wasters of excess you can get the cutting bevel and the primary problem is steel which doesn’t stock, and are used for all types of back to meet in a straight line. hold an edge very long before dulling. cleanup work. I’m sure that you can The third requirement is that the side An easy fix to increase durability is name at least a dozen other uses. If a walls of the chisel be as low as possible to raise the bevel angle from 25° to shop is going to have only one type of and that the bevel on the sides be large between 27°-30°. chisel, the bevel edge should be the one and deep. This allows getting into tight A step up on the scale, are the LV you choose. There are more makers and corners when cutting dovetails and butt chisels and the Lee Valley bevel model choices available in this type working in other tight places. edged chisels. Both have harder and than in any other form of chisel. Finally, the shape and size of better steel than the Blue Chips, but Most commonly, the cutting edges the handle must allow an easy and still use plastic handles. They too are a are ground to a 25° bevel so they comfortable grip. This criteria is very good buy. have reasonable edge retention except personal and subjective. Only testing a Crown chisels are generally in this when chopping mortises, and yet take variety of handles sizes and styles will low/mid quality area, but be warned little effort to push through the wood allow you to make a good choice. If you that they vary greatly in quality control, when paring or removing excess stock. intend to use a mallet on your chisels, steel hardness, and the flatness of the Like everything else in life, this is a you must also choose a chisel with a backs. I generally do not recommend compromise angle which can perform steel hoop reinforced end or alternately, them unless you are looking for some all tasks, but is not optimized for any one with a wood hard and durable specific job. enough to take the punishment of the Continued on Page 25 In an ideal world where funds were mallet blows. unlimited we would all own a bevel The following survey is like edged set, dedicated mortise chisels, my previous tool articles, parers, firmers, cranked neck chisels, oriented toward sources and a set or two of skews. Most of us of supply on the internet. will have to compromise, thus making While local tool suppliers our choice of a good set of bevel will carry many of these edged bench chisels an important one. choices, using the net gives Chisels of good quality which are well you a number of options not available in any store U I L D E G OF TH W IRE OO by Jack Minassian SH D P W O M R A

construction of a 1736 replica K

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• • François Blanchet Harpsichord Scholarship

illness resulted in his shop. The spine, cheek, tail and cross passing away in 1997. braces were made from poplar. The bent To keep myself side was made of laminated basswood. occupied and not let The wrest plank was made from 2˝ Adam’s efforts go to waste, I thick oak which I mortised into the thought about completing sides. I phoned Hendrik regularly to the instrument. I visited discuss progress and construction. I had Hubbard Harpsichords, assembled the case after several months kit and custom instrument and took the instrument to Hubbard’s builders then located to continue. in Sudbury, MA, to There, I used their “go-bar-deck” determine whether I to glue the ribs to the underside of could learn enough to the soundboard and install the board complete the instrument. into the case. The go-bar-deck has a I liked what I saw and height-adjustable 4x8 foot platform on concluded that the tools which the items to be glued are placed. and procedures they were It also has a 4x8 foot plywood ceiling using were within my panel about three and a half feet above scope of ability. We made the deck. After applying glue to the an agreement that I would pieces, downward clamping pressure work for them a day a is achieved by jamming strips of wood week in exchange for use between the pieces to be glued and the of their equipment and ceiling panel. These strips are an inch or set-ups. That went well, two longer than the space between the and I even improved some deck and ceiling and are approximately of the set-ups. However, 3/8˝ x 11/4˝ in cross section. The strips exert I soon realized that pressure on the pieces to be glued. This building a harpsichord allows clamping of wide objects, quickly, from scratch was going to and within the glue’s recommended his project originated with my take me quite a while and that I would open-time. son Adam and his interest in need instruction and guidance to make Tharpsichord music of the Baroque period. a viable instrument. I then applied for In early 1984, after having assembled a and was granted a Guild scholarship to French Double harpsichord from a kit help me toward that end. and while working part time for the After completing the keyboard and kit manufacturer’s representative in laminating the bent-side pieces on a Manhattan, he met a person who invited Hubbard form, some delays ensued. him to Paris where he could further There were several turnovers of Hubbard his knowledge of French harpsichords. Harpsichord’s ownership along with There, he found that a harpsichord a move to Framingham, MA. Their restorer owned a 1736 François Blanchet technical director, Hendrik Broekman, instrument, and got permission to take was now running the business. I detailed measurements and photographs knew that he had the knowledge and of it. He completed a plan and cross construction experience to guide me. I section, and made eighty pages of notes. met with him and asked for his help. He After returning to the US, he started agreed to advise me how to proceed with to assemble materials for construction the project and to allow use of tools and and did some harpsichord repair and facilities as needed. Hendrik is a very restoration work. On the Blanchet, he talented and experienced builder and an got as far as constructing the soundboard, excellent musician as well. roughing out case pieces and jacks and In the Spring of 2005, after several trips preparing stock for the keyboard. For to the Hubbard shop for advice, I began various reasons, the project stalled. Then assembling the case in my basement Go-bars provide pressure for glue up. After installing the soundboard, the hitch pin rails and other members were glued to the case assembly. The basswood lid pieces were glued together on the go-bar-deck with bar clamps across the boards and go-bars to keep the assembly flat. The instrument was ready for painting after sanding and sealing the case and lid pieces. An interior satin oil paint was recommended for painting the instrument. I started to apply paint after masking with blue tape and paper to protect the soundboard and other areas. Hendrik uses foam brushes, but I couldn’t manage them. I had to use bristle brushes which I could control better, but had the disadvantage of requiring tedious cleaning. The finish had to be sanded between coats, and I had a difficult time keeping it even and to a low sheen. The summer was nearly over by now, and I decided to return the instrument to my shop where I would have more room, and possibly more control to complete the painting. I improvised a rolling table and other constructions in order to have the surface to be painted as close to horizontal as possible. After more Traditionally, soundboards were Next, I learned how to than a month and lots of masking and painting, I often decorated with paintings of string the instrument. Hendrik finally had an acceptable finish. With the approach flowers, animals and other designs. Broekman had determined the of cold weather and early darkness, I couldn’t do the A professional artist, Barbara string diameters, based on their 42 mile each way commute and waited for the next Pixton, did an elegant painting on length and pitch frequency. There year to continue. the soundboard around the sound- are 58 notes on this instrument, In May, 2006 and after a second scholarship, I hole rose concealing these joints. I two strings for each note and a jack took the instrument back to the Hubbard shop for was shown set-ups for punching for each string. After the hitch and stringing, completing the “jack” mechanism, and and drilling the various parts of bridge pins were installed, I began “voicing.” Because this harpsichord soundboard was the “jack” mechanism that hold stringing. The string diameters made from old piano soundboards that had been the plectra that pluck the strings, went from 0.009˝ to 0.022˝. The removed and replaced, some of the pieces had to be and made and used similar drill treble end small-diameter strings scarf-joined to achieve the lengths needed. Several of jigs tailored to the particular “jack” are iron wire followed by yellow these joints were noticable near the sound hole rose. I was using. brass and finally red brass. Pin

The completed case (less stand) weighs 122 lbs. and is 341/2˝ wide by 84˝ long.

