SmoothingSmoothing CurvesCurves Trading lumps and bumps for fair lines by Ken Burton

Incorporating curves into a However, they come at a cost. The best approach to smoothing piece of furniture can really Curves take more time to cut than a curve depends on how well delight the eye. The interplay straight lines, and smoothing it was cut to begin with and between curved and straight whether a bandsaw, jigsaw, router, lines can help ease transitions In fact, if not faired properly, or some other tool was used for between sections and emphasize curvesthem demands can make a certaina piece lookfinesse. the job. In this article, I’ll show the overall form of a piece. worse rather than better. The last you how to do the smoothing Curves can also make elements thing you want are bumps, humps, appear visually lighter, more and other irregularities marring possible using common tools graceful, and even playful at the otherwise elegant sweep of a andas quickly shop equipment and efficiently as well as as a times. Whether in the form leg or table edge. And, of course, few simple shop-made helpers. curves must be clean and smooth moldings, or other shapely as well as fair, without scratches, Trimming with hand tools adornments,of contoured curvesedges, profiledhave scorches, or machine marks A few particular hand tools can a lot to offer your work. calling attention to themselves. make short work of removing

42 woodcraftmagazine.com June/July 2013 A Flat-soled spokeshaves work well for B convex curves, while curved-sole models On convex curves, a block plane will serve to remove are bett er suited to concave shapes. saw marks while fairing away lumps and valleys. saw marks while smoothing Pave The Way With A Careful Cut out any lumps and bumps to fair a curve. Traditionally, The cleaner and fairer a saw cut is to begin with, the less woodworkers have turned to ti me you’ll have to spend smoothing it, so learn to saw spokeshaves to handle this eff ecti vely. Regardless of whether you use a bandsaw, jigsaw, task (Photo A). A spokeshave or scrollsaw to make a cut, keep a few key factors in mind: is essentially a hand plane with First of all, use a sharp blade that is sized for the job at hand. For long, sweeping curves, a wide blade can help you keep the cut on curved), and handles that extend track, while ti ghter curves demand use of a narrower blade. When likea very wings short out sole to (eithereither side flat orof cutti ng with a bandsaw or scrollsaw, push the workpiece with a the blade. The short sole seats smooth, sweeping moti on rather than guiding it inch by inch. As you 1 solidly against both concave and cut, stay about ⁄16" outside your line to leave a litt le material for convex curves, and the handles smoothing away the saw marks. If you veer too close to your cutline, allow either pushing or pulling don’t suddenly veer away in correcti on. Instead, stop immediately, the tool to suit the work. For back up several inches, and then start feeding properly again. convex curves, you can also press a block plane into service as shown in Photo B. (For more on Figure 1: Spokeshave cutti ng directi on tuning and using spokeshaves, see Cut Woodcraft Magazine, issue #38.) Cut The trick to using these cutting tools effectively is to pay close Cut attention to the grain direction. If you hold your workpiece in Scrape or sand to a vise with the grain running clean up areas of horizontally, cutting with the confl icti ng grain. grain means cutting downhill, as shown in Figure 1. As the Cut drawing indicates, the areas at the crest of a hill or at the bottom of a valley are problematic because it’s here where the grain changes. Sometime a card scraper will help in these areas, or you may just have to sand away any tear-out.

Photos: Ken Burton; Illustrati on: Charles Lockhart June/July 2013 woodcraftmagazine.com 43 How To Be Fair A “fair” curve is one with a smooth sweep that’s free of visual or tactile humps and dips. No matter what tools or techniques you use to fair your curves, make sure to continually monitor your progress as you work. Having a good layout line as a target definitely helps, but simply removing material to the line doesn’t necessarily guarantee a fair curve. To do that, you need to tune in with both sight and touch. As you work, occasionally run your hand along the curve. You may be surprised at how receptive your fingers are to imperfections. Try Sighting along the curve from using your non-dominant hand, which may be more sensitive than a low, raking angle visually your dominant hand because it hasn’t been worked as hard. When foreshortens it, rendering irregularities start disappearing to the touch, scrutinize the curve from a any lumps, bumps, or flats low, raking angle, which will accentuate any remaining imperfections. much more obvious.

