September 2006 Volume 18 No. 1 Queen Anne Wing Chair Frames Hand Cut Thru Dovetails

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

vee grooving • marking your work at large • target coatings • biedermeier style lamp

Sept 16 Period Furniture Sept 23 Annual Meeting Sept 30 GSWT – new date Oct 7 BIG Oct 19 GSWT/Mt Wash Valley Oct 21 Small Meetings Oct 22 NHFMA Auction Nov 11 Period Furniture Nov 18 Guild Meeting Nov 25 GSWT Dec 2 BIG Jan 13 Period Furniture Jan 27 GSWT Feb 3 BIG Feb 17 Guild Meeting Mar 10 Period Furniture Mar 17 Small Meetings Mar 24 GSWT Apr 7 BIG photo by Dean Powell Apr 21 Guild Meeting May 12 Period Furniture May 26 GSWT Jun 2 BIG porringer table by John Siegel Jun 16 Summer Trip legs, tiger maple top Jul 28 GSWT Aug 4-12 NH Craftsmen’s Fair Turning Dutch Foot Legs president’s message by Roger Myers  A Wonderful Experience

write this President’s message with over $4,000, another new record, and for me, and many mixed feelings as it will be my demonstrations by Guild members Dave Anderson Ilast as president of the Guild. It has assured a constant crowd around the has been an been a wonderful experience for me to tent during the entire fair and generated e x c e p t i o n a l have had the opportunity to serve the considerable interest in memberships. Vice President Guild in this role for the past two years. I’ve also had the great fortune to and provided Getting to know so many of you and work with a fantastic group of people tremendous assistance. to see the Guild continue to grow and in taking care of Guild business. The Before this sounds too much like an flourish has been very rewarding and an entire Guild steering committee academy award speech, I’ll stop and just experience I will never forget. devotes a great deal of time and energy say thanks everybody. I’ve truly enjoyed Seeing so many of our members in providing the strategic direction and the opportunity! volunteer their time, energy and talents leadership for the Guild. over the last couple of weeks at the DJ Delorie spends an incredible st Craftsmen’s Fair at Sunapee truly amount of time in maintaining our ever Oct 21 , 2006 exemplifies the qualities that make growing membership database, sending our organization something we can all out reminders and membership cards, Small Meetings take great pride in. Our annual raffle and maintaining the Guild’s website. to benefit the scholarship fund raised Jim Seroskie and his team of writers, e are working on a series of three reporters, and photographers – what a Wto five small shop meetings to great job they have done with The Old be held simultaneously at different . It is truly a newsletter without locations on the third Saturday in equal. A publication like this doesn’t October. The Guild’s small meeting come about without extraordinary effort format has met with much success in and dedication! the past, so we hope you will be able to Treasurer C. Peter James, and take advantage of this opportunity to Secretaries Ed Jones and Greg Benulis see some other shops where the venue is have worked diligently behind the focused to individual interests. scenes. An email will be sent to all members Our past president, Peter Breu, in October with details. Or check into See Sunapee report on page 26 was an outstanding mentor and coach the Guild web site at www.gnhw.org.

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President Roger Myers 603-773-9634 [email protected] & 4

/ t Vice President Dave Anderson 603-887-6267 [email protected] Scholarship Committee t 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 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 Brian Sargent 603-483-1330 [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 David Frechette 802-633-2561 [email protected] Books Tony Immorlica 603-673-9629 [email protected] GSWT President Jon Siegel 603-768-5882 [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 Programs Sal Morgani 603-772-1006 [email protected] Shirts/Hats Peter James 603-435-8133 [email protected] Small Meetings Brian Sargent 603-483-1330 blsdesigns126@earthlink .net SubGroups Sunapee Fair Dave Anderson 603-887-6267 [email protected] BIG Bob LaCivita 603-942-1240 [email protected] Video Librarian Bob Trahan 603-444-5284 [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 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 

Sept 23rd, 2006 – 9:30 am many good buys, it is rumored that ebay Dana Robes Craftsmen is coming to buy our “stuff ” for resale Route 4A Annual Meeting on their internet site. Try to bring your at Dana Robes Wood Craftsmen Lower Shaker Village, Enfield, NH items early so we can put it on display www.danarobes.com for all to look over. This will also give you do not believe time to tour the workshop and gallery which Take exit #17 off I-89. Go east on Iit but another in itself is worth the drive to Enfield. Rt. 4 toward Enfield. Proceed two year has gone Presentation – Jere Osgood has been miles to the intersection of Rt. 4A. by since the last designing and making furniture in his Take a right onto Rt. 4A. Proceed Annual Meeting. own workshop for almost fifty years. three miles. You will see the Shaker Time sure flies when you are having fun During this time he has received many Inn on the left. Dana Robes is the woodworking! This year’s meeting place awards for his furniture. He was named second one on the left after the Inn. is at Dana Robes – custom furniture and a Fellow of the American Craft Council cabinet maker also offering a variety of in 1993 and was given the Award of workshops. Distinction by the Furniture Society show a few slides of his work – pieces Business Meeting – Two items of note in 2002. Jere’s work has been included he considers to be original. He will this time are the election of officers in many permanent collections such explain his approach to designing a and a discussion and membership vote as, the American Craft Museum (NY), piece of furniture, use of a sketch book, on by-law adjustments. The proposed the Museum of Fine Arts (Boston), the scale drawings, full size mock-up, shop by-laws and change summary were Renwick Gallery of the Smithsonian drawings and then the making of the included in the June issue of The Old Institution’s National Museum of piece. Then he will explain how to Saw and may be viewed on-line at American Art and the Currier Gallery design and the possible need to change www.gnhw.org/mission.html. of Art. His work is also in many private his approach. Bring your questions as Annual Auction – The annual auction collections. To view some of Jere’s work, Jere has a wealth of knowledge to share. is a big fund raiser, so let us get behind go to www.furnituremasters.org. Parking – Parking is always a bit of it and bring our hardly used “stuff ” to Jere will present Process of Design a problem, so please carpool if possible. be auctioned off. Last year we had so after our break for lunch. Jere will – Syd Lorandeau

Treasurer’s Report by Peter James

his past year has seen a lot of has awarded $10,647 in grants and numbers have activity in the financial area of the scholarships. This year, the Steering risen so quickly TGuild. I did the five year filing for our Committee decided to assist the New in my opinion. 501(c)(3) status in the fall of 2005. This England Association of Woodworking Year end status makes donations to the Guild Teachers with a grant that was used to membership is tax deductible. In addition to this filing, promote woodworking in schools. As a over 475 – up I also had the regular IRS and New guild, we need to benefit not only the about 100 over Hampshire Secretary of State’s office members but the general public as part where we were one year ago and over filing for our not-for-profit reports. of our 501(c)(3) status. The amount 160 where we were two years ago. There The big event of the year was the awarded in scholarships was $7,320. will be increases in both production Turning Symposium held in May Since we converted the video library and mailing costs for The Old Saw this at Pinkerton Academy, Derry. We to DVD format, sales have increased. coming year, but it is still within our had record attendance and record Video sales along with books, magazines budget without a dues increase. Costs expenditures. The net profit from this and shirts (the enterprise activities) are for the newsletter will approach $25 per event is split three equal ways. One third self sustaining. Income from the sale of member this year. goes to Pinkerton for use of the facility, the DVDs covers the cost of those in This report is being put together one third goes to the Guild Scholarship the lending library. with two weeks remaining in our fiscal Fund and the Guild general fund retains Costs for The Old Saw have gone up year. There will be some slight changes one third. We netted out about $9,000 dramatically due to production cost and in that period and I will give a report so Pinkerton and the Scholarship fund the greatly increased membership. The at the annual meeting in September. received $3,000 each and the general quality of the newsletter (magazine) is Again this year, it has been a pleasure to fund retained just under $3,000. something the Guild is proud of and be your treasurer. The Scholarship Committee is the primary reason membership See cash flow report on Page 27 Write to [email protected] with your questions 

Summer Swelling – Why days before waxing. Like many surface of fixing it up, or the cost? The cost Q do drawers and doors get films, water based finish dries quickly and time will often exceed reason with tight (hard to open) or stick in the but needs time to harden. making old serviceable. Most summer? – Anon importantly, know what you are buying! Used Machinery — When Don’t buy a head or planer Joe Barry replies: Think of wood as Q considering the purchase of because they were considered unsafe in a sponge. In the summer the air is used machinery. What should one our grandparent’s time. more humid and it absorbs moisture be looking for to insure that the and swells. In the winter the drier air machine is worth buying? – BL Decals — I make old post causes it to give up moisture and shrink. Q office box banks. One of the A finish only slows the exchange of Jon Siegel replies: Are there parts things that I need to keep the banks moisture with the atmosphere - it can missing? If so you should check on the authentic is numerical decals for the never fully seal out moisture exchange. availability of these parts before buying. windows. Can anyone give me a clue A house with humidity control will If the machine is old, you may not be as to where I can obtain numerical lessen the movement. However, few of able to get original parts. In this case, decals. – John Willse our customers will have a museum grade consider fabricating the parts yourself environmental control system. We just or buying an aftermarket item (such as Bob LaCivita replies: This is a stab. need to allow for this when we build. a ) which might be even Sign and banner companies have You may have heard the expression better than the original one. graphic programs that seem to produce “a nickel and dime fit.” One meaning Look for signs of poorly made repairs. any font in the world. They can make of this expression is that when fitting Castings which have been broken and vinyl letters. They also might put you doors or drawers in the winter when brazed back together are rarely accurate, on track. the wood is driest, allow a nickel sized and may break again. space. Conversely, allow only a dime Has the machine been taken care Herm Finkbeiner replies: There are at space when the wood is at it’s largest of? Obviously, you should look for least two types of decals available. Dry dimension in the summer. Experience rust, or any signs that the machine has transfer letters can be obtained in almost in your shop and with different species been stored outside. Have the adjusting any art supply store. A common brand will give you a better feel for just how screws been lubricated? If adjustments is: C-Thru Demi-Better Letters. Their much allowance is required. work smoothly, and the knives are sharp product is available in about 30 different (jointer or planer), this is a good sign. If fonts and 3-6 sizes in each font. Herm Finkbeiner replies: Drawers stick buying a machine from a woodworking The other type lets you make decals because wood gets bigger in the high shop, look at the shop itself. Is it orderly from anything you can put together on humidity of summer. For a very graphic and well kept? Although indirect, this your computer. The decal is produced explanation of the phenomenon, see the is an amazingly good predictor of the on a regular printer so it can be any web site: http://timber.ce.wsu.edu/content.htm maintenance the machine received. composition and color combination. Click on “Moisture Effects” then click on The system I use is by McGonical Paper “Next”. Joe Barry replies: With used machinery & Graphics www.mcgpaper.com. Hope I like to see it run. If not possible, when this helps. Water Based Finish — How was the last time it was run? Stick to the Q can I use water based finish & established brands that support their Jim Seroskie replies: Try these sources: get good results? I need a low VOC tools. I can still buy parts for my Unisaw • www.lettersunlimited.com product to use inside a residence. built in 1948 from Delta. I just bought a • www.brucknerhobbies.com/vinyl_ – Peter James used Powermatic shaper because I know letters.htm I will be able to maintain it and get • www.speedysigns.com/lettering/ Gary R. Wood replies: If appearance accessories. Check the manufacturer’s • www.staples.com then search for is a concern with water based finish, I web site to see if parts are still available “vinyl number letter” often over the last coat. Wax can for the machine in question. If you • www.quillcorp.com then search for give more depth and richness to the want to buy a fixer-upper, ask yourself “vinyl letter” in quotes final finish. It is best to wait a couple of why. Are you doing it for the pleasure current work by Bill Thomas 