Pilot holes being drilled in the hitch pin rail. The rails had been glued to the perimeter of the case using

Construction photos by Jack MinassianJim Seroskie by photos by & Hendrick Broekman – In-home photos Construction clamps to the case and down onto the soundboard. The case is assembled with dovetail keys slipped into matching slots. 20 registers, each with 58 rectangular holes he was playing the Blanchet, I was so that guide the jacks. Jacks are numbered pleased that I grinned as I hadn’t for to fit in specific holes in the registers. years. After he stopped playing, he told The plectra are cut to a bit more than 2/10˝ me that I had built a fine instrument. in length. Then they are trimmed on the I thanked him for his instruction and underside using a scalpel to give equal patience with me. or appropriate voice to the strings. I was There was a lot more work involved shown how to hold the jack and scalpel in building a harpsichord than I had to be able to trim the delrin. It was estimated. When it went well and There are 116 jacks – one jack per delicate work. The instrument was tuned, I was confident of the outcome, it string. Each jack is made up of six and as I trimmed the plectra, I would was satisfying. At other times, when parts. The body is made from swiss try playing a note. After weeks of work, uncertainty slowed me down, I just kept pear. The tongue is made from holly I thought the voicing was satisfactory. at it. I learned a lot during the process and and pivots on an axle. The axle is a But Hendrik told me that the keyboard enjoyed the interaction with Hendrik chrome plated brass pin. The plectrum action was too stiff and that I should and others. The Guild’s scholarships is press fitted into the tongue. The trim the plectra further. After another were a great help and also motivation to spring that returns the tongue to week of voicing, we agreed that we continue. Without Hendrik Broekman’s position after the pluck is 0.016˝ could consider the instrument playable. guidance, the instrument as it is, would diameter mono filament. The damper Hendrik then tuned it and played some not have been possible. I thank the fits into a slot in the top of the jack. Couperin pieces. I was thrilled that it Guild and Hendrik for their generosity sounded so good. Hendrik said he had and confidence in this project. known it would have a good sound locations for the nut (equivalent to the from what he heard when he thumped bridge but located on the wrest plank) the bridge with his finger. are determined by the hole spacing of Now, all that was left to do was the registers that guide the jacks. With gilding the moldings and case sides. all the strings in place, total calculated This really enhances the appearance. I pull on the instrument is 1421 pounds had bought some gold leaf rolls and when tuned at A415 Hz. Hendrik demonstrated how to apply it. When a harpsichord key is depressed, It was unnerving to apply the leaf but I it rises at the far end and lifts a “jack”, got through it. a strip of wood in which a plectrum The Hubbard Harpsichords shop is about is mounted, and plucks a string. The fifty stair risers up from street level inan plectrum is made from bird quill or industrial building. On the day I was to delrin plastic. So that the plectrum can take the instrument home, I entered drop below the string after a pluck and the stairwell at street level and heard be ready for another note, it is mounted music coming from above. Halfway in a pivoting “tongue” located in a slot at up, I thought it might be Hendrik the top of the jack. The jacks are guided playing one of the many harpsichords in the up and down motion by wood in the shop for repair or refurbishing. strips called registers and a bottom The playing and sound were wonderful. guide. There are two independent When I entered the shop and saw that by Franz Summers A Novice Approach to Guitar Making

by Paul Miller, off we went to Alan color of this wood so I decided Carruth’s school in Newport, NH. to look at what was available. In Several things impressed me about the end I settled on a wood from the school. First and foremost was central Mexico called Palo Escrito. the wealth of knowledge that This wood has beautiful grain Alan possesses. Every class we patterns and figuring but as it have gotten an impromptu lecture turns out it is difficult to work. I on some aspect of guitar making. quickly found that you could not Secondly the students are friendly plane this wood as you do most and always willing to share their woods. Planing at an angle across advice and experience with the grain produced tear out no you. Lastly, there are only three matter how sharp the blade or fine machines in the school – a joiner the cut. a band saw and a drill press. After much trial, error, and Guitars built in this school are hand frustration, I finally found the made. My first operation was to solution. I purchased a #4 Veritas join the top, also called the sound bench plane which comes with board, of my guitar. Each top is the blade having a micro-bevel made of two book matched pieces of thirty-five degrees. Reading of wood. Alan acoustically tests the accompanying literature, the each set of tops to determine what manufacturer recommends that a type of guitar they would be suited twenty-degree back bevel be used for. My top is made of Engleman for wood with a difficult grain Spruce which is a fairly soft wood. pattern. I set up my new plane as After the two pieces were run suggested and proceeded to test it through the jointer, I hand planed out. I was still getting some tear them to prepare them for gluing. out but I noticed it diminished if describe myself as a novice with some Hide glue is used to join the I increased the angle I cut across woodworking experience. Most of my experience halves. The clamping system is the grain. has been in carpentry as I did framing and unique. It consists of five lengths The final answer was to have roofing to put myself through my first two years of of wood about 3/4˝ by 3/4˝ that are a good plane with a sharp blade Icollege. Although I am familiar with most machines about three inches longer than set at a depth that produced saw in a wood shop, I am more comfortable building the top is wide. Three of these are dust more than shavings and to things by hand. I wanted to write this article for two placed on one side, top, middle, plane at a ninety degree angle to reasons – one to share with everyone the tremendous and bottom. The other two are the grain. This was a good learning pleasure a person can get from new challenges and placed on the opposite side experience for me that not all types learning new skills, and the other to encourage other between the three. Thick rubber of wood are worked the same. The novices in the Guild to not hesitate to try something bands are looped over one end trial and error and yes even the new. With that said on with the article. of the wood, stretched over the frustration were worth the effort. John Whiteside got me back into woodworking in sound board, and looped over the My back came out better than I January of last year when he got me interested in the other end of the wood. Simple yet could have ever hoped for. Patience kitchen island he was building. He encouraged me effective. The top is allowed to dry and persistence does pay off. to join the Guild, which I did. About a month after for two hours before the clamping The sides are first prepared by we had finished the island, John mentioned that he is removed. scrapping the exterior to remove would like to find a school and learn how to build a Alan’s suggestion for the all the tool marks. Then they guitar. I told him that I would be interested in that back and sides was East Indian were taken down to a thickness and to let me know if he did. In early summer, joined Rosewood. I did not like the dark 22

of 1.7 mm using a Wagner Safety Plane (more on These are then cut every 1/4˝ on the this tool later). 1/4˝ side leaving only 1/64˝ uncut. A form matching the style of guitar you are This allows the liners to follow building is placed in a vise. A side is then dampened the curve of the sides. Since this with water and placed between two thin sheets of is a repetitious task, I knew that metal. Over this is placed a heat blanket and the there was a way to do this fast and wood begins to soften. Wooden clamps are used to accurately. hold the side to the form. The side is pressed down at I ended up building a jig for the the waist of the guitar first. Once this is clamped in band saw which not only kept a place, the two ends are clamped down and the heat consistent depth but also allowed is reduced by a third and allowed to continue heating me to index the wood 1/4˝ each time. for five minutes. The heat is then turned off and once If you are new to woodworking, all is cooled to room temperature, the side is removed designing and building jigs is a from the mold. When both sides are done they are skill that can make life a whole put in an open frame shaped like your guitar and the lot easier and less frustrating. It is sides are trimmed to shape. The sides are trimmed my feeling that a jig can be built using a hollow form. for almost every situation where A guitar top is not flat but rather is rounded to repetitive tasks are required. As match the arc of a 25 foot circle, thus the form is December ends I have my liners hollowed out with a 25 foot radius. This was quickly glued to the sides, my back needs and usually the back of the guitar. accomplished using the form as a reference and a good 0.3mm of thickness removed, and Alan showed me how to set it small block plane. For me, bending and trimming the I need to do at least one more test up, gave me a safety lecture, and sides has been the easiest process so far. piece with my router plane before then proceeded to give me a I then proceeded to work on the head and tail I cut the inlay for my rosette. demonstration. He then told me blocks that will be used to join the top and bottom Building a guitar is unlike any to have at it and I almost ruined of my sides. The tail block is glued in place using experience in woodworking that I have the sides of my guitar. The lesson Titebond while the headblock is attached using two ever had. Although frustrating at here is just because something part epoxy glue. This is done for added strength. My times, it has been a very rewarding looks easy doesn’t mean it is. next step will be to glue in the liners that will allow experience so far. Also running some trial pieces me to glue the top and back to the sides. To do this, I have learned several new would have been helpful. Using strips of wood about three foot in length are cut and skills and had to remember skills practice pieces is always a good planed smooth until they reach a dimension of 1/4˝x1/2˝. long dormant. Having to plane idea especially if you are new to ninety degrees across the grain woodworking or if you are trying was a new experience for me. I something new. mentioned that at the Guild As luck would have it my sides meeting in November and one were salvageable. The second time member said he had done that I used it, it showed me that it with burled maple. Paul Miller doesn’t always live up to it’s name told me to use paraffin wax on the as a “safety plane”. A good deep bottom of my plane as it helped cut in my thumb proved that. lessen the friction as it was pushed The last item concerns tool across the wood. He also noticed purchases. As I am just getting I was having problems scraping. started, I am buying tools as I go. This is because of severe arthritis I had already purchased a good in both hands. His suggestion was to pull the scraper rather than push it. Good suggestion Paul, you probably saved my guitar-making career. If you have a physical problem, there is probably a way that you can find to complete a task that will be easier for you. On to bigger lessons. I mentioned earlier the Wagner Safety Plane which in my opinion is not all that safe. This is what the school uses to thin the sides Rotary safety plane photos by John Whiteside 23 block plane and realized I or flea market so I am only I’ll let you all know how this For more information on the would also need a bench out about $34. An additional turns out. My main concern Alan Carruth School, go to plane. Not having two to thought, when looking for right now is learning how to www.alcarruthluthier.com three hundred dollars to a school or an instructor to play the darn thing. spend on a top-of-the-line teach you something new, plane, I came up with the pick a person that is not only following idea. I decided to knowledgeable but someone purchase a GROZ plane who can explain what they which is a copy of the old are teaching in plain english Record. It has a decent body and not just technical jargon. with a very flat sole but the As I mentioned earlier, blade is carbon steel. Alan gives us impromptu After doing further lectures on different phases research, I found Hock of guitar making quite often. blades which are made from At a class in early December, I tool steel. Both of these Items ask him about different types are carried by Woodcraft. of wood used for making A quick trip to Newington, soundboards. For the next NH and I had both of these hour he sat and explained the items all for the sum of $83 properties of wood and their (with my Guild discount of relationship to sound. This course). After running the was done in language that I blade over a superfine stone, could understand together I installed it in the plane and with an introduction to tried it out. It cut beautifully, some technical terms. Alan however the weakness would is not only a highly respected show up at my next class. The guitar maker, he is also a blade adjustment mechanism good teacher. If you really is poorly designed and I want to learn, this is the type spent more time playing of person you want to learn with the blade adjustment from. than using the plane. I have I want to leave you with since purchased a Veritas this message especially if bench plane which is a work you are new to the Guild of art. and to woodworking. There The lesson here is don’t are many opportunities try to skimp on tools. If you and new challenges in the can’t afford it at the time, it is field of woodworking. Take worth waiting until you can. advantage of them and also This was fairly cheap lesson take advantage of the Guild as I can use the blade in a scholarship fund. They Groz plane Stanley/Bailey or a Record have been very generous in if I find one in a yard sale assisting us with this project.