Power sanding aggressive cut while virtually As much fun as spokeshaves are layout line, as shown in Photo C. eliminating the chance of to use, they do require a certain flatFor on concave the table curves, and sand the idealto your scorching or burnishing the work. tool to use is an oscillating spindle When using a spindle sander, quicker, if less elegant, solution is sander (Photo D). Whether a choose the largest diameter toamount turn to of powerfinesse abrasives. and patience. If you A have the resources and space, a sander accepts drums of different smoothing. The broader stationary belt sander or a belt/ diametersfloor or benchtop to suit amodel, variety a spindleof surfacedrum that contact fits the helps curve prevent you’re disk combination machine can do curves. As opposed to the type you from sanding divots into a lot of the grunt work of truing of drum sander you might use the edge of the workpiece. As up curves. A benchtop model will in a drill press, a spindle sander when working with any power work almost as well. For convex rises and falls as it rotates. sander, use a light touch and curves, simply hold your piece This makes for a cleaner, more keep the workpiece in constant motion, feeding it against the rotation of the spindle as you work to your line. Your stationary belt sander can also serve for sanding some concave curves. Although there are very few instances when you should use a machine without its guards in place, this is one of those times. Removing the top belt guard presents the machine’s upper drum for use as a sort of spindle sander (Photo E.) The shortcoming is that you won’t have a table to help support your workpiece. All C D the same, the approach can be When sanding a convex curve on a To get the fairest curves and useful if you don’t have a spindle stationary sander, keep the piece longest abrasive life from a spindle sander. Just make sure to stand moving in a consistent sweeping sander, use the largest drum that off to the side of the machine stroke to fair and smooth the curve. the curve will accommodate. to avoid a face full of dust.

44 woodcraftmagazine.com June/July 2013 E F When shaping curves on the drum of a stationary A portable belt sander clamped sideways next to a belt sander, hold the piece perpendicular to the axis raised platform on a bench becomes a stationary of the drum, and check your progress frequently. sander for smoothing both concave and convex curves.

If your budget and/or shop the life and effectiveness of the space doesn’t allow for dedicated edges. As you sand, move your abrasive. Because the drum stationary sanders, you can workpiecesection works in the fine direction for convex doesn’t rise and fall, it’s not as sometimes trick out other opposite the belt rotation. effective as a spindle sander, machines to do the work. For You can also use your drill but it’s the next best thing. example, try tipping a portable press as a drum sander by Alternatively, you can quickly belt sander on its side and mounting commercially available throw together a shop-made mini- clamping it to your workbench. sanding drums into the drill drum sander with nothing more 1 Then use scrap plywood to chuck. Add a platform with a hole than a 3" length of 2"-diameter make a raised platform that in the center so you can support dowel (Photo H). Cut⁄ a 2"-long sits at the level of the abrasive your work perpendicular to the slit down the center of the dowel, (Photo F). The drum at the tool’s drum as shown in Photo G. By fold a 4 × 5" strip of sandpaper nose approximates a spindle raising or lowering the drill press in half lengthwise, and insert sander for smoothing concave table, you can adjust the point of it into the slit with most of the sanding contact, thus maximizing abrasive projecting to one side. Chuck the dowel in your drill curves, while the flat platen press, set the machine for a slow to medium speed, and feed your workpiece against the dowel. The abrasive will wrap around the dowel, effectively creating a sanding drum. As the paper wears, simply tear off the used section to expose fresh grit. Tip Alert Sanding end grain with power tools can create enough heat to scorch or even crack your G workpiece. To avoid this, use A boxed platform that accommodates a sanding a light touch, keep the piece drum substitutes for a spindle sander. A port in moving, and make sure to use the side allows attachment to a shop vac. sharp, clean abrasive.

June/July 2013 woodcraftmagazine.com 45 H I Insert a scrap of sandpaper into a With a tablesaw-mounted sanding disk, work slotted dowel to turn your drill press only off of the forward half of the disk, which into a sort of mini-drum sander. is spinning downward into the saw slot.

You can convert your Hand Sanding tablesaw into a disk sander Whether you’ve done the brunt up with hand sanding. Whenever using a commercially available of fairing and smoothing your possible,out the sheet the tricksandpaper to hand to sanding finish steel plate designed for the curves with spokeshaves or curves is using a backer block job (Photo I). You’ll also power sanding equipment, that’s shaped to complement the need PSA (pressure-sensitive eventually you’ll need to break workpiece curve. This works best adhesive) sanding disks to mount on the disk. One neat feature of these tablesaw Sanding Block Stock sanding disks is that you A good sanding block should be firm, yet resilient. For working can tilt them to sand bevels. flat surfaces, a solid block of cork about 1" thick is ideal. You can Unfortunately, a tablesaw- provide this same resilience to a curved sanding block by gluing a mounted disk spins considerably layer of sheet cork to it. Another option for sanding block material is faster than one on a typical polystyrene, commonly available as rigid insulation for the building disk sander, necessitating trade, inexpensive food coolers, and internal product packaging a very light touch to avoid reinforcement. Both cork and polystyrene can be easily abraded burning your material. to create sanding blocks that complement almost any curve.