building Queen Anne Wing Chair Frames

Photo by Frank Cordelle

then, and appreciate I also had to learn about the that I had the requirements of upholstery frames. opportunity to get I had some experience making slip the proportions seat frames in school, but knew little correct at the about wing chairs. I got out my books beginning. Queen of antiques and looked up every photo Anne wing chairs I could find of bare frames as well as are big and wide, upholstered chairs. One thing became but the lines of the clear pretty quickly. While more modern wings and arms chairs are often covered with quite thick balance the cabriole upholstery – “overstuffed” is the term – legs and turned eighteenth century practice was to use a stretchers to form a minimum of padding for comfort and let refined whole. the frame define the shape. My term for The proposed good period upholstery is “crisp”. When arrangement was I went to measure the original chair, I Photo by Bill Truslow by Photo that once I made a worried about getting the shape of the sample frame they frame without taking the upholstery n 1982, when I had would keep it in their shop to show off. I need not have worried because the been in business for potential buyers. When an order came padding was thin enough to make the just a few years, I was in they would call me and I would have dimensions of the parts pretty obvious. approached about eight weeks to fill the order. Initially they An important consideration is the idea of building offered me $500 per frame. Even in the how the upholsterer is able to pull the Newport style Queen Anne wing chair best light in 1982, $500 seemed close fabric tight over the frame. An advance frames. The two people involved were to slave wages, so I knew that to make over original antique frames was the an antique dealer and the owner of a it worthwhile I would have to work fast. introduction of “spreaders” or upholstery shop selling reproduction furniture. The I knew I could make one chair from rails to allow the fabric to be stretched idea was that since antique Queen Anne scratch, but to make multiples I was on the inside of the wings and back. I wing chairs were so scarce and highly going to need jigs that would allow me was warned early on to include these as sought after, there would be a market for to make the same parts over and over they make the job much easier. well-made reproductions. The antique with consistent results. Chair frames I knew from school that the best dealer knew someone who owned an don’t necessarily lend themselves easily wood for an upholstery frame would original chair and knew that he could to working this way, but since the wood be ash due to its resiliency. A frame has borrow it so that I could measure it. The of a wing chair is only seen below the to be able to accept and hold hundreds desirability of these chairs was proved seat frame, I realized that the majority of of tacks. Every time it is re-upholstered when he brought the chair into his shop the frame could be done by this method. it needs to stand up to being re-tacked. and got immediate offers to buy it. It helped that I had been spending time So the frame would be ash, with the Measuring the original was a big visiting a shop in Concord, NH where primary wood the choice of the buyer advantage for me. I have seen many I had been learning about the use of (traditionally walnut) for the legs, and so-so interpretations of the design since shapers in production work. some poplar for the turned rolls. 

surface. A fixed ring eliminates this the coil springs for the seat. It consists problem. The shaper knives are set in of a front and two side rails cut from line with the outside diameter of the 13/4˝ ash with the side rails horizontally ring and shape the work piece exactly to mortised into the front rails. The side the jig. This method is used to profile and front rails are profiled on the shaper, all the other major shaped parts of the the tenons for the back posts are cut, chair frame if they are square edged. By and then the side and front rails are changing knives, I can shape the molded glued together. parts with the same setup. Next, the side rails have to be mortised At this point in the process I start for the wings and arm stumps. This is to employ a jig I designed which helps the real reason I built that mortising out quite a bit. It is a mortising jig for jig. These mortises are at an angle to my plunge , and it consists of a the inside faces of the side rails. I rectangular platform of stacked the side rails to the front edge of the about two inches thick which is set on jig, using the back edge of the front rail low legs so that it can be held in the as a locator. The fence then has angled dogs on my . The leg height positions for routing the wing mortises is just enough to allow a bar clamp to and the stump mortises – both left and pass underneath. right hand. The final steps on the seat In use, the work piece is clamped frame are the square through mortises Indespensible shaper & wing chair jigs to the front edge of the jig. A fence is for the front legs. positioned on the top of the jig to line Making the base of the chair consumes Building the first frame involved the router up to cut specific mortises. about a third of the total time. Since this is not only constructing the chair, but The fence is held with through bolts the part where wood is visible, it is worth also building the jigs and planning my that thread into t-nuts on the underside it. This is especially because Queen approach to solving joinery problems. I of the jig so that it lines up exactly the Anne chair legs and stretchers are started with a full size drawing, which same every time. beautiful designs. I traced the original allowed me to see all dimensions, For the back posts, the fence has a cabriole legs. Note that the way the leg joints, and angles actual size. A wing position which lines up the side rail and is incorporated into the design makes chair frame is a complex assembly side stretcher mortises, a position for it end up not entirely symmetrical. The with angled joinery and odd-shaped the back rail, and another position for most obvious detail is the joint with parts. I couldn’t afford to make a huge the crest rail. I can do all the joinery for the side stretcher. This is a rectangular investment in elaborate jigs at first, so the back of the chair in a very short time. even though the I solved each joinery puzzle with the The back seat rail and crest rail are made front of the stretchers are round. A simplest methods I could come up with. and their tenons cut and fit. The turned round tenon would take too much I will describe how I go about back stretcher is then joined to the posts material away and seriously weaken the building a chair and talk about my with round tenons and the back frame legs at their narrowest point. The back solutions as they arise. Of course, I am is ready for glue-up. The crest rail is edges of the leg blanks are the shoulders going to simplify things, or I would take bandsawed and shaped after the back is of the stretcher tenons so a flat is left up the whole newsletter. glued. I start a chair with the back frame. The New England first pieces I cut are the two back posts. Queen Anne wing These are shaped in a profiling jig with chairs always had my shaper. The type of jig I use involves one-piece back two straight knives and a 1/4˝ high posts. In later concentric fixed ring held in the shaper practice the posts table. This bears were often scarfed against the above the seat bottom edge of frame. The upper the jig. Many back would be people would framed separately do this with a out of secondary ball bearing rub wood. collar, but in The next part of practice the ball the chair is the seat bearing is sloppy frame. This heavy enough to leave horseshoe-shaped Shaper ring guide a scalloped frame supports Router mortising jig in use on a seat frame Shop photos by Bill Thomas  around the mortises in the legs for the is smaller in diameter stretchers to butt up against. The tops of than the ring, the the legs are faired into the curve of the edge of the ramp that seat frame. The blocks are glued the ring bears against on to each leg and the non-symmetrical needs to be set back the seat curve is drawn on the top face of corresponding distance the leg. As the knees are shaped, their from the line it follows. form changes according to this line so The first ramp I made that the front knee blocks are quite was for the wing stile different from the side blocks. Most of bottom tenon. The the legs of my chairs have turned pad wing stile leans back feet, but I have made several with ball and leans out, so I and claw feet. planed the ramp to The side stretcher joinery is carefully have a face that slopes marked out on the square blanks before at two degrees to the Cutting a post they are turned as it is much harder to horizontal. I clamped do the layout afterwards. I don’t cut the ramp so that its end was on the pattern, but more recently I have been the tenons beforehand as that would angled tenon shoulder line. I glued a building the second design. remove the centers for turning. Once fence to the bottom butted against the The first roll and arm design is the stretchers are turned, the tenons front edge of the stile. With the ramp constructed with rectangular stumps are cut and fit. These are angled tenons, properly located and the router bit set to mortised into the seat. The rolls are of course, and I have always cut them the correct depth, it was no problem to made from a split turning. Two pieces by hand. The front end needs to be left rout a close fitting angled tenon which of poplar are glued together with paper with enough wood to support paring was also at an angle to the line of the between them, and once turned, they are the tenon shoulders. I don’t turn up to stock so that the wing stile was properly split apart and the halves are glued to the the marks, but leave a quarter inch or so. positioned. I actually made two of these outside of the stumps. The inside front The waste is pared down to the turned ramps. One left and one right. edge of the stumps are then rounded profile after the joint has been fit. The The joint between the wing rail and back over to continue the curve around the long mid stretcher can be joined with post is very complex. The posts lean back, inside. The stumps are mortised up round tenons into the blocks of the and the wing rails are at an angle to through the horizontal arms that are side stretchers. Once the base frame is both the horizontal and vertical planes. made in the shape of a letter “P” with joined and sanded, the main frame of I thought about mortising the wings the round part of the “P” the shape of the chair can be glued up. The front leg into the fronts of the posts, but aside the top of the roll. These arms are then through tenons are wedged, and then all from the complexity of the angles, there fit to dados in the wing stiles. the joints are pegged. are already large mortises for the crest The two-roll variation has stumps The upper frame consists of the wings, rail. It just appeared to be too weak. I mortised into the seat frame, and the arm stumps, arms and rolls. The wings are decided instead to lap the wings to the “P” shaped pieces are glued vertically made from two pieces mortised and sides of the posts and screw them in to the back edges of the stumps with tenoned together. All the rest of the place. Even this is complex joinery. The the “P”s facing the outside. Short arms joinery involves angles. To cut these lap in the post has an angled bottom are through mortised into the “P”s and joints consistently I decided to make a and shoulder, and the wing rail lap does then mortised into the front faces of the series of router guide ramps that rely as well. I made a symmetrical keystone wing stiles. on a template ring on the router base. shaped ramp for the router to cut the The arm to wing joints are quite This works similarly to the shaper ring lap on the inside of the left and right complex. I usually make mock-ups of but upside down. Since the router bit wing rails. It sits at a two-degree incline the arm to get the angles and lengths to the face of the wing. The post laps are right. The mortises in the wing stiles are cut with another double-ended angled not parallel to the edge of the stock, but jig. That one has the router template plumb. A two-degree ramp is clamped ring follow the interior cutout. to the side of each wing to guide the Wing chairs are differentiated by the router for cutting the mortises. The design of the arms and rolls. The best- arms have angled shoulders and angled known Newport design has one vertical tenons. tapered roll at the front of each arm. A The small tapered vertical rolls second roll design has a short vertical are also split turnings, but the large roll at the front and a larger cornucopia horizontal rolls are single pieces turned shaped horizontal roll on the arm. Most to a bullet-like shape, then one side of the chairs I have made are in the first is cut off and planed flat, the ends cut Cutting a wing lap joint Continued on Page 25 tips & techniques by Brooks Tanner 

fast box construction technique Vee Grooving

machines. Insert type bits are typically used in the commercial industry since you can change the cutter in a matter of minutes, and continue your work. The down side, however, is that they may have some vibration since the is not balanced as a whole. If you have significant vibration – Stop.

Box Design – In box design, the two opposing faces (i.e. front & back, or top & bottom) are typically separate pieces that the four sides are assembled upon. These two faces should be rabbeted around the perimeter allowing room for insertion of a wood edge. The also allows rapid construction by providing a positive reference for square and keeps the pieces in alignment. The wood edge may then be routed with a detail, which gives an appearance of solid wood panels. I have found that application of the wood edge ee grooving is a fast and easy manufacturers. Some will cut the takes longer than the routing, cutting and assembly of method to make a box. It bottom of the to a point, the rest of the box. Details will get you every time. Vis extensively used in speaker similar to a bit, but will Before cutting the groove, determine how you manufacture with veneer covered cut an extra few tenths of a degree plan to cut the pieces to width. If you cut the vee MDF. This method allows the to allow room for folding and glue. groove across an entire sheet first and plan to cut to panels to be rapidly glued, folded Another method, which I chose to width second, you may have a surprise. Since each and made into a box with minimal go with, uses a bit that cuts a true groove is now a hinge, large areas are hard to handle. clamping. It also allows the grain 45° , but leaves a flat at the Also, if the “hinge” is flexed a couple of times, chances to be continuous around the bottom of the groove. This also are the piece will separate. box. Although I have only used allows room for folding and glue. this method with veneer covered Bits for hand held routers Cutting the Sides – Several methods may be employed MDF, it can be successfully used are available, but do take some to cut sections to width. The most straight forward with other sheet goods as well as research to find. The bit I use method is to cut the pieces to width before grooving solids. is manufactured by Her-Saf and then clamp them together while grooving. If I was introduced to vee grooving (www.hersaf.com), model V090, an entire sheet is to be used, a sacrificial sheet of while trying to gain prototype and is an insert type bit. This bit cheap ply may be used for support to keep the pieces work with a local speaker company. is also designed for use in CNC together while sawing. Grooving is performed with At the time, I was not eligible the sacrificial sheet in place to keep the grooved sheet for the work since I did not vee from moving independently. This can still be a bit groove. Now I do and use it for unwieldy and should not be attempted alone. short run speaker construction in You may also choose to assemble the box before my own shop, but still cannot gain cutting. A long box would be assembled and then prototype contracts since I do cut to width as required. Two issues arise with this not have a CNC operated router. method. First is squaring the box while the glue dries Now if only I could find an extra and the second is cutting all sides without leaving saw $50,000 somewhere… marks or dings. I assume you chose the first option (cut to width The Bit – To begin, you first before grooving). Congratulations on a wise choice. need to obtain a vee grooving Cut pieces to length allowing an extra 1/4˝, plus at bit. Methodologies for cutting both ends. Length is simply the outside length of all the groove vary between sides added together. Photos by Brooks Tanner 

Tape should now be applied to the finish (outside) of the sheet under where the vee groove is to be cut. Tape performs multiple functions. It aids in the formation of the corner by keeping tension on the wood fibers as they are bending and breaking. It is also the clamp which holds the box together as the glue dries. Tape does not need to be applied to the end cuts. Adjust the router to cut a groove to within a 1/64˝ or less of severing the material. You want just enough material to hold things together after cutting. If too much material is left, the break at the corner will leave a rough broken edge. Too little material will not allow handling, allowing the panels to sever as soon as they are moved. Use a guide for the router and make the first cut, leaving a scrap cutoff to be removed on the far side of the bottom of the vee. I have First cut found that a cutoff of at least1/4 ˝ is best. To make the second and fourth cut, I usually use an MDF guide cut to the dimension that allows placement of one side of the guide on the edge of the initial vee and the other to dimension for cutting of the second vee. This allows for accurate placement of the router in multiple locations. Accurate placement of a guide is difficult by measurement. Inaccurate measurement or alignment will cause the box to not have equal sides or be misaligned. Use of a second guide similar to the first is used for the third and fifth cut. A scrap section should be left at the end of the fifth cut.