Blade geometry Veritas plane by Chris Kovacs Square Peg in a Round Hole

Chris Kovacs is the editor of the Eastern Massachusetts Guild of Woodworkers’ newsletter as well as a GNHW member. This article first appeared in the EMGW newsletter and is reprinted with permission.

a brad point bit. The brad point Do not use a sander. Remember, makes a clean hole and has a flat your peg material is harder than bottom. A Forstner bit would also the surrounding material and be a good choice. Using a very it has end grain showing which sharp 1/4˝ chisel, I begin to make is even harder to sand. If you the hole square. Make sure you use a random orbit sander with do not make the hole too big. Do a relatively soft pad, you will not worry about making the hole end up sanding off a lot of the square its entire depth. It is more surrounding material and the peg important that the surface of the will still stand proud. hole be clean and chiseled square. This does bring up one style Try to clean any chips out of the option. If you are building hole before driving the peg into it. Craftsman style furniture, you To make the peg stock, I usually may well want the peg to stand use a contrasting exotic wood proud of the surface by an 1/8˝ or such as ebony, rose wood or blood so. Use a sharp chisel to shape the wood. Exotic woods are often peg into a traditional craftsman an interesting color and they are style peg. usually harder than the domestic The oval peg on the opposite page woods we typically use. If you is just a round dowel that looks oval in have chiseled a nice 1/4˝ square the finished product. To accomplish hole, start with a square piece this look, I drilled a 1/4˝ hole in peg and a sliding dovetail Square of peg stock about 12˝ long. It a block of wood at some long should be just over 1/4˝ square or forgotten angle – let’s say 30°. You he lowly peg has many uses in woodworking more precisely, it should just fail can try different angles to achieve – from holding something on the wall to holding fitting into your chiseled hole. the effect you want. This block Ttogether a furniture joint. Most commonly, we use I find that 1/4˝ square stock fits then became my guide block for round pegs to hold mortise and tenon joints together. into my pencil sharpener which drilling holes into the table leg However, pegs do not always have to be round dowels. does a real nice job rounding one and through the tenon using a They can be square or oval or some other shape and end of my peg stock. If your pencil portable drill and 1/4˝ drill bit. can hold together more than just a mortise and tenon sharpener does not work, use a joint. I have used them to lock sliding dovetails, knife to round the end of stock. secure dovetails in drawer boxes and to add decorative The rounded and tapered portion elements to a project. There are numerous ways to peg of the peg should be about three- a joint and I will cover a few of those here. quarters of the depth of your hole. As seen in the photo on the opposite page, I have With a little dab of glue on the pegged a dovetail joint together. In this case, the joint peg stock, use a metal hammer to is intrinsically weak as I designed the drawer so the drive it into the hole. Listen to dovetails were visible on the front instead of the side. the hammer taps and when the Every time the drawer is opened, the joint is being pitch changes, you know you have pulled apart. The pegs (one inch long with two on bottomed out in the hole. If you the top and two on the bottom) ensure the joint stays whittled just the right amount closed. of the peg and chose a very hard I have also secured table legs and aprons using wood, the peg should have done oval and square pegs. I find the typical round peg to even more work squaring and be a bit boring and I like the added interest that an cleaning up the hole. oval or square peg adds to a piece of furniture. Using a Japanese flush So how do you get that square peg into the round hole? trimming saw, cut the peg close There are number of ways. After laying out the to the surface. Then use a chisel to Square peg locking a tenon on back of a location of the peg, I start by drilling a 1/4˝ hole with pare it flush. book shelf photos by Chris Kovacs 25

piece of square stock that is a bit more than 1/4˝ square slightly. Using either a metal drill bit sizing gauge (cheap Yankee-ingenuity way) or a special dowel plate (such as the Lie-Nielsen plate below) begin driving the stock through holes in the plate. Start large and slowly work your way down to the size you want. You can make endless amounts of dowel in any species this way. As a last bit of advise, do not put glue into the hole, instead put glue on your peg. If you fill the hole with glue and begin driving the peg, the glue has nowhere to go and you may inadvertently crack your piece of furniture.

Square peg locking in drawer sides Oval pegs in table leg

A round dowel is merely glued more decorative than functional, and driven into this angled hole. I will often use a plug cutter to When it is cut and chiseled flush, make the dowel. These are short, you have your peculiar oval peg. but you only see the surface. You If you want to use an exotic can make end grain or flat grain wood or some other wood species plugs this way. that you cannot find in readily If you need the strength of a real made dowels, then you have to peg, you have to make your own make your own. I have a couple of dowels. To make a 1/4˝ dowel for ways to make these. If the peg is instance, start with a 12˝ long Lie-Nielsen dowel plate

Bench Chisels – continued major tuning. Their highly marketed under the Swiss Made handles are of a comfortable design though small for polished finish hides a multitude label by Woodcraft. These too someone with large hands. An optional long and large of sins. are chisels with good steel and an handle is available. The A2 tool steel is of excellent One of the oldest makers in excellent reputation. quality, properly hardened, and the backs need almost England, Robert Sorby is a step At the upper end of the no flattening. A minor warning is that A2 is more up from the Crown in both price quality and price spectrum are difficult for the beginner to sharpen to the same level and quality, but occasionally still the offerings by Ray Isles and Lie- of sharpness as all of the other chisels made of high suffers from steel which is a bit Nielsen. carbon steel. This problem goes away once you have too soft. They do however require The Ray Isles are offered in further developed your sharpening skills. very little flattening of the backs both a butt chisel, which they In summary, as long as the chisels you buy fit your and little honing of the bevels. call an American Pattern, and hand and have good quality properly hardened steel, A very popular chisel is made in a standard full length bevel your main choice is whether you have more money by Hirsch of Germany and edged bench chisel. The steel is or more time. Increases in quality are generally those marketed with different handle excellent, the backs require very things like flattening, honing, and tuning which cost styles under both the Hirsch and little flattening, the handles are money to perform, but which you can do yourself. the Two Cherries brands. These comfortable, and they are priced As you would expect, quality increases are priced are an excellent buy with great accordingly. accordingly. The sidebar lists some web sites and steel, good durability, and they The Lie-Nielsen bevel edge sources of supply. require relatively little prep work. chisels, unlike all The only two caveats are that they of the other chisels Bench Chisels – Sources of Supply require soaking in lacquer thinner reviewed, are not www.leevalley.com Hirsch, LV to remove the protective lacquer tanged chisels, but www.lie-nielsen.com Lie-Nielsen coating from the steel, and the are of the socket type. www.thebestthings.com Sorby, Two Cherries different handle styles should A taper on the end of www.woodcraft.com Crown, Sorby, Pfeil, Irwin be tested to see if you find them the handle fits into www.toolsforworkingwood.com Ray Isles, Sorby, Two Cherries, Crown comfortable. a socket on the end Another European entry of the steel portion Other sources are available for many of these brands is from Pfeil in Austria and is of the chisel. The U I L D E G OF TH W by Peter Breu IRE OO SH D P W O M Hats R