J K To refine the shape of a complementary Even if the curve on an offcut is a bit lumpy, it sanding block, line the workpiece curve with will serve as a sanding block to fair the curve sandpaper and rub the block against it. on the piece from which it was sawn.

46 woodcraftmagazine.com June/July 2013 Tip Alert Sanding Profiles When hand sanding curves, Shaped profiles can be begin with the finest grit that troublesome to smooth, so aim will remove any spokeshave from the start to minimize the tool marks, saw marks, or amount of cleanup they might power-sanding scratches before need. When machining them, working your way up through use sharp bits that cut cleanly the finer sanding grits. and produce crisp edges. All the same, there will be times when you’ll need to sand a when the curve you are dealing profile at least somewhat. with is a true arc–a segment of Shaped profiles typically 1 a circle. Fortunately, many of don’t require fairing. In fact, as Contour sanding pads allow you the curves woodworkers deal you sand, try not to deform the to smooth a complex profile by with are true arcs or close to it. shape or dub over the edges. targeting one section at a time. To make a complementary Toward that end, contour sanding pads can be a big help. the radius of the arc by using Sometimes called “tadpole asanding compass block, or by first tracing establish the sanders,” these resilient backer workpiece curve directly onto pads are available in a variety the block. Then cut the block of profiles for detail sanding of on the bandsaw, staying a bit all sorts (Photo 1). Pick a shape proud of your cutline. Finally, that matches a section of your sand away the saw marks to profile, wrap it with sandpaper, arrive at the line. In some cases, and you’re in business. Another commercially block by abrading it against a available sanding accessory is a workpieceyou can refine curve the that’s sanding lined with sanding mop, which is essentially sandpaper, as shown in Photo J. a bundle of narrow strips of Another option is to use the sandpaper attached to a mandrel 2 offcut from the workpiece curve for mounting in your drill press A sanding mop smooths molding as a sanding block. As long as (Photo 2). As you hold your profiles in much the same you are reasonably careful workpiece against the mop, the way brushes in an automatic when making the initial cut, the abrasive strips conform to the carwash clean your vehicle. waste piece should be almost profile, smoothing it without a perfect match to the curve altering the piece’s shape. you are trying to smooth. Wrap Finally, you can make a a piece of sandpaper around custom sanding block that conforms to the workpiece the curve on the mother piece, profile using a relatively soft asthis shown scrap in and Photo use it K. to n refine material such as Homasote or polystyrene. Attach sandpaper to a sample of the profile About Our Author using double-faced tape. Then Ken Burton has been working rub your sanding block over wood for over 30 years and the sample to cut the profile 3 writing about it nearly as long. into the block, as shown Line a profile sample with He offers classes at his studio in Photo 3. Then line the sandpaper, and then rub a in New Tripoli, PA. Visit www. sanding block with sandpaper block against it to create a wrwoodworks.com for details. to smooth the workpiece. complementary sanding block.

June/July 2013 woodcraftmagazine.com 47 SUBSCRIBE! 2 YEARS for $29.99!

go to woodcraftmagazine.com and click SUBSCRIBE -or- Complete the form below and mail in an envelope addressed to: WOODCRAFT MAGAZINE PO BOX 7020 PARKERSBURG WV 26102-9916

□ Payment Enclosed □ Bill Me Name Address City State Zip Country E-mail

Best-ever DECORATIVE FINISHES Build Better Send in now to get LUMBER RACK Done Right with a CUT LIST

Projects, Techniques and Products

Build this 2 Years for $29.99! classic SPICE BOX And learn how to… Dovetail a case

Divide a cabinet into compartments or go to woodcraftmagazine.com and click SUBSCRIBE Create a cornice

By providing my e-mail address, I am indicating I’d like to receive information about my subscription and other offers from Woodcraft Magazine via e-mail.

Outside of the U.S and Canada add $30 for postage. Plus… Foreign orders must be prepaid. Payment in U.S. Funds only. 4 more projects Famous furniture