Assembly – Now the fun begins. Break the scrap sections off from both ends. Attach tape to one end leaving half exposed. Apply glue to the rabbet of one of the front/back panels. Apply glue to all vee grooves. Apply glue to the end cut that does not have the tape applied. Roll the Router guide clamped in place, cut completed. vee groove panel onto its edge. Fold the panel into the box and use the Note tape on finish side. exposed tape to tape the two ends together. Now pick the box up as a unit and place it into the rabbet. Check for square. Apply glue to the rabbet on the remaining front/back and apply to the box. Light clamping may be used between the front and back of the box. No additional clamping is necessary.

Breathe – The box is done except for application of the wood edging, flush sanding of the edge and detail routing. One variation or addition used by some manufacturers is the use of a small amount of water in the bottom of the vee just prior to folding. This will make the wood fibers more pliable for the bend. I have not found this necessary, but use of this method may allow for thicker material below the cut.

Scrap being broken off after last cut

Folding the box Edging applied period furniture by Joe Barry Marking Your Work

here are a number of reasons for being sold as antiques. A good mark Tmarking your work as your own. will reduce the risk of your work being First is pride in your work – “No, it’s misrepresented in the future. not a kit!” Second is the marketing of I have gone through a couple of your work. Others will see the mark iterations as my marking of my work Joe Barry is a woodworker from and associate you with quality work. evolved. I was initially drawn to the paper This may be the best source of new labels of the period furniture makers. Randolph, VT. A graduate of Keene work beside the word of mouth from They were wonderfully complex and State’s Industrial Arts Education satisfied customers. “Branding” yourself evocative of a time when furniture was program in 1980, he taught for several in the same way as Thomas Moser, “bespoke”. However, I passed that idea years and worked as a cabinetmaker. George Nakashima or Sam Maloof up as paper labels do not hold up well He now supports his woodworking will associate your name with a certain and are easily removed without damage vice as an occupational therapist. genre or style of work. And finally, there to the piece. I wanted something a little is the obligation to posterity to identify more permanent, and less fragile. the date of manufacture and the maker. The first branding iron that I style or inspiration. I make traditional Can you imagine an appraiser of the purchased was based upon a Viking American country style, Shaker inspired future stating that your chair is “…in era rock carving. The response to this pieces and roll-top desks. The interlaced the style of Dunbar, likely from New logo was always very positive. However, dragons said nothing about my work or Hampshire?” I soon came to see a number of flaws me. Poor choice! There are reports of reproduction with my choice of logo. Aside from The multiple fine lines were an style work being sold as original. We the plagiarism suit awaiting me in additional expense in the manufacture use the tools and methods of the past Valhalla, there is the issue of it not of the branding iron and always a and copy the best work of well-known clearly communicating who I am or problem in getting a good impression. craftsmen. There are reports of Wallace what I do. I am not Swedish. Shake my It was difficult to get a consistent line Nutting pieces and Mike Dunbar chairs family tree and only Micks fall out of value when heating this iron. Some lines having the maker’s marks removed and it. My work was not Scandinavian in would be too dark and others too light. I

Original Norcraft iron Second Norcraft iron (electric) from Final logo with date numbers on Herget’s Quality Engraving BrandNew Industries electric iron Photos by Joe Barry 11

experimented with using a torch without Thus, my second branding iron. This with a new issue each year I would have much luck in getting a consistent heat. time I went with my name and a simple used a Vermont quarter for the year I finally arrived at placing it face down early American style trade sign. The of building. However, the mint didn’t on an electric burner – thus the charred traditional oval with a to signify cooperate so I gave up on the coin idea. handle. a woodworker clearly communicated I could use a hot pen and number the The major fault with this design is what I wanted. Notice that this time piece under the brand. However, anyone it doesn’t say anything about who the I upgraded to an electric handle. This who has seen my handwriting knows maker is and where he can be found. I branding iron has served me well for a that to be a poor choice. I ordered a did put my initials “JB” and the initials number of years. branding iron with my new logo that “VT” for Vermont in the center. Both In the past year I have re-established had the capability of doing changing were cryptic and too small to be readily my shop and re-examined both what numbers or letters. One advantage of seen. I later removed the VT when I left my goals were and how I would achieve the computer age is that I was able to e- Vermont. This led me to believe that you those goals. One thing about the second mail the graphics from my designer should never choose a business name branding iron that I was dissatisfied to the branding iron manufacturer and that ties you to a particular place unless with was the quality of the artwork. not have to worry about camera-ready you are absolutely certain you won’t My drawing that was the model for copy. With such a large head, I needed move. this branding iron was just not up to a an even larger electric element for this A nearby shop is named Freighthouse professional level and professionalism brand. Woodworks and is located in an old was a part of my marketing message. I An alternate marking method is to railroad freighthouse alongside the bit the bullet and hired a professional use a builder’s plate like a boat builder. tracks in South Royalton. I I contacted an advertiser that is don’t know the details but most a regular in Fine Woodworking buildings alongside the tracks magazine that makes brass plates. belong to the railroad and He is located in England and you can only lease them. If at it was all done by email. I sent some future date the railroad the graphics file, he sent a quote, does not renew the lease or the and I paid by Paypal. He did shop needs to move to larger suggest that I reverse the image quarters, the name may become for better reproduction. So I also inaccurate. People searching for got what I had wanted initially the freighthouse in the future when I did the re-design. may find it to be something Between the branding iron other than a wood shop. and the maker’s plate I have I later came to the conclusion two options to mark my work that I would use the business Builder’s plate from Makers-Mark in a permanent and professional name Heirloom Custom manner. The response I have Woodworks. The name summed up graphic designer to re-do my logo. I had from customers has been very what I was doing. I continued with the initially tried to do it myself on the positive and I find that they often direct use of my old logo and chose a typeface computer and found my efforts still attention to my mark. With luck, that that was somewhere between the runic not good enough. I gave the designer may bring me more work. Or, at the alphabet of the interlace period and several pages of drawings and criteria least, they know who built it. the typeface of the colonial period. I to start with and a good idea of what I gradually came to see that I did not wanted. This made her job much easier have a consistent and clear commercial – and much less expensive! What were image for the marketplace. In fact, it interesting were the options she gave Makers-Mark was a muddle. me. There were things that I hadn’t www.makers-mark.co.uk/ I re-examined what it was I did and considered and I ended up choosing the message I wanted to communicate something that I had not initially Herget’s Quality Engraving to my buying public. I will never be more considered. I had originally wanted a (Norcraft branding irons) than a one-man shop and a maker of black plane on a white background and www.brandingequipment.com reproduction furniture. I do not need to ended up choosing the opposite. operate under a DBA (“doing business Another part of signing my work that BrandNew Industries Inc. as”) identity for privacy, liability or the I considered important was dating and www.brandnew.net need to be able to sell the business. So, numbering my pieces. Chris Becksvoort the important things that I want to hides a dated silver dollar in each piece, communicate to the public are my name which appealed to me. If they would and what I do. have continued the state quarters series shavings and by Caleb Dietrich with Bob LaCivita Hand Cut Thru Dovetails With the understanding that I would share what I learned, I was invited into Bob LaCivita’s shop in Nottingham for a lesson in hand cutting dovetails. This is what I learned.

the layout across the end grain. Bob demonstrated a 1/4˝ pin that is easily divisible for practice, yet common and attractive in drawer construction. With the stock secured in a bench vice, mark each of the half pins 1/4˝ in from the edge. Bob cut two tails, so he easily found the center of his piece and laid out his third pin. If you cut three or more tails, you can quickly space them out evenly by walking a divider across the stock. Begin with one point in the center of one of the half pins – in this case 1/8˝ from the edge of the stock. Make adjustments to the divider until it takes the desired number of steps and lands at the center of the other half pin. Each step will mark the center of a pin. Make your s Bob gathered the tools he’d marks square across the end grain 1/8˝ to need for the demonstration, either side. Darken your marks with a he told me, “The key to if visibility is an issue. Marking set to thickness of stock woodworking is getting your tools to work.” He went on, “Instead of learning Use a specifically designed dovetail saddle or how to cut dovetails, I think it’s most a bevel square to lay out the angle of the tails important you learn how to use your on the face of the stock. Dovetail saddles tools. When you’ve done that, you’ll usually come in the traditional slopes be able to do a lot of things well.” He of 8:1 used for and 6:1 for added a marking knife to the collection . These rise over run ratios of well used tools already organized on can be used to set a bevel square. Mark his bench. He moved his coffee, and I the chosen angle on the face of the snapped a picture. stock beginning at the marks in the end grain and stopping at the shoulder line. Bob’s Procedure… With practice you might find you only Use a marking gauge set to the thickness of need to mark the angles with a pencil your stock plus 1/32˝ to scribe the shoulder on the front face of the stock. However, line on the two pieces to be joined. A sharp marking out the tails on both the front cutter with a beveled or slightly rounded and the back will help you analyze your inside edge will leave a clean line while work with the saw, and using a marking drawing the gauge face tight against knife will give you a clean line to pare to the stock. A deep scribe will be helpful if you are not satisfied with your cut. when paring out waste and can add to the character of the joint. However, if Shade the waste between the tails. Set you would like your finished product to your kerf in the waste and saw to the be clear of unnecessary lines, you can shoulder line. As Bob implied, cutting postpone this step until after you have clean joinery is a natural result of being laid out the tails and pins and be careful comfortable using your hand tools. Be to only scribe the areas to be removed. sure your saw is sharp and properly set, and work on your technique until you Determine the spacing of the tails. Use a can get consistent results that need little Lay out pins on tail stock first marking knife and a small square to carry to no alteration with a . Shading Photos by Caleb Dietrich the waste with a pencil might seem with your palm up. Guide the chisel unnecessary but it gives you one less between your left thumb and index thing to think about. It is crucial that finger. Use your right arm and upper your cut begins square across the end of body to apply downward pressure. the board and that you begin with your saw tilted to the angle of the dovetail. Use the tails as a template to lay out the pins. Changing the angle to follow your Lining both pieces up can be awkward. reference line once you’ve begun the cut Bob made this step less problematic by will only cause problems. Bob used his using a simple piece of 3/4˝ thick scrap. left thumb to guide the saw. With the He secured the unmarked pin stock in saw started on track, he cut with long his bench and used the piece of smooth strokes. Posture is important. If 3/4˝ scrap to space the end up about 7/8˝ you make one cut standing up straight above his bench top. He then moved Waste sockets for pins in tail stock and the next leaning over to look at your the scrap to the center of the bench and line, it will be difficult to get consistent used it to support the back of previously results. Bob made all his cuts in one cut tail stock. With the edges aligned direction, then altered his stance to and the shoulder of the tails even with make the others. the inside face of the pins, Bob held the In my limited experience, I have pieces in place and traced the tails on found that cleanly starting a kerf the end grain with his marking knife. alongside a knifed line is one of the most challenging tasks in cutting Square the layout down the face of the board, dovetails. Bob accomplishes this by stopping at the shoulder line. While this tilting his saw forward a bit as he begins, step resembles marking the angles of and leveling it out as he settles into his the tails, it requires that you be more rhythm. With practice, I was able to precise. These marks are not merely improve using Bob’s technique. But I references as the others were. They must was also tempted into ordering a kerf be followed exactly or the resulting joint starter from Glen-Drake toolworks will be unsightly. To make these marks after seeing his demonstration at Lie- rest your marking knife in a line cut in Nielsen’s 25th anniversary celebration. the previous step. Move your square After using it, I felt I would need to over tight to the flat back of the knife. mention it in this article. Follow the square down to the shoulder line. Repeat this to mark out each pin Use a saw to quickly remove most on the front and back of the stock. of the waste. Rather than marring the edges left by your dovetail saw, begin a Shade the waste. Set your kerf in the waste and new kerf in the center of the waste. Cut saw to the shoulder line. Again, rather than down and then off to one side to remove trying to follow the line, focus on your half of the waste. Cut to the other side technique. Keep the saw perpendicular and take out the rest. Be careful not to to the stock, and use long even strokes. damage the tails. If you run off, your lines will be there to Clamp the piece on its side and use pare to. But don’t be content with that. your dovetail saw to remove the half pin Look for tendencies you can correct waste. Leave 1/32˝ to be pared off neatly. through your mechanics – like a pitcher on the PawSox would in order to make Chop and pare back to the shoulder line with a the Bigs. Mark & cut pins by wasting sockets for tails in pin stock sharp chisel. Bob used a and chisel to remove most of the material. He was Use a to quickly remove the waste. careful not to chop out the back of his This step is repetitive, except now you Hold your breath and assemble. If you are piece by working in from both sides have to be extra careful not to cut into just beginning, don’t be frustrated if and leaving a slight hump in the center. the angled pin. they don’t fit. Every set reads like a book. Finally, to remove the hump, rest your Look to see what you might do better chisel in the shoulder line and take the Chop and pare back to the shoulder line with next time. Keep at it. Try to eliminate last shavings. a sharp chisel. Again, chop in from both one flaw with each practice set. Before Proper lighting is as important as sides. Pare back the hump and leave a you know it, you’ll get consistent proper form. Use a piece of scrap to slight hollow to ensure a tight fit. Work results. And your new skill will open protect your workbench. If you are right carefully. It would be a shame to bruise up a whole range of furniture making handed, lay your left hand on the stock the edge of a pin at this point. possibilities. at large by John Whiteside