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removed another 10 lbs and that became the blank for the mini-hat. Then came the patient, exacting turning to the thinness needed to produce a 6 ounce hat. JoHannes has his own grind and is developing his own line of gouges – stay tuned for these – we tested prototypes and they are really good! I cannot explain the grind, but come over to my shop and I’ll show it to you. It really reduces catches and allows for that very, very fine cutting to make a 1/16˝ thick hat. The rear edges are swept back and require some practice at the grinder, but it isn’t really that hard to learn. Then it was lunch time – breakfasts and lunches are provided and are congenial, wonderful breaks! Then, the neat light bulb inside the hat trick to see the depth of the cut – ala Peter Bloch’s lamp shade turning. And then, magically, we all had hats by supper time. They went into the bender overnight to make the hats fit our heads. The mini-hats on Sunday gave me fits and I don’t have one to show you let his fall I took a three day hat a large and powerful bandsaw! We along the micro-hats that JoHannes turns with two turning course with JoHannes all came away with mega-bandsaw sets of reading glasses on! TMichelsen thanks to a Guild envy. JoHannes quickly turned I won’t go into the hat making business – I’ll leave Scholarship. What a delight! huge chunks of cherry into rounds that to JoHannes – but I will approach my turning I have seen JoHannes at least just right for a hat (there went 20 differently now. I’ll teach you his grind if you want, three times over the years make lbs!) and I’d be happy to show you my hat and tell you hats and I had always been greatly Next, I worked on his personal more about the course if you are interested. impressed with his turning skills lathe which was a turn of the You can go online to his website to learn more too as well as his warm personality. I century monster – massive cast – www.woodhat.com. I can certainly recommend it for wanted to make a hat, but more iron is really good! Coring the hat any intermediate turner. Once again, many thanks to importantly, I wanted the skills the Guild for the scholarship! needed to turn that carefully. There were three of us for the course, all of intermediate skills, and we all left with a beautiful hat as well as new skills and a greater appreciation for JoHannes. The first afternoon at his shop in Manchester, VT, we watched and took notes as he turned a hat. The next day we all made a hat, and the last morning we all tried to make a mini-hat. At every step of the way, our patient teacher was there to help us along. One turner ruined two hats before he got one to take home ( JoHannes quickly turned another to the point just before destruction and let him go forward from there!) So, what specifically did I learn? First, I have never seen such by Rob Edelstein home woodshop Air Quality Health Issues

Guild of American Luthiers member Robert Edelstein is a medical doctor as well as a luthier. He offers an overview of the health risks posed by dust in the home workshop and some thoughts on minimizing those risks. This well researched article first appeared in the Summer ‘06 issue of American Lutherie – the Journal of the Guild of American Luthiers (www.luth.org). Reprinted with permission.

ndoor air quality is an important shop and making some healthful changes. filter upwards of 500 cubic meters of air issue for the luthier and woodworker I checked with the Environmental per day, it makes a relatively poor small Ito consider. While certainly not a Protection Agency and confirmed that particle scavenging mechanism and glamorous topic, the benefits of learning there really are no regulatory standards really serves more for humidification some of the important concepts (and that govern the home shop, so in making of the respired air. The smaller particles making appropriate changes to protect my recommendations, I have relied on (ranging from around 0.3 to 10 your health) are certainly worth the putting together all of the available microns) are the most dangerous with effort. material that I could find, and have respect to respiratory problems, as they Like most of us, I look forward to deliberately aired on the conservative have the ability to remain suspended my time in the shop. The pleasure of side of the street. In reality, most in the air until they reach the deepest woodworking is tempered with chores woodworkers will likely remain healthy recesses of the lungs where they become though, and I spend some time cleaning throughout their careers. However, since trapped. Particles smaller than 0.3 up the place before and after each work most of the dangers that are in the shop microns, interestingly, are often able to session. When I first walk in, it looks are invisible, such as small particulate escape from the lungs, as they remain fairly clean. However, upon closer dust and radon, and each of us has a suspended in the air column, but are inspection, I find a thin layer of dust is different and unknown sensitivity to not without their risks. In 1979, Ervin actually covering a surprising number of these factors, then it seems reasonable Somogyi, in his article for this journal the surfaces. This became more apparent to do what we practically can to protect Wood Dust – Beware, performed an to me recently when my son and I ourselves and preserve our health. analysis of the size of the particles remodeled our basement shop, and the found in his workshop. Particles in tremendous amount of dust hidden in Basic Theory the portion of the shop where power the crevices became visible. In addition, The basic considerations in looking at indoor air tools were used ranged from 2.6 to 660 my son began to wheeze within a few quality for our purposes include: microns, with significant concentrations minutes of entering the shop, and only 1 Airborne dust (wood, metal, abrasives and of sizes ranging from 27 to 260 microns. fresh air provided relief. other suspended particles). In the room where he performed more With this in mind, the larger problem 2 Volatile chemicals (stains, finishes, solvents, hand sanding operations, the particles of indoor air quality in general beyond etc.) were much smaller, ranging down to the issue of just dust began to interest 3 Biologic problems in the workplace, such as 1.5 microns. Interestingly, he found a me. Although a paper such as this cannot molds and bacteria significant concentration amongst the present an exhaustive discussion of the 4 Radon smaller particles of the sanding abrasive field, my goal is to highlight some of the 5 “Human issues” such as carbon dioxide, itself, in addition to wood and the other particular issues facing woodworkers tobacco smoke and noise and lighting issues. materials sanded, such as bone and and luthiers, who often work in home ivory. and especially basement shops. Airborne Dust – Especially Wood Dust In researching this article, it soon Clearly, there are certain costs that In general, health risks of dust are became apparent to me that almost breathing poor quality air may bring. In inversely proportional to the size of the every species of wood, including hard addition to the obvious personal health particle. Larger particles, such as wood and softwoods, tropical and non-tropical, care risks, with their attendant costs of shavings and the largest of the dust have all been associated with health risks. health care provider visits, medications, particles, fall to the ground quickly, and Typical Partical Size Ranges etc., there is also a substantial risk of while they may pose a fire hazard, tend dust related damage to equipment and not to be much of a direct health risk. Mold decreased productivity. The topics I will With smaller particles, however, the Bacteria touch upon include general principles risk is substantial. Particles less than 10 Dust Particles of indoor air quality theory, a basic microns (millionths of a meter) in size Smoke discussion of air cleaning and filtering will remain suspended in the air for 0.001 0.01 0.1 1 10 100 technology, and finish with some many hours, and can be deeply inhaled Microns (millionths of a meter) practical suggestions for surveying your into the lungs. Although the nose can 28