Part One – Our Adventure Begins Adventures in Lutherie

hat if we approach a woodworking describes himself as a novice, although find money? We Wproject as an adventure? The he has experience in and has remember that exciting part is then the unfolding worked as a machinist. None of us has the Guild offers scholarships and submit experience, the unexpected discoveries, ever built a guitar. an application as a group. The committee the uncovering of strange and marvelous Our first step is to find a . After is friendly and responsive. Within a few new tools, new techniques and ideas. researching the internet, we find weeks, John McAlevey tells us that we Even the setbacks, struggles and Allen Carruth of Newport, NH have been awarded a scholarship that difficulties in acquiring new skills and – www.alcarruthluthier.com. We visited will cover a big piece of our expenses. perspectives, the indecisions and the his shop on a day that he was teaching. In return, we promise to give back outright failures add spice to the journey. It was like entering another world. The knowledge to the Guild and this series Indeed, they cause the experience to be shop is small with accommodation of articles is in part a fulfillment of that an adventure instead of merely some for a handful of students. Guitars, in commitment. If all goes well, we hope mechanical and programmed following various stages of completion are piled eventually to perform a small concert at of defined steps and procedures. everywhere. In one back room are stacks a Guild meeting. I recently placed an ad in The Old Saw of bookmatched sets of Indian So we sign up and take our first class. asking if anyone would be interested in for sides and backs, and sheets of Lutherie is unlike other woodworking. Much finding a luthier to teach us, as a small for soundboards. In another room is a of what we “know” is not applicable. For group, to make guitars. Two members oscilloscope and related equipment for example, here is a photograph of Alan answered that such an undertaking has sound measurements. holding a guitar top and showing the been a lifelong dream. So, without delay One of the students takes out a bracing underneath. As you can see, the and in high spirits, we have embarked finished guitar and starts playing. The bracing is glued to the top and, even on our adventure. sound is exquisite, the finest any of us We have just started. I propose in has ever heard. The guitar is breathtaking. this and follow up articles to provide an Paul asks if he can play it. When he does, account of our quest. The plan is to tell a rare smile crosses his face. you about our journey as we experience For a guitarist, something called it, writing as it were, in real time. My action is critical. The action is the focus is on the process, on making distance that a string must be depressed something out of nothing, on what we to make contact with the fret and so go through starting with a dim idea and produce the desired note. If the distance ending, hopefully, with beautiful guitars. is too great, the guitar is difficult to play; The outcome is not at all guaranteed. too little and the string is apt to buzz. My hope is that some readers are The difference between a good and a though diagonal, crosses the grain in inspired, if not to make guitars, then poor action is measured in fractions of violation of standard woodworking to undertake a project of their dreams a millimeter. Furthermore, the distance practice. There is no option. The top that is currently beyond their skills or must be uniform along the entire length is only 2 mm thick and needs support. experience. I hope also to capture the of the fretboard, meaning the strings Plus, it has to resist the force of stretched excitement of the process itself, of the strings. However, in order to partially actual doing, because I believe that the relieve the cross-grain expansion and soul of our craft lives in each moment of contraction stresses, the top is not undertaking it. actually flat but curved to follow the My companions are Paul Miller and arc on the circumference of a 25 foot Franz Summers. As a trio, we cover an diameter circle! interesting range of experience levels. Lutherie introduces an aspect of wood Paul is a juried member of the League selection hitherto unfamiliar to us – namely of New Hampshire Craftsmen. He its acoustical properties. A fine guitar must makes world-class windsor chairs and must be precisely parallel to the neck. be beautiful both visually and aurally. teaches both carving and turning. I am Paul says that the action of the guitar he Much, but not all, of the sound quality not as experienced as Paul. But I am is playing is perfect, the best he has ever is due to the top (called the soundboard). competent in a number of areas, such encountered. Using both existing literature and also as joinery and finishing, and have sold The cost of classes, tools, and materials is his own extensive measurements, Alan several pieces to satisfied clients. Franz significant and we are all retired. Where to has extensive knowledge of the sound Photos by John Whiteside properties of many and each of the abalone is sanded, its appearance jokes from Franz who has already glued us has a different style of playing in will change completely as different his spruce top and from Paul who has mind. Franz is interested in a flamenco microscopically thin layers are revealed. both glued his top and steam bent his guitar; Paul in a jazz steel-string guitar I decided to make my own rosette and sides by the end of class. which may be amplified; I play acoustic know exactly what I want — something On Alan’s recommendation, the dark finger-style steel-string guitar and favor called a Greek Key. As a consequence, elements of the Greek Key design will torch songs from the ‘30s. In addition, all I have to be shaded, that is, made up of two strips both Paul and Franz want light-colored show for my side by side, one of and one of guitar bodies. So Alan sets Paul up first day’s koa, both with side grain showing. The with a red spruce top and wavy maple work is a rough drawing on the back of white parts will be hard maple, with sides and back. Paul is persuaded to add a manila file folder and have to endure end grain showing. This should produce dark banding on the perimeter of his interesting effects as light plays on the guitar else, says Alan, the shape of the rosette. otherwise light-colored instrument gets The ebony, koa, and maple pieces lost, visually. I get an Engleman spruce must be 1.8 mm thick if my calculations top and dark Indian rosewood sides are correct! Unfortunately, that does not and back. Franz opts for an Engleman correspond to standard veneer thickness. spruce top and is still contemplating he photo shows some of what is involved No matter. The photo shows a tool (one his choice of back and sides having Tin making the Greek Key design work. of the few power tools in Alan’s shop) narrowed it down to California Laurel, The plan is ten times full size. Part of the that may be Black Acacia, or Palo Escrito. challenge is getting a rectilinear design to unfamiliar to Perhaps the most individualistic feature of fit around a circle. The dark horizontal pieces most readers. a guitar is the rosette, the decorative band near the outer circumference will be 14 mm It is a - that surrounds the sound hole. Rosette long, whereas the corresponding pieces on press-mounted making is an art unto itself. It is possible the inside circumference will be 11 mm. . to buy pre-made rosettes but even that Another challenge is sizing the design so The rotating is not trivial. Catalogues show hundreds that not only is its relative rectilinearity bit shaves off of them. Deciding to make one’s own preserved, but also that an integer number wood and the rosette is a big deal. of repeating patterns make it around the operator moves Nancy, one of the students, has circle. Since there are 30 design repeats and the workpiece spent five months making hers, shown eight little strips across the horizontal axis a r o u n d in the photograph. This rosette involves of each design, any errors in strip width are underneath it. inlaying thousands of 1 mm thick pieces amplified 240 times by the time the circle To actually make the rosette, ten is completed. Each strip is supposed to be of wood into a 1 mm deep channel small jigs are to be made. Each holds a 1.8 mm so an error of 0.1 mm would throw routed in the soundboard. tiny sandwich of glued strips at a precise everything off by an inch! The second rosette shows another angle, measured off the ten-times-scale option chosen by Bill, another student. Fortunately, the design of a guitar itself diagram, so that a shaves off He spends the day selecting and gluing comes to the rescue. Notice that in the two material at the required angle. Then the tiny strips of abalone into his rosette, photographs of finished rosettes, neither angled strips have 1 mm thick pieces cut trying to create the appearance of one forms a complete circle. The gap is covered off, in the manner of slicing off a piece up by the guitar neck where it attaches to continuous band without gaps. He of french bread. This requires a tiny the body. asked me to take this photograph in miter box and a razor saw. The resulting part because he realized that once hundreds of pieces are to be individually glued into a routed-out circular channel in the soundboard and, if all goes well, the pattern emerges. We shall see. So there we have the first leg of our adventure in lutherie. We are all in a high state of excitement. As Franz puts it – “I embark on this project with a sense of anticipation of creating something that will be beautiful and hopefully will become a family heirloom.” Paul states clearly, and I believe him to be completely serious, that he wants to make the finest guitar ever built. Me? I want to enjoy the process and already am. So what if the rosette takes months, Nancy’s rosette – thousands of pieces Bill’s rosette – strips of abalone what better way could I possibly be spending my time? at the lathe by Jon Siegel step by step Turning Dutch Foot Legs

ack in 1990 when both ones which are at the center of the to form the toe and the bottom of the Guild of New square on each end. The second set the foot. BHampshire Woodworkers of centers are offset in opposite Nearly always the offset is and my business, Big Tree directions so that one part of the along the diagonal line. The Turnings, were new, I was turning (the node) will run true in exceptions to this would be for a making table legs for various both setups. round table (with a round apron) furnituremakers. Both Teri On simple legs, the node is at or a center leg. Masaschi and Matt Burak the transition point at the bottom The first thing to calculate is repeatedly ordered Dutch of the pommel. This is the point the offset at the bottom, or the foot legs, and in a few years, where the square meets the round Foot Offset. Just remember this I turned hundreds of them. and must be centered. The simplest simple rule: Subtract the radius of Over time I tried different form of leg has just a straight taper the ankle from the radius of the foot, methods of turning the legs. from the ankle up to the pommel and you have the Foot Offset. The procedures described (square part at the top of the leg). For example, if the square is here were developed More complicated forms have 113/16˝, use 13/4˝ (1/16˝ less) for the during those years of decorative beads just below the foot diameter (7/8˝ radius). The experimentation and pommel, and sometimes the leg ankle diameter is 3/4˝ (3/8˝ radius). production. has a long curved form instead of Therefore the Foot Offset is 7/8˝ Dutch foot legs were a straight taper. On these the node minus 3/8˝, or 1/2˝. popular in the Queen Anne period. They were is at the fattest point in the curve. The smaller offset at the top also called club foot, pad foot, spoon foot, or even (pommel) can then be computed (incorrectly I think) cabriole legs. Dutch foot The Turning Process from the law of proportional parts furniture legs are turned on a lathe and are different Basic legs can be made in two (X/Y). For example, if the top from cabriole legs. Cabriole legs are sculptured legs steps – first off center to make square is 5˝ and the turned part is usually cut out with a band saw, then finished with the taper, the ankle, and the top 20˝, then the Pommel Offset is spoke shaves and other tools. The Dutch foot legs of the foot; then second on center 5/20 of 1/2˝ (that is 1/4 of 1/2˝) or 1/8˝. described here are produced entirely on the lathe requiring no band saw work prior to and no hand work after the Pommel Pommel Offset Offset turning. But there are also hybrid forms in which the ankle is hand carved after the turning to obtain more curvature than is possible by turning only. This is multi-axis turning, which means that more than one pair of center points are used on the X workpiece. One set of center points are the normal X

Rough cut to this line

Y Y

Foot Offset Foot

Ankle Foot Foot Offset Offset

Foot Diameter - Ankle Diameter X Foot Offset = Pommel Offset = (Foot Offset) 2 Y Photos by Patrice Martin, drawings by Jon Siegel

1 2

Using a center-square to mark diagonals. Make four lines. Marking the offsets. Squares available from Grizzly.

3 4

Making the transition cut at the node with a skew chisel. The transition cut completed. Notice that it is about 1/8˝ deeper than the flat. The left side is the finish side.

5 6

Rough out to 1/8˝ above the second shadow line as pointed out Draw a line indicating the height of the toe on the flat by my fingernail. produced in the previous step.

7 8

Cutting the top of the foot. Top of the foot completed. The length of the top 9 10 square (pommel) should be an inch or two longer than the width of the apron. After preparation of the square, mark the limit of the top square with a dark pencil. Mark out and the true centers in the usual way at both ends of the square. Then mark and punch the offset centers on the diagonal line. Check A shallow spindle gouge is used for final finishing. The left hand that they are in opposite dampens vibrations and can detect errors that the eye cannot. directions, and that the larger offset is at the bottom (foot) end. 12 Mount the work first A 3/4˝ roughing gouge is used first to on the offset centers, and taper the leg. The left hand is used make the transition cut on to dampen workpiece vibration. The gouge is guided by the thumb. the pencil line. On straight tapered legs, the diameter at this point is usually 10% to 15% smaller than the 11 square. Rough turn the leg to remove a little of the outside corner. Proceed to within about 1/8˝ of the first Light pressure and patience are required to carefully sand the shadow line (see diagram). intermittent part at the top of the foot. Now you can mark the point of the toe with a 14 dark pencil line drawn on the flat area formed in the previous step. Make the top of the foot first. Make sequential curved cuts which approach Before & after showing the pencil line and the an alternate foot design correct ankle diameter. Turn the taper of the A broken sanding belt works well on leg using a straight edge to straight tapers. check your progress. Sand this part including the whole length of the leg and 13 the top of the foot. Mount the work on the true centers and starting at the heel, cut down to the bottom of the foot. Sand this part being careful not to blunt the sharp line at the toe which is important to the look of the finished leg. Use a 1/2˝ spindle gouge to round the bottom of the foot. The curve begins just above the point of the toe. Finis By Jim Morris 19 An Overview of Target Coatings Fine Water-Based Coatings for Furniture, Architectural and Marine Applications

Ultra Seal-WB Shellac Sealer Target Coatings has also engineered a water- based dewaxed shellac. Using the same shellac flakes as alcohol based products, this product is designed to function as a sealer, color toner, and barrier on all wood products. Just like alcohol based shellac, the WB shellac has a shelf life of one year. We have found that the shellac works exceptionally well as a first coat underneath stains to prevent any blotching or unevenness. The shellac comes in four different colors – Amber, Blonde, Garnet, and Golden Red. Ultima-WR Stain System Using emulsion technology, the folks at Target have developed a water-based linseed oil that penetrates deep into the wood bringing out the natural color tones. The stain has a longer open time to prevent the lapping and fairing effect that you might find in other acrylic based stains. We have noticed that with the clear base stain, it ages to a nice soft amber tone over time. This product will not spontaneously combust so there are no fire safety issues with this linseed oil. The line of stains consists of fifteen different colors each Photo by Jim Morris with a blend of UV absorbers and reflectors so the colors remain vivid and true. f you have ever considered with its exceptional clarity and switching to water-based depth of image. Unlike other Other Products Ifinishes, then Target Coatings is water-base finishes, this lacquer Target Coatings has a full line of water-base the finish to use. The good people dries to a straw-like tone and products including super clear polyurethane, universal at Target have spent over twenty still allows the wood to oxidize sanding sealer, high solid grain filler, pre-catalyzed years on research and design to and age to a deep rich patina just conversion , an exterior polycarbonate urethane, produce a full line of water-based like its solvent based counterpart. and is always working to develop new products. products. Even with its quick drying time, We, at Maine Coast , the lacquer levels out unbelievably. OTC Compliant are a manufacturer of dovetailed As one of our patrons proclaimed With the new laws going into effect by the OTC drawers. We have used a couple to us – “This stuff makes me look (Ozone Transport Commission), more and more of different finishes to spray our like a professional finisher when people are looking into water-based products to products but were not happy I’m done.” The USL has a 30% be compliant with these regulations. All of Target with any of them. A customer solid content, so it will build up Coatings products are HAPS-free, low VOC, and recommended we try Target’s more quickly than most solvent nonflammable. Our insurance company, along with water based Ultima Spray Lacquer. based lacquers with solid content others, was happy to learn that we were using water- We were pleasantly surprised ranges in the low 20’s. It also is base in our spray room. There are no special needs for when it surpassed all our tests. self sealing, so no sanding sealer disposal of Target products and they easily clean up Now, after about a year of using is needed. Even though this sands with water. the lacquer in our drawer shop great there is a 100% burn in rate. So if you ever tried water-base products years and with all the benefits of water- This means it fuses to the last before and been disappointed or never tried them at base, we have made the decision coat so no sanding is needed for all, then give Target Coatings a shot and you’ll soon to become a distributor for Target next coat to bond to its self. There be a believer in water-base just like us. Coatings. are no limitations on how many coats can be applied. The USL is Target Coatings – www.targetcoatings.com – products are available Ultima Spray Lacquer available in four different sheens from Maine Coast Lumber in York, ME. You may contact Jim Morris at The Ultima Spray Lacquer is – gloss, semi-gloss, satin, and flat. 800-899-1664. the flagship of the product line current work by Larry Books Larry Books is a furnituremaker who specializes in one of a kind make a and unique contemporary designs. Now Biedermeier Style Lamp retired from teaching, he is very easy to make something divides his look complicated. Simply make time between a box shape and stick moldings building contemporary furniture and working with his wife, Janet, in their all around it. To make something floral shop and gallery, Gallery Florist, look simple, clean and beautiful in Vancouver Washington. and make the design work is hard! I always try to make things as simple as possible in my design Lamp Body and have found what he told me 1 The Tulipwood Veneer I bought from to be true, regardless of what I Constantine’s was not wide enough to am building. Two – You can take make the blanks for the front and backs. a poorly crafted piece of work These need to be 8˝ wide and 13˝ long, and put a beautiful finish on it so I had to glue the veneer together. I and people will love it. You can also make up equal veneer of a cheaper take a beautifully crafted piece of species for the inside of the lamp at this u i l d i n g work and put a poor finish on it time. If both sides are not veneered lamps is not and people will hate it. The finish equally, it can warp before assembly is a hot topic makes the piece if you don’t know complete! in woodworking woodworking, or look too closely. 2 The base material is MDF particleboard magazines, but is With the second thing in and I cut at least two additional pieces not only a project mind, you can take a beautifully to put at the top of my stack to equally that is fun, but also crafted and finished lamp and distribute the clamping pressure when one you can use up put a cheap shade on it and it will gluing the veneer to the particleboard. scraps of expensive take five times as long to sell than 3 My clamping method is primitive in the materials that have if you choose a really good shade. age of vacuum bags, but it works well! been lying around Remember you are a woodworker. I just stack the pieces on the edge of your shop collecting Find a really good lampshade shop my table saw with wax paper between dust. Scraps that you might have been wondering and have them help you choose a layers and newspaper underneath to how you might ever use. Building a lamp requires a shade. cushion and help equally distribute number of steps, and choosing the correct lampshade Making the body of the lamp pressure throughout the stack. I roll when you have finished the lamp is equally important can entail any 5 1/4˝ 5 1/4˝ in showing off your finished piece. number of methods, 3˝ 3˝ About twenty years ago, I was looking at all the from using a solid 3/4˝ 3/4˝ scraps of beautiful hardwoods I had accumulated in block of wood to my wood rack and wondering what I could do with freeform pieces, 24° 2˝ them. So I got out a Fine Woodworking Design Book turnings and in 1˝ and thumbed through looking for ideas. I was tired of this particular lamp, 3/4˝ building boxes and turning small bowls to use up left veneer and solid 1/4˝ over material. I ran across a lamp that struck my fancy wood together. and have been building several lamps, along with the This lamp is other furniture I enjoy building, every year since. heavily influenced 3/8˝ When I started to build lamps, I saw it as a way by the Biedermeier to use up my scraps from other projects. Aside from style so popular in the shade and hardware, it was almost pure profit! the nineteenth 12 5/16˝ Ironically, some of those first designs I have quit century, but with making, as they can run over $300 a piece just for what I believe is a materials now. I began making veneer lamps when contemporary flare I saw great veneer on Ebay at reasonable prices. to it that is at home 3/4˝Ø Freeform, veneered, turned or carved, they are all fun with most any style 3/4˝ 3/8˝ to build! of furniture, from 86° There are two things my mentor always told antique to modern. me that apply equally to building lamps. One – It 7˝ 4 3/4˝ Photos & drawing by Larry Books 21