It is not even clear whether the wood periodically, and keep them moisturized, of hard wood species, may increase the itself is the culprit, or any number of which acts both as a barrier to exposure risk of developing nasal cancer. Whether organic extractives in the wood may be as well as to reduce the incidence of this is due to some intrinsic difference in to blame. Some of the commonly cited cracking in the skin. There are many the chemistry of hardwoods, or whether causative extractives include classes of web sites that have color photos of the more respirable dust is created during compounds such as alkaloids, tannins typical skin rash of dermatitis, such as: the sanding and shaping of hard woods and aldehydes. During the life of the tree, www.nlm.nih.gov/medlineplus. Once is not known. Although other tumors extractives do serve important biologic there, click on “Medical Encyclopedia”, such as lung cancer and Hodgkin’s purposes (e.g. natural insect repellents), and then navigate from there to disease (a type of lymph node cancer) but clearly may have toxic properties “Dermatitis”. have been evaluated, no firm evidence for humans. Keep in mind that in some Respiratory Problems (asthma) – One exists that exposure to wood raises the cases wood contaminants, such as fungi, of the greater risks associated with risk of developing these diseases. In glue residue or left over paint or stain the inhalation of wood dust is that of some cases, many decades of exposure may be responsible as well. Therefore, developing asthma, a form of chronic elapsed before nasal tumors appeared, the dust from any type of wood should obstructive pulmonary disease (or therefore long term studies have yielded be thought of as potentially hazardous. “COPD”). In the short term, symptoms the best information. For example, 22% In general, remember that the finer the may include sneezing or coughing, of the deaths attributed to nasal cancer dust, the greater the risk. tightness in the chest or wheezing or in North Carolina between 1956 and What then, are the risks of wood a feeling of restriction when trying to 1974 occurred in furniture makers. dust? In general, they can be divided breathe. In fact, a good clue is that these Increased incidence of nasal cancers has into certain broad categories. I will symptoms may start soon after entering been reported in furniture makers in concentrate here on personal health the shop, but in some cases may become many other countries around the world risks, although it should be noted that noticeable in the evening after work. as well. the risk of fire increases in a dusty shop Some patients have had cold like as well. Also, dust buildup in power tools symptoms, such as a runny nose, that Volatile Chemicals significantly degrades their operation have persisted for years. Needless to say, A wide variety of volatile chemicals, and safety as well. if one is a smoker, the risk is that much both organic and inorganic, may be Broadly speaking, the major greater of developing chronic respiratory found in the home shop. While many categories of health risks include skin problems in this situation. In the long of them are related to woodworking rashes (known as “contact dermatitis”), term, COPD may lead to shortness activities, such as finishing agents, asthma and nasal cancers. of breath even outside the woodshop, solvents, lacquers, etc., the home Contact dermatitis – The symptoms sensitivity to other inhaled agents, or basement shop also may contain of a contact allergic dermatitis may even congestive heart failure. As with combustion products from furnace include itching, redness of the skin and contact dermatitis, there have now been operations (such as polyaromatic hives (raised, fluid containing vesicles). so many species of wood associated with hydrocarbons and carbon monoxide), The eyes may be affected as well. In asthmatic change in the literature that it tobacco smoke and pesticides. So-called most cases, repeated sensitization would be prohibitive to list them all here, “off gassing” may occur from carpets, is needed, but since cross reactivity but in my review, I eventually found insulation materials and construction exists between many wood species, an almost all of the more commonly used adhesives, and may present a risk as well. apparent reaction can occur even if lutherie woods. Again, cross reactivity Simply being able to smell these agents the individual has not contacted that probably exists between some species, does not imply that they are causing a particular type of wood before. Further, and woods with a higher amount of health risk, but a healthy guide is to work a long time can pass between the initial extractives, such as cedar, may be more to bring these levels as low as possible, exposure and subsequent exposures, able to produce these types of responses. primarily by bringing a fresh air source making the diagnosis more difficult. If If you believe that you have developed into the workspace. When working in a contact dermatitis is suspected, a “skin any changes in your breathing ability close proximity to these agents, other patch test” can be done at a physician’s or comfort, it is important to discuss steps may be used such as wearing an office to determine if, in fact, the this with your doctor. Before a visit, approved mask or respirator. wood is responsible. While many of make a list of all of the types of wood, the symptoms can resolve over hours solvents and finishes that you use in the Biologic Problems or days after the exposure, in some shop, as well as a family history of any The basement location of many shops cases treatment with medications may respiratory problems. This information may present several unique biologic be needed. Keep in mind that these will definitely be useful in helping to problems. First, many basements are reactions can occur even on parts of the make the diagnosis. moist, providing a potential growth body that do not seem to be exposed, Cancer Risk – A fair amount of opportunity for molds, bacteria, algae, since fine dust particles can easily get epidemiology data over the years has and insects, all of which pose a potential inside clothing. One simple strategy that confirmed the fact that long term threat to human health. Common sites may be helpful is to wash your hands exposure to wood dust, particularly that of growth may include the concrete 29 walls, either unfinished or behind Close attention to one’s personal small electric charge to the air stream finishing panels, under or in carpeting health is also important, and signs being filtered to attract dust particles or insulation, and in the filters of air or symptoms such as a cough, rash, to the walls and floors, thus removing cleaning units or in the drip pans of headache, watery eyes or breathing them from the respirable air. These dehumidifiers, which many of us use in difficulties may signal an environmental units may therefore eventually soil basement locations. The primary risk of problem. Keep in mind that these these surfaces. these organisms is that they may cause symptoms may not necessarily start Note that both electrostatic and infectious disease, allergies, or act as a immediately upon entering the shop, ionization type filters may produce skin or respiratory irritant. but may be delayed until hours later. ozone, which is not a desirable by- In general, all airborne hazards, such product. Radon as dust and volatile chemicals (including Air filtering units can be rated in Radon is a colorless, odorless gas tobacco smoke) become more hazardous terms of their “clean air delivery rate formed by the radioactive decay of as their concentration increases. (cadr)”, which refers to the volume of radium (a naturally occurring element Therefore, allowing a fresh air source filtered air delivered by the unit. The found in soil). As radium changes into the shop is critical, as long as the higher the “cadr”, the more air is being into radon, it can diffuse into the air source of that air is not contaminated filtered. In general, choose a model of air and dissolve into water. The highest itself. The temperature and humidity cleaner that has a cadr rating number at concentrations of radon are found are important as well. As temperatures least 2/3 that of the room’s floor square in the basements of homes. Radon go up, bacterial growth increases, and footage. The website www.cadr.org (a accounts for about half of the naturally off gassing from carpeting, for example, service of the Association of Home occurring radiation that we are all may increase as well. Relative humidity Appliance Manufacturers), provides exposed to during the course of normal is probably best kept between 30 and comparison data for participating life, and is present in 5 to 10 times 50%, with low humidity increasing the manufacturers. Proper maintenance greater quantities indoors. The main likelihood of skin irritation and higher and filter changes are very important risk of radon is that it has been linked humidity increasing the growth of (set up a schedule!), as all filtering units to the development of lung cancer. All biologic organisms. lose their efficiency as they clog and basement shops should be tested for become a haven for bacterial and mold the presence of radon and if high levels Air Filtration Units growth. Many units also have washable are detected steps must be taken to Many of us use air filtration systems filters, which is a nice feature. I would lower the levels. The National Radon in the home shop, with a goal to reduce recommend that every shop have at Information Line can be reached at 1- the microscopic particles as much as least one of these units, preferably a 800-767-7236. possible. There are several types of air HEPA rated air filter to help control As a final thought on the health cleaning units available for home use. airborne dust. The size of the model impact of environmental factors in the Some are free standing “bench top” may be based on the unit’s rating for a home shop, I should also encourage models, and others may be hung from particular size room. Air filters should all of us to be aware of the need for the ceiling. There are several basic types be placed in a part of the shop where adequate lighting and control of excess of units. In general, all of these operate they have access to good circulation noise. by drawing air into the unit with a fan, throughout the work space. While and forcing the air through some type controlling dust suspended in the Strategies for Lowering the Risks of filter, which can be either purely room is always a good idea, there is no Having briefly discussed some of mechanical or electrostatic in nature. substitute for a fresh air source. the potential sources of risk, how do Filter types are as follows… A note on ozone – Ozone generators we go about protecting ourselves? First, HEPA filters – HEPA stands for “high are sold by a number of manufacturers we have to recognize that a problem efficiency particulate air”, and to make as air cleaners/purifiers. Ozone occurs may exist, even if the shop looks this claim the filter has to be able to naturally in the upper atmosphere of superficially clean. A close inspection, remove 99.97% of particles from the the earth, where it acts to absorb some perhaps with a friend or colleague who air greater than 0.3 microns in size. of the ultraviolet radiation that would is not very familiar with your shop, can This would include the majority of otherwise reach the Earth’s surface. In a be invaluable in assessing at least the dust particles found in the shop setting. closed space, however, ozone is harmful degree of visible dust, the adequacy of ULPA (Ultra-HEPA) should be able to humans, and may cause throat lighting and noise containment, and to remove 99.999% of these same irritation, worsen asthma, and lead to the presence of any unpleasant odors particles. lung problems. There is no convincing that could indicate either volatile Electrostatic precipitators and electrostatic evidence that ozone technology provides chemical products or molds or bacteria. filters – These units charge the filter any significant air cleaning ability, or Commercial kits are available for with an electric charge in order to that it neutralizes volatile chemicals radon testing, and should be used in theoretically increase the amount of in any way that would justify the risk. accordance with the manufacturer’s dust attracted to the filter. An excellent source of more detailed instructions. Ionization filters – These units add a information is the Environmental 30