on Gorilla Glue with a small roller. the inside of the rabbet will not break This works very well with oily woods out with the drill bit. such as rosewood. 17 Make a 5/8˝ diameter plug with a 5/8˝ 4 When the stack is dry, I trim off one plug or tenon cutter and glue in making edge with a chisel and square up the certain grain is the same direction as blanks. Joint one edge. Rip to width. the veneer of the lamp. Crosscut to length. Tape the veneer 18 When the glue has dried, plane off where you are cutting so it will not excess material with a sharp block splinter. Leave the sides oversize to plane until the plug is flush with the be cut to length later. Front and back surface. Take care not to cut into the blanks should be 71/4˝ wide and 121/2˝ veneer on the lamp face. inches long. The sides are 5˝ wide by 19 Drill a 5/16˝ hole in the center of the 123/4˝ long. plug. 5 I always have trouble cutting hopper/ 20 Round over the sides of the hole where Right & left tapering jigs compound joints to fit exactly, so I the cord exits the lamp using a 1/8˝ make simple jigs to taper the edges radius round over router bit. The pilot and cut the 45° angle. on my bit does not have a bearing. I 6 The front and backs of the blanks are cut believe it is copper so it fits easily into first with the good side down. With the the hole. second jig, they are cut with the good 21 Rabbet the edges of the lamps with a side up. Grain orientation is critical and 3/8˝ x 3/8˝ rabbet, cut the length of the it is easy to mess up if you aren’t paying edges to accept the contrasting wood close attention! and hide any imperfections that might 7 Miter side pieces 43/4˝ wide on the table have occurred in gluing the bodies saw. together. I generally make these cuts 8 Rabbet the top and bottom of the front in two passes on my router table, and back with a 3/8˝ deep by 3/4˝ wide with a fence and a carbide two-fluted rabbet on a router table. straight cutting router bit. The second 1st cut tapering panel with good face down 9 To cut sides to length, measure off the cut is a climb cut to minimize any 2nd cut tapering panel with good face up side of the front and cut to length at chipping. Climb cuts are cutting in the the angle of taper. wrong direction with the cutter and 10 Rabbet top and bottoms of sides at an you must hold onto the material firmly angle so the top and bottoms will fit so it will not be thrown away from straight into the rabbet. the cutter. DANGEROUS – I would 11 Laying pieces flat on a table, tape not recommend a climb cut on this together front, back and sides to test operation if you are not accustomed fit. Match veneers for best possible to making this type of cut! grain match. Fold together and tape to 22 Make 13/32˝ x 13/32˝ strips about 1/2˝ too check the fit. long for the trim. I like to run these 12 Glue together the bodies of the lamps though my wide belt sander for the Rabbet top and bottom with yellow glue using masking tape final size. If they are being made of of front and back as clamps. an oily wood like the Macassar Ebony 13 When dry, clean off tape and scrape I used, make certain to clean the wood off excess glue with a cabinet scraper. well with denatured alcohol and a Make and glue in top end plugs for the clean rag prior to the glue-up. top of lamp and glue in. 23 Glue in the strips with Gorilla Glue and 14 When the glue is dry, touch ends on use plenty of masking tape for clamps. a disc sander and miter gage to make You can really stretch the tape tightly ends flush and lamps equal in height. and get good clamping pressure, but 15 Mark and drill a hole in the top for the test the tape first as some masking lamp pipe and cord. First drill with 3/8˝ tapes do not work as well as others! spur bit and then ream out hole with Make certain you wear gloves for this 13/32˝ twist drill bit to allow pipe to move operation though it does interfere with freely through the hole. stretching the tape tightly. 16 Mark and drill the plug hole for the exit 24 When the Gorilla Glue dries, I use a cord in the back face of the lamp. Make chisel and cabinet scraper to clean off the hole 5/8˝ diameter and 1/2˝ deep the excess glue. Test fit pieces and glue-up with a forstner bit. Use a filler block so 25 To trim off the 1/32˝ excess of the trim Nut to t Strike shade riser with soft mallet pieces, cut a piece of 1/4˝ plywood or melamine to fit underneath the body of the lamp to raise it off the table. With the plywood under the lamp and between the trim pieces, use a 1/2˝ trim bit in the router table to trim off the excess. This too I climb cut to minimize tear-out and recommend not climb cutting if you are not familiar with this procedure! 26 Rough sand what the trim bit missed with an orbital sander and 100 grit and trim off the excess at the ends with a and finish on the disc sander. Make certain not to cut Making the finial into the veneer! remove the nut and re-clamp each edge. The nut will hold 27 You can put any type of design you better if the metal surfaces have been freshly cut with the file. want on the edges, but my favorite is 7 Clean both the nut and hole with denatured alcohol. rabbeted, again with a climb cut in two 8 Glue in the nut with epoxy. Use a nail to make certain that cuts each face. The are 1/8˝ deep there is some glue that wraps slightly up the exposed face and by 1/4˝ wide. make certain no glue gets on the threads. I use the shade riser 28 Finish sand with 100 grit, 150, 220, 320 to make certain the nut is aligned properly, but take it out so it and 400 grit . Take care not doesn’t get glued in! Let the glue set at least 24 hours. to cut through veneer. Make certain 9 When glue is set, cut the blank round on the disc sander. to raise the grain and sand again with 10 Make up a faceplate for the lathe with bolt through the center 400 grit for a great finish! To do the and turn and sand to 400 grit abrasive. edge designs, wrap abrasives around a small block of wood for a sanding Top Spacer block. 1 Cut blanks and square the ends on the disc sander. Finial 2 Lay out a taper and hole for the threaded rod. 1 Cut an approx. 11/2˝ square block and 3 Drill the hole on the drill press with a 3/8˝ spur mark to drill on the end grain face. bit and ream out to 13/32˝ with a twist drill bit. 2 Make certain that the nut you have for 4 Sand the tapers on the disc sander and finish the finial fits the shade riser before sand to 400 grit abrasive. Remember to you start. Measure across the flats of raise the grain! the nut and it should be 7/16˝. Drill a 7/16˝ diameter hole 7/32˝ deep with a forstner Top Plate or spur bit. 1 Cut the blank to size. It should overhang 1/4˝ all 3 Then drill a 5/16˝ diameter hole 5/8˝ deep around the top of the lamp. exactly centered in the first hole with 2 Drill a hole on the drill press with 3/8˝ spur bit and ream out to a twist drill bit. The second bit should 13/32˝ with twist drill bit. center exactly in the center of the first 3 Cut angles on table saw using tenoning jig. hole. 4 Sand to 400 grit abrasive. 4 Thread the nut onto the shade riser and insert and center in the holes. Strike the back of the shade riser with a soft- faced mallet to mark the hex shape of the nut centered into the block where the nut will fit. I use an old shade riser I keep just for this operation. 5 Chisel out a recess to where the nut protrudes from the block about 1/64˝ Top plate & shop and does not fit too tight. made tenoning jig 6 File a fresh edge on all six edges of the nut and cut a groove roughly 1/32˝ Bottom deep in each of the edges with a metal 1 Cut MDF to fit in the bottom and rout a slot for the cord to pass. cutting file. Clamping this is about the 2 Drill countersunk holes for screws making certain not to drill easiest way to do this, but you must through the sides of the lamp. 3 Rub out with 0000 steel 8˝ Harp 3 Way Socket wool and wax if needed. If the wood is dark like the Macassar Ebony, I 1/8 IP Hex Nut use a dark tinted wax like Lock Washer Dark Brown Treewax. 1˝ Washer Harp Base Assembly 8´ Cord 1 Cut 3/8˝ diameter lamp The bottom piece is shown upside down pipe to 41/2˝ length and 1/8 IP Brass Knurled Nut here. Note the rabbet around the edge file both outside of cut to fit the bottom flush in the lamp body and inside to remove burrs. 3 Since the body of the lamp was trued 2 A three-way socket is the best choice. up on the disc sander, the rabbet may The different levels of light can help not be quite deep enough to accept make your lamp’s wood come alive the bottom flush, so I rabbet the face and it costs pennies extra for the three- on the table saw to fit. way. 3 Tie a safety knot in the cord so the knot On/Off Switch (Key) will sit in the bottom of the socket. Safety knot 1 I purchase brass on/off switches at The safety knot is a slipknot tied into Cord exit is an added touch Namoi’s Lampshades or my local another slipknot. worth the extra effort hardware store and refinish them to 4 Remember to put the cord through the give them that “extra elegant˝ look. exit hole before final assembly! salesperson can help you with 2 Polish the on/off switch on a buffer 5 Test fit everything prior to assembly to make your lamp look its with white diamond abrasive and then and put in a bulb and make certain it very best! Buying the correct jeweler’s rouge. It gets HOT, so wear works! lampshade makes the lamp. I leather gloves. 6 Assemble and screw on the bottom. take my time to get the 3 Clean the abrasive 7 Cover the bottom with suede leather best results. off with cleaner. I use using contact cement. The suede is 3 A lampshade with a Barkeepers Helper available from Tandy Leather. Cut the gold foil lining costs a (In the cleanser/ suede about 1/2˝ oversize before glue- bit more, but it really soap area at your up. Make certain to put a minimum of brings the wood to life grocery store) and two coats on the wood and three on and is well worth the a toothbrush and the leather. The solvent based seems to extra money. On figured toothpick. Dry work the best in my opinion. woods it is a must! thoroughly. 8 Trim the excess leather with an Exacto 4 Spray with two knife with a NEW blade. Be careful not By now you can coats of brass lacquer. Make certain to cut into the wood or your hand! see that building a that the area is well ventilated! I spray nice wood lamp is it outside, as the smell is strong! I use Choosing a Shade more involved than Staybright Brass Lacquer™, available 1 After all the work of building the lamp, the lamp kit you can Applying suede to bottom from Woodcraft Supply. I have seen too many of my former buy and install in a students skimp on the shade and ruin gallon jug that was Finishing the beauty of the lamp by saving a few popular for many years. 1 After sanding everything to 400 grit and dollars on a cheap shade. This is one of It is tedious work, but it making certain to have raised the grain, the most important steps of the whole is fun as well and you I like to burnish the wood with 0000 process! have built something steel wool and seal everything with 2 I have bought shades from Naomi’s that is more than just orange shellac. I use the flakes mixed Lampshades in Lake Oswego, OR a lamp, a priceless in denatured alcohol to seal the oils for about twenty years now. They heirloom. It is a in the wood. When using , have not only great shades, but project that you like Tulipwood, finish rarely will stick good advice as well. Selection tips can use up some of without sealing the wood first. are available on their web site – those scraps of exotic wood 2 Spray with pre-catalyzed sanding www.naomislampsandshades.com. It is you have sitting around your sealer and finish with two coats of pre- always best to choose shades in person. shop and use or develop catalyzed lacquer. It takes a number of The size of the shade and the height your woodworking skills as coats of sanding sealer to give a good above the lamp are important well and a project to enjoy finish, sanding well between coats. considerations that a lampshade for many years! U I L D E G OF TH 24 scholarship by Jack Grube W IRE OO SH D P W O M R

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a success story W E S

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• • Creative Enterprise & Graham Oakes Scholarship

hosted a Granite State Woodturners Creative Enterprise was designed, meeting at Pinkerton Academy in as the name implies, with three goals. IApril, 2004. Beth Ireland, the presenter, The first is to rejuvenate the students’ began by explaining how to be creative creativity that has frequently and and later divided the fifty people who unfortunately been stifled. As Beth said, attended into twelve teams to put into “We want to set people free.” The second practice what she had talked about. is to create an environment where Each team was asked to create an object students are willing to explore risky that represented a month. At the end ventures or activities. The third is to of the workshop, each group presented offer students an opportunity to market their object starting with January. It a product line they create. was at that meeting that I thought Graham Oakes was in the first group about how my students would benefit of students exposed to the Creative and enjoy similar activities. I met with Enterprise program at the start of the Beth during the summer of 2004 to 04/05 school year. Having completed Beth Ireland & Graham Oakes talk about what, if anything, we could the introductory woodworking class as a do. Like many others, Beth was willing sophomore, no one would have guessed Each of them helped in some way to “set to donate a couple days to come to that Graham would become the poster people free.” It was rewarding for me to Pinkerton. However, we agreed that a child for Creative Enterprise and so see the excitement on the student’s faces year long program would be the best much more. After being introduced to when I announced these people were idea and I was left with the challenge a “skill set” using primarily the lathe coming and many of them came back as to how to finance it. I turned to and band saw, Graham made eight several times. Once they met Dustin the Guild. The Steering Committee coffee scoops for the first sale. The $40 no one was more excited than Graham was willing to entertain a proposal. that he made from that sale changed his when Dustin came to Pinkerton, or later Beth quickly named the program life and mine. when I took Graham to Dustin’s shop. Creative Enterprise and we put together What happened over the next During this time Graham’s work a grant proposal that was funded by the eighteen months was beyond my continued to evolve as he began to GNHW scholarship program. Basically, wildest dreams. Keep in mind, that only refine his skills and techniques. It the grant covered the cost for Beth to Graham’s story is being told here. There was apparent that I was not going spend a day at Pinkerton every other were dozens of other students who to provide much assistance in those week for the 04/05 school year. benefited fromCreative Enterprise. areas so I decided to promote what B e t w e e n I later called his unbridled passion. B e t h ’ s He presented at the New England visits other Association of Technology Teachers woodworkers, and the MA Industrial Technology m o s t l y Teachers Conferences the past two years. G N H W He demonstrated for the Association m e m b e r s , of Revolutionary Turners (ART) the came in to GSWT, and most recently at the 5th New s u p p l e m e n t England Turning Symposium. He has the Creative been featured in over a dozen newspaper E n t e r p r i s e articles including front page stories in p r o g r a m . our school newspaper and our alumni D o n n a newsletter. He was the featured artist B a n f i e l d , in the May 2006 edition of Woodcraft Dustin Coates, Magazine and recently named the Steve Cox, 2006 Tradition of Excellence winner by Steve Henry Woodcraft Corporation. Graham and and William Pinkerton were both presented with Shunute were $1,000 Woodcraft gift certificates for all involved in this award. Tiffany Eddy at WMUR The Advanced Woodworking class and their totem poles this program. wasted no time when I submitted a story Photos by Jack Grube 25 idea to Chronicle Chair Frames – continued where Graham’s story square to that face, and was shared across then the rolls are glued New Hampshire in to the arms. The whole April. While all of tops of the rolls and this was going on, we arms are then shaped to were producing an make a consistent taper. “in-house” DVD at Once the wing and arm joinery is fit, there Pinkerton called, One is always a certain amount of fairing in of Tool Wonder. It shows corners where pieces meet. The back corners Graham making of the wing stiles have to be faired to the fourteen cuts with a seat frame. The arms have to be faired side grind Ellsworth to the rolls, etc. Also, before the wings bowl gouge. Rod can be added, the spreaders need to be Daily, a GNHW joined on. The horizontal spreaders are member, with whom Part of booth at a Pinkerton sale – Graham Oakes positioned about an inch up from the Graham has bartered, seat frame. The back one is a simple rail produced the artwork and Peter Bloch piece, Turned for Two, was stunning lap-joined into the back posts. duplicated the DVDs. both technically and artistically. The side spreaders are very odd Beth returned this spring to check In addition to the publicity, the shaped pieces. To derive their shape, on the students she met the year awards gave Graham the funds to buy I cut the dados in the wing stiles and before. During her two visits she made a 20˝ Rikon band saw and half the cost pockets in the back edges of the stumps totem poles with students in Advance of a used Nova lathe, which he bought to receive them and then make a pattern Woodworking. Many of these students from a GSWT member. that fit the space thus created. These were the ones Beth started with in the With all of this going on, Graham spreaders are cut to the pattern, but Creative Enterprise program. The totem never lost sight of a goal he set shortly since they are just to hold the fabric, poles were a lot of fun and were displayed after he sold his eight coffee scoops for they don’t have to fit perfectly. They are at the turning symposium. The full $5 each. At that time he decided to screwed in and meant to be replaceable. totem pole story will be featured in an “make” $10,000 turning wood before he The vertical spreaders for the back edges upcoming issue of Woodcraft Magazine. graduated from high school. Although of the wings are set about a half inch in In June, Graham won first place he fell a little short of his goal, his front of the posts and mortised into the at the 3rd New England Student sales exceeded $9,000 and his work is seat and wing rails. Finally, the wings Design Competition hosted at Mount now featured in several retail outlets and arms are glued in, and the wings Wachusett Community College. Last including Shaker Village. glued and screwed to the posts. year Graham won fourth place with You might have seen him this When I started making these chairs, I a nestled Cherry Burl bowl set and summer at Wood Days or Sunapee planned on building one in forty hours. I did walked away committed that he was where he demonstrated turning. He manage that for a few of them. Sixty going to win first place this year. His continues to do a lot of demonstrating hours is a more reasonable time frame. Photo by Rod Daley and was awarded a Jet 1014 lathe as After building a couple, I realized that one of the winners in the Youth Lathe even though I was familiar with the contest held in conjunction with the process, I was making errors – so I Youth Symposium at Pinkerton in wrote out a detailed procedure list. This May. Graham will be attending UNH step-by-step list has been amended over Manchester in the fall and turning the years and runs to over sixty steps wood at home. I suspect I will see him detailing measurements and angles, as occasionally when he needs access to well as pitfalls to watch out for and the 2436! He has two long term goals unexplainable variations from one chair – to be recognized as “one of the greats” to the next. Predictably, number thirteen in the community and to was the worst chair of all to build. return to Pinkerton to teach. I found that it was efficient to make I would like to thank the Guild the chairs two at a time, which worked for the financial support and for the out because I have had many orders for opportunity to share the success of pairs of chairs. The most I ever made one student in the Creative Enterprise at once was four together. I have made program in The Old Saw. Last year was them with legs of walnut, , one of the most exciting and rewarding cherry, and maple. Gradually the years in my 30 year teaching career. amount of money I received per frame Thanks Graham! Thanks Beth! was increased. My total to date is thirty- “Turned for Two” – Graham Oakes Thanks GNHW! two wing chair frames. League of NH Craftsmen Photos by Jim Seroskie The 73nd Annual