Protection Agency’s web site: their use and efficiency. The system is lighting for yourself, and take steps to www.epa.gov/iaq/pubs/ozonegen.html. as follows: N = protects against aerosol lower the exposure to unnecessary noise particles free of oils (e.g. wood dust); R including wearing ear protection. Keep Vacuuming = protects against oily aerosol particles; your hand and power tools sharp, as dull Controlling the pollutant dust at P = protects against very oily aerosol tools produce more dust. its source is one of the mainstays of particles. The number rating that In summary, be aware that certain improving air quality in the shop. If follows gives the mask’s efficiency in risks may exist in home woodworking practical, all power tools that generate terms of filtering out a percentage of the shops. While specific recommendations significant quantities of dust should particles. For example, a simple mask regarding air quality standards exist be hooked into a properly grounded such as the 3M sanding respirator, used for the industrial workplace, they are vacuum system to reduce the amount for wood dust protection, carries a rating not readily available for the home shop. of dust that is free to get into the air. of N95, demonstrating 95% efficiency Although it is not practical to remove Electric grounding lowers the risk for in filtering out non-oily aerosolized all of the potential risks in the shop, static electricity induced fire in the particulate such as wood dust. it is reasonable to study your unique dust. I usually vacuum the floor at the Masks should be tightly and situation, and take some reasonable steps beginning of a work session to get the properly fitted to lower the amount of to at least lower your risk. Use the three dust that has settled overnight and again air that gets in around the mask and guiding principles of bringing in fresh at the end of a work session to get the replaced when breathing through them air, controlling the pollutants at the dust that has been visibly generated. I becomes difficult or in accordance with source and cleaning the air if possible. make sure to vacuum the workbench and the manufacturer’s recommendations. Above all, always respect your health. It all of the little dust hiding places that I In general, most simple masks do not is your most important asset. have discovered as well. I try to avoid provide protection against volatile sweeping unless there is an unusually vapors. For this purpose, a properly References large quantity of larger dust and wood chosen respirator with replaceable 1. Somogyi, Ervin, Wood dust: Beware, Journal of chip particles, and then I sweep slowly cartridges is a much better choice. American Lutherie, 1979 to avoid stirring up extra dust. Sanding 2. Dust Collection Basics (Recommendations seems to generate the largest number Dermatitis Protection for the home shop): 2nd edition, Woodstock of small particles, and there are a few There are a few strategies that can International, 1991 strategies available to lower the risk. First, be used if skin sensitivity becomes an 3. Woodshop Dust Control, Sandor Nagyszalanczy, consider sanding outdoors (and using issue. First, gloves may be worn during The Taunton Press, 2002. An excellent volatile organic chemicals outdoors) if the steps that have been shown to be text, with an aim to designing systems for the weather permits. It’s a great way to irritating to the skin in the past. Hand controlling dust in the workshop. decrease the amount of dust that you washing helps reduce the amount of 4. Understanding Indoor Air Quality, Bradford breathe, and the view is certainly more irritant on the hands, but does little O. Brooks and William F. Davis, CRC Press, interesting than in my shop, for example! to protect other parts of the body that 1992. An excellent overview of the science of Keep in mind that vacuuming does not may be exposed to dust even under the understanding air quality. guarantee that the air will be kept clean, clothing. If possible, the use of a skin 5. Medline and Toxline (internet access) of the however, as a surprising amount of dust moisturizer may act as a barrier to lower National Library of Medicine. may escape from the bag directly into the amount of direct particle contact the air. If hand sanding must be done with the skin. 6. Environmental Protection Agency Web site: indoors, consider the use of a sanding www.epa.gov. This site contains much useful table equipped with a vacuum duct A Few Final Thoughts: information, particularly the sections on drawing air through the surface. If the Carbon monoxide sensors and fire indoor air quality. job allows it, wet sanding will decrease detectors with battery backup are always 7. Association of Home Appliance Manufacturers the amount of fine particulate that a good idea, and be sure to test the “peak” web site: www.aham.org. Presents reaches the air as well. reading from time to time if the unit is so information on various manufacturers and equipped and to change the batteries on models of air cleaning devices. A related Masks a schedule. Proper maintenance of the website is www.cadr.org, which compares the For particularly dusty operations, or home furnace including filter changes “clean air delivery rate” of various types of air when using volatile chemicals indoors, can certainly improve the general air cleaning devices. the use of a properly fitted, clean mask quality in the shop as well, particularly 8. The 3M company runs a website called or respirator is prudent. One of the in the winter months when it becomes www.filtrete.com, which provides useful most important things to remember more difficult to open the windows and educational information on filters and about masks and respirators is that you bring in fresh air. Carpeting should masks. must choose the proper model for the probably be avoided in the workshop. job at hand. Masks use both a lettering Check for radon, and take steps to lower and numbering system that defines it if high levels are found. Provide proper meetings and events 31

Jan 27th, 2007 by Marcel Durette Granite State Woodturners from a log to a bowl – meeting at Scott Ruesswick’s shop in Canterbury, NH

The atmosphere was times during his demo, Ron shared festive to say the least. Andy’s approach to bowl turning which is Scott and Barb, always breaking it down to its three components the perfect host and – the outside, the inside and the bottom hostess, provided not or foot of the bowl. Although expensive, only coffee, but pastries Ron made a strong case for buying a and more importantly, chuck. I became convinced when he had seating for almost such difficulty in re-centering the blank everyone! No small feat on the faceplate to hollow out the inside. for such a group. Forty-five onlookers didn’t make it any Jon Siegel reminded easier either! us of the benefits of While claiming to favor the 5/8˝ bowl being a dues paying gouge with the side grind made famous member of the by David Ellsworth, he also uses a 3/8˝ GNHW as well as the bowl gouge for some finish cuts in the photo by Tony Immorlica Tony by photo AAW. Dick Batchelder interior part of the bowl. When asked reminded us that Jon why, he simply responded, “Because I ith the outside temperature has served as president of the GSWT like it”. Of course he elaborated on the Win the single digits and a light for three years and urged us to consider reason but to this writer, he had summed snow falling most of the day, forty-five stepping up. He assured us that the up his approach to woodturning. Ron is people gathered at Scott Ruesswick’s candidate would have the support and comfortable at the lathe and has a solid shop to hear and watch Ron Pouliot backing of all the past presidents! base of knowledge about the craft, and demonstrate bowl turning – From a Log Ron was introduced and quickly he likes it! It shows. to a Bowl. took control of our attention. Noticeably Jon gathered everyone to the opposite Bob Coleman and I arrived at 8 am well prepared, he came complete with end of the room where the auction was sharp to find Scott preparing coffee props and fresh from having given the to take place. Watching him auction off and the wood fired furnace was already same demo only two days earlier at the all the great stuff that people brought, warming the shop up to a toasty warm. CNEW meeting. He gave us tips, ideas including some bubinga donated from A steady stream of old and new faces and instruction ranging from safety Rockler, is always great fun. I swear that started at 8:30 and once again I watched and the importance of a face shield, to he could have you bidding on your own forty-five “strangers” gather to share their fiddling with a jam chuck to turn the shirt and you’d probably thank him for passion for woodturning. bottom of the it as you handed over the money! He bowl – he finally raised almost $350 for the guild in less resorted to the than an hour. I collected the money paper towel trick! from the winning bidders and you know Quoting Andy what, all of them thanked me! Nice job Motter several Jon.

photos by Tony Immorlica photos by Paul O’Connell meetings and events 32

Feb 3nd, 2007 by Greg Benulis

Beginner & Intermediate Group photos by Jim Seroskie tapered sliding dovetails

which when To begin, on fitted in the the sides, we slot, allows you use the slot we to rapidly align cut in the top the router bit to set the proper on a centerline height for the located on the bit in the router work piece. table. Bob he GNHW BIG met on Bob stressed the importance of makes a couple TSaturday, February 3 at Bob marking all the parts to insure that of test cuts in LaCivita’s shop in Nottingham, all the cuts are made on the proper some scrap NH for the third part in the pieces and everything lines up. The to make sure cabinet design and construction slots are cut in the top and bottom everything is series. pieces while the male dovetails are lined up properly. The meeting opened with an cut on the sidepieces. The first cut At this point, we stop and choose the actual examination of the effects of the is made with a straight router bit top and bottom pieces of the cabinet based on the passage of time on the parts of our to clear out the slot. presence of any defects and the figure of the wood. cabinet. The top and sides were in Following this, the slot is The male dovetails on the sidepieces are initially good shape but the shelves had finished with a ten-degree dovetail cut straight to fit the wide end of the tapered slot. developed some cupping which bit. This angle was selected to We will make multiple cuts to work our way to the may require a design change. match the angle of the ECE precise size we need. The lesson for the day was the dovetail plane that will be used on The final taper is done with the dovetail plane. tapered sliding dovetail, which is the mating male joint. You have This is achieved with multiple passes of the plane the joint we will use to attach the to pay attention to the rotation with each cut starting closer to the end of the board sides to the top and bottom of our of the bit and it’s relation to the that will be the narrow end of the taper. After several cabinet. The point of the taper is direction of cut so that you do passes, we make a test fit to ensure that our joint will to have the initial fit of the joint not break out the wood as you cut fit tightly. This process is repeated until the full taper loose and then tight when the each side of the slot. You also must is achieved. part is in it’s final position. Bob not lift the router at the end of the The meeting finished with the assembly ofthe showed us the router jig that will cut but continue until clear of the shell of our cabinet. be used to cut the tapered dovetail wood. This is because of the taper slot. The taper is small, roughly on the dovetail bit. tapering 3/32˝ over the thirteen After routing, the slot is cleaned inch length of the jig. up with sandpaper to make fitting The jig uses a small block, easier. When the top and bottoms are slotted, both pieces get their final surfacing before the male dovetails are cut on the sides so that the depth will be right and everything fits tightly. Lynn Szymanski guided members thru the UNH woodshop Harvey Best T meetings andevents on at an upcoming meeting, please let me let please meeting, upcoming an at on University of NH campus inDurham. ofNHcampus University ie o hr ad ie sot discussion short a give and share to like Group, asked its members to look over look to members its Group,asked Guild Meeting at UNH know. has repaired furniture in the past, agreed format, Guild member Harvey Best gave repair techniques. the examining suggestions.repair After to the Guild meeting and discussed his discussed and meeting Guild the to table, along with restored before and after the photos brought He it. restore to Harvey,meeting who PFG the at table make and table antique damaged their a short a discussionshort on a table he restored person knowing of the Period Furniture regularour meeting.to business prior A Feb 17 If you have a topicIf you or project would In a departure from our normal normal our from departure a In ed t h woso o the on woodshop the at held was meeting general February he avys icsin a s well so was discussion Harvey’s th , 2007 aig h Beast the Taming Was it the location,Wasthe demonstrator,it topic, David Upfill-Brown. He is He Upfill-Brown. David E H cle hs lecture his called He ME. rfsasi i Rockport, in Craftsmanship with the regular business meeting.The business regular the with influences attendance at aGuild meeting. received,should format new the think I the lead instructor of the nine- everyone sits in their chair chair their in sits everyone meetwithlike-minded individuals. can meeting to moved then discussion month comprehensive class class comprehensive month go people most that seems It meeting? or do you just go because it’s a Guild Guild a it’s because go just you do or t h Cne Fr Furniture For Center the at attendance.what to as taken was poll A because it’s a Guild meeting and they they and meeting Guild a it’s because be continued. The main presenter was presenter main The ae nesn hn proceeded then Anderson Dave by SalMorgani . Normally Normally . ai’ fakes n sne f humor of sense and frankness David’s with each tool. Maintenance and tuning also safety.He on emphasis big a with o t oeae ah ol effectively, tool each operate to how shop.Going the in machine individual rm rl pes t bnsw o jointer, to bandsaw to press, drill from o alsw o ah. ai discussed David lathe. to tablesaw to each around gathered time.We all this discussed various jigs and fixtures used fixtures and jigs various discussed f h mcie ws lo reviewed. also was machines the of added spicetothetalk. and watches a demo at a workbench. Not David Upfill-Brown photos by Myers Roger 33 meetings and events 34

Mar 10th, 2007 by John Whiteside Period Furniture meeting at the Old South Church in Newburyport, MA

at the early massive 1756 post and beam structure raised by Newburyport’s finest shipbuilders. How often is it that you get to see a 6˝ thick mortise and tenon joint into a 16˝ square x 40+ ft. hand- hewn white oak timber that was cut in the spring of 1756 along the banks of the Merrimac River.” A Paul Revere bell graces the steeple. Inside the church, there is a view of the photo by Mike Noel by photo magnificent sanctuary. photos by John Whiteside nfounded concerns that Period off his tiger maple Shaker-style rocker. UFurniture Group standards One of the neat things is that during intimidate members and discourage construction, Mike sought and received all but the most accomplished have from the group a lot of advice on what been forever put to rest. At the March finish to use to make the figure really meeting, we strongly encouraged less pop. As you can see, it does. experienced members to show off their New member Mike Noel showed projects and so were more than a little a granite-top coffee table that he concerned when Guild President Dave designed and built using walnut and Anderson said he planned to bring the maple. Notice how his maple side rails Queen Anne tea table he has been contrast with the walnut stretchers. working on for over a year. Furthermore, Mike had the design idea Oh, dear, we thought, Dave’s piece to turn the sapwood faces of his walnut will so outshine everyone else’s that legs outward and visible, rather than people will be discouraged. Well, we hiding them towards the center of the never got to see Dave’s piece. He reports table, thus harmonizing with his side that when he lifted it up to carry it out rails. to his car to bring to the meeting, all Also, we got to see Bill Daunis’ the legs fell off. He muttered something beautiful Queen Anne tilt top table Bill Daunis with his Queen Anne tilt top table about maybe mixing the hide glue at which will harmonize well with the the wrong temperature (for the record, Queen Anne side chair Bill showed off it should be 140 degrees and not too at the last meeting. thick - closer to cream than molasses Mike Cyros had arranged for in consistency). In any event we got us to meet Old South Church in to see three excellent works by group Newburyport. This is the oldest wooden members. church in New England and has great Meeting host Mike Cyros showed historical significance. Its governance structure was a model for the US constitution. Benedict Arnold and his men mustered for the invasion of Canada from there. The church steeple has just been restored and members had the opportunity to climb up inside with his tiger maple rocker Cyros Mike the steeple. Members entered the extremely narrow passage way and stairs, wondering if they would fit. As Mike put it: “I’m pleased that many of you ventured up into the attic and then all the way up the steeple with me to look Mike Noel with his granite-top coffee table bulletin board 35