raftsmen’s byF Daveair Anderson C fair attendance was large and we almost always had a crowd watching members demonstrate their skills. At all times we had at least two scholarship fund are ample testament lathes producing turnings and two or to their success. To those members more demonstrators showing a diverse who donated the 22 regular prizes and selection of woodworking related crafts. the nine daily raffle prizes solicited Guild representatives sold raffle tickets, and collected by Jim Dimick, your explained the guild to fair visitors and contribution is greatly appreciated. The signed up a number of new members. Cherry Shaker table made and donated Bob LaCivita puts final touches on bamboo table legs For those of you who joined the guild by Greg Benulis and Bob LaCivita was at Sunapee, I hope we’ll meet you at the highlight of the prizes and garnered y the time you read this, the 73rd the annual meeting at Dana Robes on the largest ticket sales. BAnnual Craftsmen’s Fair at Mt. September 23rd. Many thanks to everyone who Sunapee State Park will have become I would like to take this opportunity participated or donated! Without your history. Our Guild participation this to thank the 38 guild members who participation and generosity, we could year was unusual in that we had fewer donated a total of 79 working days never achieve such great success. The members participate but the results still selling tickets, explaining the guild to nine days of surpassed previous years. fair visitors, and demonstrating bowl Wood Week at The weather could not have been turning, carving, shaker box making, Sunapee is one better, not a single bit of rain over the furniture making, cutting dovetails and of the most nine days. The moderate temperatures a host of other skills. i m p o r t a n t and low humidity made working our Thanks is also due to our members guild events of 20´ x 40´ tent a real pleasure. The raffle who loaned lathes, and the year. We of member-made prizes was a smashing other equipment for our tent. A special are exposed success and we were able to better thanks to Peter Scheffer who donated to almost last year’s record ticket sales. Guild eight days of his time and wowed the 30,000 visitors, members sold $4,107 worth of raffle crowds while he produced almost a refresh our tickets to benefit our scholarship fund years supply of legs for his windsor treasury and – an increase of $141 over 2005. chairs. There was always a crowd around have a great The League of NH Craftsmen gave watching a master at work. Similarly, time. Will us a new and better tent with more Len Chaisson carved and talked with you be one headroom and large windows on all visitors for five of the nine days. Guild of next year’s sides making our workspace lighter and representatives were aggressive but not volunteers? We Lon Zabohonski turns more airy. With all the fine weather, pushy. The ticket sales benefiting the need you. basswood ornaments

Len Chaisson power carves a variety of sculpted pieces Peter Scheffer and some of his windsor chair leg stockpile meetings and events 27

by Jack Grube Four Students Awarded Complete Turning Packages

he generosity of those that Committee and the Guild we because it becomes very peaceful and I can forget attended and bought raffle would like to congratulate these about everything else that is occurring in my life and Ttickets at the 5th New England young tuners. Here are excerpts let the tool glide into the wood making some form of Woodturning Symposium allowed from the winning applications. art, crappy or beautiful.” us to present four complete turning packages to Mark Hansen Mark Hansen – “Turning is Dan Pelrine – “At Merrimack High School there of Souhegan HS, Madison Barnes fun for me. I like the feeling of is a program called “Bowls for Hunger” which is - home schooled in Concord, NH, working the wood and shaping sponsored by the Art Department. This organization Ben Chandonnet of Pinkerton it into something unique and is for creative students to make bowls to sell at Academy and Dan Pelrine of expressive from nothing. I like the meetings to support the needy in New Hampshire. Merrimack HS. The packages smell and feel of the wood and I have looked at this as an opportunity to practice included a Jet 1014 lathe, Nova I like the satisfaction of having my skills by spinning bowls in class to support this Midi Chuck, Slow Speed Grinder, made something creative and program and to help the people in need in the Wolverine Sharpening Jig, tools functional, whether for my own community.” and wood. The scholarship use or for someone else’s use.” committee would like to thank Treasurer’s Report – continued Woodcraft (Newington, NH), Madison Barnes – “When I Oneway Manufacturing, and make something good I look at it CashFlow Report Turning Blanks by George for and say I can’t believe I made that. Sept 1, 2005 - Aug 16, 2006 their support in this program. A Using the lathe is just fun. I think General Operating Fund fifth lathe was awarded to Graham it’s more fun than video games, all Beginning Balance 15,618.73 Oakes to allow him to continue to of my friends love video games.” Income demonstrate. Ben Chandonnet – Donation 500.00 Students were asked to answer “I like to turn Dues 11,705.00 seven questions designed by the because it inspires me to design Books, Clothing, Videos Sold 4,590.28 Scholarship Committee. Twenty- and create works of art, sometimes Misc. Income 1,772.25 two applications were reviewed. beautiful, sometimes not. One of Turning Symposium 20,753.00 Money Market Interest 652.52 On behalf of the Scholarship the main reasons I like to turn is Total Income 39,973.05 Expenses Awards & Donations (1,576.25) Insurance (500.00) Internet Expense (167.50) Meeting Expenses (677.71) Membership Expense (1,159.95) Misc. Expense (457.30) The Old Saw (8,920.18) Clothing, Books, Video Supplies (6,097.17) Turning Symposium Expenses (15,161.23) Total Expenses (34,717.29) Transfer 1/3 Symposium Net to Scholarship (3,000.00) Transfer $5 per Member to Scholarship (1,595.00) Mark Hansen Madison Barnes Ending Balance 16,279.49 Scholarship Fund Beginning Balance 13,999.46 $5.00 per Member 1,595.00 Raffle tickets (‘06) 4,107.00 1/3 Turning Symposium Net Income 3,000.00 Scholarships and Grants (10,647.35) Ending Balance 12,054.11 Equipment Capital Reserve Fund Beginning Balance 2,023.74 No change 0.00 Ending Balance 2,023.74 Ben Chandonnet Dan Pelrine Total Cash Assets 30,357.34 meetings and events 28

June 3rd, 2006 by Greg Benulis Photo by Greg Benulis Beginner & Intermediate Group he subject for June, 2006 GNHW blade of the saw and had a very BIG at Bob LaCivita’s shop slight bevel along one of the long Tin Nottingham, NH was about edges. When the blade is laid sharpening. down on the plate with the teeth Bob began with the restoration and over the beveled edge you can set sharpening of hand . He covered the teeth by taping down every such things as the difference between the other tooth with a nail set. Then profile of the teeth on rip and crosscut you flip the saw around and do all the bits are handled by carefully filing the saws, and how the tooth count on a teeth you skipped in the first pass. One appropriate edges. saw relates to the use. As he sharpened of the big advantages of this method is The end of the meeting was devoted a , he spoke about files for that it is very easy to get a consistent to scrapers. Several methods were given sharpening and proper technique for amount of set across all of the teeth. for the preparation and maintenance filing. Next he brought out his dovetail The second topic was sharpening of card scraper edges. Bob emphasized saw which has very small (18 tpi) teeth boring tools starting with twist burnishing the edge with just a single and uses a rip profile. One of the things and spade bits sharpened freehand on stroke. After some discussion of the I found interesting was the method he a powered grinder. He showed us a various types of burnishing tools, Bob used to set the teeth. Bob had a steel hole saw and said that you can touch finished up with the setup, sharpening plate that was a little longer than the them up with your saw files. Forstner and use of scraper planes.

th June 16 , 2006 After completing our rounds at sanded and finished. They work hard at Starrett, we adjourned to the Old Mill controlling the humidity to keep all the Summer Trip in Leominster for a very pleasant buffet parts fitting. The members felt the tour lunch. We were somewhat under the to be worthwhile and many of us picked eventeen members of the Guild went gun for time but were able to get in and up a few pointers. – Dave Frechette on the summer field trip. The first out in an hour. Sstop was the L. S. Starrett Company in Our second tour was of Nichols and Athol, MA. We spent two hours there Stone – the oldest on-going furniture WorkBench … and barely scratched the surface. The manufacturer in the U.S. This company Laguna 5’ Bench – This company was founded in the late 1800s was also founded in the late 1800s by &OR3ALE bench is in the shop at by L.S. Starrett. He was a farmer and the Nichols family, although the family Pinkerton Academy and a tinkerer. His first invention was an had been making furniture on a small we need the space. It is automatic meat cutter. This sold but was scale before this. There was a rough in near perfect condition with the exception not a great success. He then had the idea patch in the early 1920s and the Stone of one chip made by an unknown student of a combination or adjustable square. family invested and ran things for – www.lagunatools.com/5workbench.htm. This took off and so did the company. several generations. This factory was Original price is $995, asking $700. The company is hugh with plants also very large and we only had time Jack Grube: [email protected] in China, Scotland and Honduras. We to tour the chairmaking side. They also started in quality control where every have a table and cabinet operation in Carving Tools & Blanks … Starrett measuring tool is inspected by the plant as well as a plant in Honduras. 12 carving tools (some Buck) and several hand. Next, we toured the tool and die They also outsource from China. At one boxes of butternut, pine and basswood department where mockups and custom time, they operated their own . carving blanks – $100. tools are made. Some of the machinery Their operation starts at their kiln. Peter James: 603-435-8133 was quite old but well maintained. Some They primarily build from with Shopsmith Mark V … was new state-of-the-art equipment with some cherry and maple as needed. They computerized controls. There was also a also use partially air dried wood in A great multipurpose woodworking tool museum containing old machinery and their bending operations. They do 80% (drill press, lathe, table saw, disk sander, products including one of the original of their own turning while farming horizontal boring) in excellent condition. squares – not all that different from the out larger pieces. When they start This tool now lists for over $3000 and has current ones. There is no retail outlet at manufacturing a chair, they will make changed little since the Mark V came out – Asking $950.00, includes caster set. the plant, so we were unable to purchase the components for 1000 to 1500 and Starrett products on the tour. But they then store them awaiting orders. As Tony Immorlica: 603-673-9629 evenings do have an annual “yard” sale each June. orders come in, the chairs are assembled, meetings and events 29

July 22nd, 2006 by DJ Delorie Granite State Woodturners annual critique — moose mountain lodge meeting

Harmony and Balance phrase most spoken) was “Harmony continuing the outside curve, such as – Every year, the and Balance”. in my segmented bowls, where the Granite State It’s not about always doing things “foot” is a lip half way up the side (where Woodturners hold one way, it’s about doing different the legs attach), leaving the otherwise their annual critique things in ways that work together well. “hidden” bottom fully exposed. meeting at the rustic A good balance could mean curves and Smoothness and symmetry of curves Moose Mountain lines mixed together, or it could mean was noted on many of the pieces. While Lodge. Located at the top of a mountain a simple curved box with a complex the actual curve defines the overall (it’s a converted ski resort), they say you detailed lid. Design elements themselves shape of the piece, it’s still important can see for a hundred miles. Well, we are balanced too; a strong edge can’t be that the curve be smooth and, again, could see about a hundred feet due to too big, but if it’s the right size, the “balanced”. Too many different curves, the fog and rain, but the real action was strength won’t overpower the other or curves that change in awkward ways, inside anyway. This was my first time design elements. can detract from a piece. A simple bowl at the critique, and unlike our usual One common topic was foot size. with a well-executed curve can be more technique meetings, I was about to learn Even though some folks had a history attractive than an otherwise exquisite a lot about style and design. of extreme opinions on an ideal foot piece with a subtly wrong curve. I was a little intimidated about the size, there were examples of when it was I’m not sure exactly what I took home idea of being “critiqued”, but only a appropriate to have an unusually large with me after the meeting (besides my little, as I knew most (if not all) of the or small foot. Peter Bloch made the rare bowls, of course), as “design” is still a people there, and they’d commented on and unexpected comment at one point somewhat mysterious process to me. my designs in the past. There was a full that one of the bowls needed a bigger Maybe my furniture background is still spectrum of both designs and turners foot (Peter is a fan of small feet) and Jon fighting for straight lines and square present, from beginners with simple (a fan of big feet) noted one bowl that corners, but I’m a bit more at ease with bowls to experts with complex creations. could have had a smaller foot. It just curves and transitions now. All that was And, contrary to my expectations, there proves that there’s no hard and fast rule left to do was to be at harmony with wasn’t a simple relationship between about design elements – each part of a the rain, bowls balanced in hand, as I “experience” and “getting it right.” design has to work with the other parts. walked back to my truck for the long Whether beginner, intermediate or We also talked about how the utility of ride home. Photos by DJ Delorie expert, there were examples of both good a piece influences the design, such as a and bad at all levels. I think everyone salad bowl needing a larger foot than a learned something, and while nobody natural edged bowl, since its purpose was immune to criticism, none of the requires more stability. Reid’s large criticism was demeaning or insulting maple platter had a foot nearly as big – the atmosphere and discussion stayed as the piece, but Graham’s set of natural helpful and friendly throughout the edged bowls appeared to have no feet at meeting, with the emphasis on learning all! by example, not just pointing out flaws. One of the trickiest things to get I don’t know if there’s a different right in a turned bowl is keeping the theme each year, or if there’s a theme wall thickness consistent, and the at all, but there seemed to be one this quality of such was noted for many of year. This year’s theme (or, at least, the the bowls. The transition from wall to foot makes this more difficult, and one design element that was talked about was what to do with the area inside the foot. Even though it’s normally hidden, it’s important to do something with that space that works with the rest of the design. This can be either adding some detail that reflects details elsewhere in the piece, such as a trio of burned-in rings on Donna’s hard maple bowl; or bulletin board 30

Malcolm Tibbetts Presentation gala reception and auction and receive of item (hard or softcover book, video or Malcolm Tibbetts will be doing a a 2006, four-color commemorative DVD), list price and the ISBN #. presentation for the Mt. Washington auction catalogue. To purchase tickets Valley Woodturners at their regular or obtain additional information, visit All email orders will be acknowledged monthly meeting on October 19 from the Association’s website. within one week. So if you do not get 7 to 9 pm in the shop at Kennett High 603-898-0242 or www.furnituremasters.org a response, please call me – I have School in Conway NH. Malcolm is a vigorous anti-spam software. I’ll email professional artist who lives in South Annual Discounted Woodworking you with the net cost when the books Lake Tahoe, CA but graduated from Book Sale – Nov. 19 Deadline arrive. Payment is due immediately and Kennett HS! After a long career in the ski One of the advantages of Guild the books are not returnable. This gives industry and many years as an amateur membership is the opportunity to us a premium discount. Happy hunting woodworker, he became “hooked” on purchase books at wholesale prices. for some really good woodworking the lathe in 1993. His turnings have We have arrangements with Taunton books. won many awards, and he has pieces Press (www.taunton.com) and Sterling Note that discounted magazine in many prestigious collections around Publishing (which includes Lark and subscriptions are also an annual event the world. His signature works are Guild of Master Craftsman titles which takes place after the first of the creative applications of segmented – www.sterlingpub.com) and others to new year – watch the February Old Saw turning, but his work is versatile and purchase books once a year at discounts for details. diverse. He is the author of The Art of 20% to 50% depending on quantity Tony Immorlica – Book Coordinator of Segmented Woodturning, released in ordered. 603-6763-9629 (evenings) 2005, and he wrote an article called This year we are adding or use my new email address Lamination Trickery in the Summer another publisher, Fox Chapel [email protected] 2005 issue of Woodturning Design. His (www.foxchapelpublishing.com). Fox work can be viewed on his website at Chapel is a publisher but also sells Scholarship Awards www.tahoeturner.com. Malcolm’s work books from other publishers such as Scholarships were awarded this is pictured (chess table and chairs, all Taunton but at lower discounts. If there past spring to Jack Minassian, Graham turned) in the August 2006 issue of Fine is sufficient demand, I will also place Oakes, Ryan Phelps, Bob St. Laurent Woodworking in the Reader’s Gallery orders from suppliers we have used in and Jo Stone. section. the past. However, we need a minimum Jack Minassian’s scholarship was Kennett HS is in Conway, NH on of ten titles for each… used to further his work making a the left as you enter Conway village • Astragal: www.astragalpress.com copy of a 1736 single-manual Blanchet from the south. Admission is $10, with • Stackpole: www.stackpolebooks.com harpsichord. Jack has been working proceeds to benefit the woodturning • Tiller: www.tillerbooks.com on his own and in conjunction with program at Kennett HS. For further • Schiffer:www.schifferbooks.com Hubbard Harpsichord. This has been a information or questions, contact: • Penguin/Putnam: long term project for Jack and he hopes Ed Good www.penguinputnam.com to finish making the instrument this 603-383-6944 or [email protected]. Orders will be accepted at the year. fall Guild meetings starting at the Graham Oakes was awarded a Jon Siegel is encouraging members annual meeting in September. The last scholarship to purchase the necessary of GSWT to attend this meeting as chance to place an order will be at the tools to spend time working in the a way to bring the Mt. Washington November meeting. Books should be workshops of Dustin Coates and Beth Valley and Granite State Woodturners available in early December for pick up Ireland. Dustin and Beth generously together. This should be an interesting at my home in Mont Vernon, NH, or at did not charge Graham for the time he presentation to anyone interested in a future guild meeting. spent in their shops. . Email Jon if you I will have catalogs at the meetings, Ryan Phelps and Bob St. Laurent want to car pool. or you can view titles on the publishers’ were awarded scholarships to study Jon Siegel – [email protected] web sites and email your order to me. If windsor chairmaking at Michael you email your order, you must include Dunbar’s Windsor Institute. Both have NH Furniture Masters Auction the following in addition to your name successfully completed their courses and The 2006 NHFMA Auction will and telephone number: I would like to suggest that sometime take place on Sunday, October 22 the Guild might consider a windsor and will again be held at the beautiful For Taunton – The exact title, author, type of chairmaking symposium inviting chair Wentworth-by-the-Sea Hotel in New item (hard or soft cover book, video or DVD), makers from the guild and elsewhere to Castle, NH, with auctioneer Frank the list price and the Taunton Product Code demonstrate their craft. Eaton presiding. (NOT the ISBN #). Jo Stone’s scholarship funds Tickets to the event are $75 per person were used to help allow her to and entitle the holder to attend the For all others – The exact title, author, type participate in the 2006 International bulletin board 31

Woodturning Exchange (ITE) as this series of topics as in the past, I would like furniture in styles that originated before years furnituremaker. As Jo wrote in to take the BIG participants through an the Industrial Revolution – that is her application “Each year, the ITE entire project. The project will be a small around 1820. Meetings typically have provides work and living space to five cabinet with a drawer and two doors. The a presented topic plus an opportunity woodturners, one furnituremaker, one design will have Asian influence – simple for attendees to present projects, photojournalist and one scholar to work and clean. The participants of BIG will either finished or contemplated. It together for up to eight weeks. The ITE obtain a comprehensive understanding is an especially good place to ask for is carried out as one of the primary of the steps, techniques and processes advice, guidance, and support. All mission goals of the Wood Turning to accomplish the intended result. I Guild members are welcome to attend. Center.” encourage you to take the time and Meetings last year drew between 12 The New Hampshire Furniture sharpen your skills and knowledge. and 24 people and are held around Masters Association was awarded a grant The first BIG meeting this year is NH and occasionally in MA. Meeting to further their educational programs Oct. 7 at Bob LaCivita’s shop at 365 announcements giving directions are through the New Hampshire Institute Stage Road (Rt 152) Nottingham, NH emailed about two weeks before each of Furniture Making and their current from 9:30 am to 12:00 noon. Please e- meeting. series of lectures and exhibitions. mail or telephone (before 9 pm) if you The next meeting will be on Sept. 16, Congratulations to all of those who plan to attend. 2006 (note this is the 3rd Saturday in were awarded scholarships. We look Bob LaCivita September, an exception to the general forward to hearing about your various 603-942-1240 or [email protected] rule) and will be at Tom Zimmerman’s experiences. – John McAlevey shop in Moultonborough, NH. Tom Granite State Woodturners makes and restores antique clocks and Upcoming Guild Meetings The next meeting of the Granite State we will be able to see his workshop • Sept. 23 – Annual Meeting at the Woodturners will be Sept. 30. This is one and showroom. He is also preparing a Dana Robes shop in Enfield, NH week later than normal due to a conflict presentation on inlay and banding. – www.danarobes.com. See page 3 with the annual guild meeting. David As an experiment for this year, I for details. Belser will demonstrate how he makes would appreciate receiving RSVPs a day • Oct 21 – Small Meetings at various his turned wood containers which lock or two beforehand, from those planing shops throughout NH. There are with a secret code. The location is TBA. to attend a meeting – it helps us plan typically three to five from which Contact Jon Siegel to be added to the e- the refreshments. Meetings run from 9 to choose. An email will be sent mail notification list. am to noon. It is a good idea to bring with details of the day’s events. Or Jon Siegel – [email protected] your own collapsible chair. you can check in at the Guild web Contact John Whiteside to be added site in early Oct. – www.gnhw.org. Period Furniture to the email list. If you do not have email, The Period Furniture Group is a I will contact you by phone. Beginner & Intermediate Group subgroup of the Guild consisting of John Whiteside: 603-679-5443 This year, rather then demonstrate a members who are interested in building or [email protected]

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