Treasurer’s Report Outstanding checks make it difficult To get on the email (or phone) list to The state of the Guild finances to balance the checkbook and the bank receive meeting notifications, contact: remains strong with income and may not cash checks that are more than John Whiteside: 603-679-5443 expenses tracking on budget. This has 90 days old. Also, the cost of replacing or [email protected] been a quiet year compared to the lost checks is $20. last two in which we had the Joinery Peter James - Treasurer and Turning Symposiums. Our major Closing Shop … Beginner & Intermediate Group expense is the publication of The Old Moving west and selling &OR3ALE Saw and this year it will run close to $25 This year, Bob LaCivita is taking most tools from my shop per member for the five issues. It should BIG participants through an entire in Enfield, NH. be noted that the Steering Committee project. The project is a small cabinet with Nova Comet mini-lathe voted to have three oversized issues. a drawer and two doors. – 10˝swing, 14˝ long/add on cap., #2 MT, 1˝x8 The scholarship committee has The next BIG meeting isApril 7. The TPI, 1/3 hp motor, 10 years old but barely used, been active and has awarded several meeting location is at Bob LaCivita’s very portable – $250 scholarships and also some special shop at 365 Stage Road (Rt 152) Powermatic 66 10˝ tablesaw on open roller grants. Of the $30 dues, $5 is directed Nottingham, NH from 9:30 am to noon. stand, Biesemeyer fence, extension table, to the education fund. The other major Please email or telephone (before 9 pm) some jigs, 1 ph,(available end of June) source of income for education comes if you plan to attend. – $1800 from the Sunapee raffle. Bob LaCivita 603-942-1240 or [email protected] Porter Cable Saw Boss 345 circular saw, 6˝ Our other Guild expenses are blade left, dust ejector, carrying case, like minimal and income for auctions at new – $110 the annual meeting and at the Turning Granite State Woodturners Kity bandsaw – 12˝ throat,1hp, 4˝ dust port, Group meetings covers most of them. The next meeting of the Granite tilting table, floor model on roller stand, extra The “enterprise” activities – book and State Woodturners will be May 26 from blades(available end of June) – $200 magazine sales, clothing sales, and video 9 am to noon. The location and topic is sales are self sustaining. The revenue TBA. Contact DJ Delorie to be added Other tools, accessories, and some wood will from the sales just about covers the to the e-mail notification list. be available by the end of June. costs. DJ Delorie: [email protected] Mary Lou Bryant: 603-632-7480 or [email protected] Account balances as of 3/14/07 Period Furniture Joiner/Planer … General Fund $22,467 The next Period Furniture Group Robland 12” Joiner/Planer in excellent Education $10,699 meeting is scheduled for May 12. In Capital Equipment $2,024 condition. Comes with HSS, Carbide and response to member interest, we plan disposable knives. 220 v, 3 hp. This is a great to show samples and techniques for machine! – $975. If you do receive a Guild check, a number of staining and finishing Peter Breu: 603-647-2327 please cash is as soon as you can. methods.

Suppliers offering discounts to Guild members Tools & Supplies Wood Products Big Tree Tools www.bigtreetools.com 888-TURNING Classic Designs www.tablelegs.com 800-843-7405 Brentwood Machinery www.brentwoodmachine.com 800-582-7229 Goodfellow www.goodfellowinc.com 800-990-0722 Chester Tool Works www.chestertoolworks.com 603-887-6267 Goosebay www.goosebaylumber.com 603-798-5135 Gary R Wood & Co. www.garyrwood.com 603-523-4337 Highland Hardwoods www.highlandhardwoods.com 800-442-1812 Lie-Nielsen Toolworks www.lie-nielsen.com 800-327-2520 Maine Coast Lumber www.mainecoastlumber.com 800-899-1664 Rockler – Cambridge, MA www.rockler.com 617-497-1136 Northland Forest Products www.northlandforest.com 603-642-8275 Rockler – Danvers, MA www.rockler.com 978-774-0241 The Millwork Shop www.t-n.com 603-643-3658 Rockler – Salem, NH www.rockler.com 603-898-5941 Wolfgang’s Wood Strafford, NH 603-664-7691 Williams & Hussey www.williamsnhussey.com 800-258-1380 Woodcraft – Newington, NH www.woodcraft.com 800-234-3818 Schools Woodcraft – Woburn, MA www.woodcraft.com 781-935-6414 Homestead Woodworking www.woodschoolnh.com 888-659-2345 Western Tool Supply www.westerntool.com 603-627-4957 McLaughlin Woods www.experiencewoodworking.com 603-783-9700 The Breed School www.allanbreed.com 603-749-6231 Services The Windsor Institute www.thewindsorinstitute.com 603-929-9801 Navis Pack & Ship Center www.gonavis.com/nh1063 603-424-1035 The Wood Finishing School www.patinarestoration.net 978-363-2638 Each supplier offers a minimum 10% discount to current GNHW members – some restrictions may apply. Ads are displayed in “The Old Saw” on a rotating basis. MINUTEMAN PRESS ® “The Old Saw” is printed by MinuteMan Press • 88 Main St, Nashua, NH • 603-883-4890 • www.nashuaminuteman.com

Williams & Hussey Machine Co., Inc. LASSIC ESIGNS C D Gary R. Wood & Co. by MATTHEW BURAK Straight, Round, and Elliptical Select Finishing Supplies Molding SOLUTIONS FOR THE PROFESSIONAL WOODWORKER Simple, Easy, Safe Table Legs, Columns, Cabinet Feet Quality Construction Shellacs, waxes, stains, Windsor Chair Kits & Parts Seven Year Warranty varnishes & tools for an elegant finish. Your questions are always welcome! MADE IN THE USA 10% Discount to 10% Discount to GNHW Members GNHW Members 24 Gristmill Hill Rd • Canaan, NH 1.800.843.7405 www.garyrwood.com 603-523-4337 OFFER EXCLUDES CUSTOM KNIVES AND OTHER PROMOTIONS www.tablelegs.com 10% discount to Guild members 800.258.1380 • www.williamsnhussey.com

10% Discount to Guild Members MAINE COAST LUMBER, INC 17 WHITE BIRCH LANE %BWF
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--$ SOFTWOOD LUMBER - MELAMINE XXXDIFTUFSUPPMXPSLTDPN MARINE PLYWOODS Strafford, NH EDGE BANDING - VENEER - MDO - MDF *MRIXVEHMXMSREPLERHXSSPWQEHIJVSQJMKYVIH I\SXMGLEVH[SSHW PARTICLE BOARD - CUSTOM MOULDINGS 1EVOMRKORMZIWE[PWGYXXMRKKEKIWFS[WE[W TPERILEQQIVW 603-664-7691 DOVETAILED DRAWERS - TARGET COATINGS  www.mainecoastlumber.com 
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10% discount to members! 52 BALD HILL ROAD ® NEWMARKET, NH 03857 NAVIS 10% Discount to 603-798-5135 PACK&SHIP CENTERS Guild Members Sawmill & Lumber www.goosebaylumber.com HOMESTEAD Reliable No-Hassle Shipping Partner for Your OODWORKING CHOOL 83 Dover Rd (US Route 4) W S Fine Furniture, Arts & Antiques Chichester, New Hampshire Alan S. Mitchell One-Stop White Glove Packaging & Shipping (10 Minutes from I-93 Concord • Take exit 15 east) Director In-State, Out-of-State & International Delivery 10% Discount to GNHW Members Local Pickup & Warehousing Specializing in Bird’s Eye & Curly Maple 25 yrs Experience Specializing in FLAV Green & Kiln Dried Bowl Blanks & Turning Squares www.gonavis.com/nh1063 • 603-424-1035 PHONE: 603-659-2345 Email: [email protected] Rare & Hard to Find Domestic & Imported Hardwoods TOLL FREE: 1-888-659-2345 Web: www.woodschoolnh.com 180 Locations in US – 5 Miles from Manchester Airport

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Serving NH for Over 30 years The Wood Finishing School e Highest Level of Customer Service Contractor’s Tim Corcoran Quality Stationary & Powered Hand Tools Choice!™ Store Manager 978-363-2638 www.patinarestoration.net 10% Discount Learn wood finishing to Guild Members individually or as part of a group on Non-Powered Tools Twenty-seven years experience Low Prices – Guaranteed 10% Discount to Guild Members 10% Discount for Guild Members Except machinery, power tools & already discounted items 100 Cahill Ave • Manchester, NH Teaching & Class Instruction Only 313 Route 125 • Brentwood, NH Off South Willow St. in front of Home Depot Bruce Hamilton Antique Restoration TEL 800-582-7229 • www.brentwoodmachine.com www.westerntool.com • 603-627-4957 Each supplier offers a minimum 10% discount to current GNHW members – some restrictions may apply. Ads are displayed in displayed Ads are “The Old Saw”restrictions may apply. listing. GNHW members – some complete rotating basis. to current See page 31 for a on a 10% discount supplier offers a minimum Each