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Sharpening Beveled Blades with Abrasive Sheets by Spencer Hochstetler and Bill Tindall

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Sharpening Beveled Blades with Abrasive Sheets by Spencer Hochstetler and Bill Tindall Sharpening Beveled Blades With Abrasive Sheets by Spencer Hochstetler and Bill Tindall Whether a novice or an experienced information on selecting bevel angles and most woodworker, you may find that tool sharpening everything else about sharpening various tools is one of the most frustrating tasks in all of can be found in an excellent sharpening book, woodworking. Many people who make the The Complete Guide to Sharpening, by Leonard attempt and use the tool with a sub-optimal Lee. edge sometimes “get by”, while others may yield to frustration and give up on the idea of using hand tools altogether. However, a properly sharpened hand tool can lead to unimagined speed and enjoyment of woodworking. The purpose of this article is to provide straight-forward instructions for sharpening tools with flat bevels, such as chisels and plane irons, and guide the sharpener in the choice of sharpening equipment. The use of jigs and honing techniques using affordable, commonly available abrasive sheets will be discussed. Traditionally, sharpening was done with Definition of Sharpness and General stones. Abrasive sheet sharpening is a faster Overview and cheaper alternative to stones. (Because the Basically, an object is sharp when two abrasives that are glued to abrasive sheets geometric planes intersect with relatively little consist of a variety of synthetic materials rather radius at the line of intersection. For than sand, we prefer the term “abrasive sheet” woodworking, the angle at which the two planes rather than sandpaper.) The main goal of this intersect is important. If the angle is too small, article is to instruct how to make the bevel the blade will require less cutting force, but the intersect with the face with near zero radius edge will crumble under the cutting forces. If using abrasive sheets. Although the techniques too large, the edge will be very sturdy, but will are the same that would be used with stones, require a cutting force that makes using the tool abrasive sheet sharpening has several difficult or impossible. For blades such as advantages over sharpening with stones. First, plane irons and chisels, the basic shape is abrasive paper is cheap and readily available in shown in Figure 1A. Figure 1B shows the a variety of grit sizes and materials. Therefore, difference between a sharp edge (near-zero it is practical to use the optimum selection of radius) and a dull edge (significant radius). The grits to achieve sharpening and optimizing grit two geometric planes that are flattened during selection results in very fast sharpening. In the sharpening process are the bevel and face. addition, rolls of abrasive enable relatively long The angle that includes the bevel and face is lengths of abrasive to be used, particularly in called the bevel angle. The appropriate bevel comparison to the relatively short water stones angle depends on how the tool will be used, as available. This factor is particularly important well as the properties of the metal. In general, when using a sharpening jig, because the jig the smallest bevel angle that will hold up is occupies several inches of the abrasive surface. best. For plane irons, a bevel angle of 25° is a When using a jig the effective length of a water good starting point. For chisels sharpened for stone can be as little as 5”. A 13” length of general use in hardwoods 25 to 30° bevel angles abrasive sheet doubles this effective length. In are common. Mortise chisels require bevel either stone or abrasive sheet sharpening the angles closer to 35° for durability. Additional abrasive surface must be flat to achieve a sharp turned to allow blade-jigging at commonly used straight cutting edge. A third advantage of sharpening angles, allows one to easily and flexible abrasive sheets is that they only need to repeatedly find the same angle when be affixed to flat surface to be used. Worn resharpening. The Veritas jig also helps with abrasive sheets are simply removed from the aligning the blade edge perpendicular to the flat surface and thrown away. Conversely, a honing guide motion. Another type of jig stone will wear and develop curvature with use clamps the blade from the sides. It is more and must be flattened regularly to yield a flat difficult to align the blade in this jig and the sharpening surface. Cost and speed are final smaller roller makes it more difficult to keep considerations. With proper selection of grit the blade aligned with the abrasive during sizes, metal removal progressing from a rough sharpening. However, this jig can be used to to a mirror-smooth surface is accomplished far sharpen spoke shave blades. faster with abrasive sheets than with a series of stones. Start-up costs for low-headache sharpening are also significantly lower with abrasive sheet-sharpening. A good set of Japanese water stones can cost as much as several hundred dollars while with some creativity, abrasive sheet sharpening can cost as little as five dollars to get started. The method for using abrasive sheets for sharpening has been made popular on the Figure 2B. Woodworker’s Supply side internet (http://www.shavings.net/scary.htm) clamping jig. and most people refer to the method as the “Scary Sharp” system. Unlike the original posting of the Scary Sharp method, this article Flat Surfaces also aims to provide information on selecting A flat, rigid surface is an essential grit size and composition as well as descriptions component of abrasive sheet sharpening. of various equipment to use with abrasive Flatness to within 0.001 to 0.002” over a foot is sheets. acceptable. Further, to minimize the number of strokes one must use on a particular grit, a Sharpening Jigs minimum of a twelve inch length is best. Glass, A sharpening jig is a great aid to quick polished marble tile, Corian, granite surface and consistent sharpening regardless of the plates, and, in a pinch, shop machinery beds are abrasive format used. A few examples of all excellent choices for flat surfaces. Glass sharpening jigs can be seen in Figure 2. In our plates should be at least 3/8” thick to minimize flexing. Occasionally, home improvement stores like Lowes or Home Depot will have close-out sales on 12” x 12” polished marble floor tiles. Bringing a good straight edge, such as a Starrett combination square, to the store can help you select sufficiently flat tiles. By placing the straight edge on edge orthogonally and diagonally across the tile and holding the Figure 2A. Lee Valley Tools “Veritas tile up to the light, you can determine which Sharpening System tiles are flat by looking for light shining through the straight edge and the tile. Tiles with light opinion, the Lee Valley “Veritas Sharpening shining through are rejected. Corian, a System” is definitely worth the $30 price tag. synthetic material commonly used in kitchen The angle jig, which is a pentagon that can be countertops, has also been used. It is machinable with shop tools and some people final polishing. Aluminum oxide is have gone so far as to drill an array of holes in a exceptionally durable and it wears by rounding Corian slab, then mount the slab in a box that the grains so the effective grit size becomes has a vacuum port on it to make an inverse smaller with use and cutting efficiency plenum. When the vacuum is turned on, suction decreases. It is the recommended material for generated at the holes in the Corian is used to grinding and polishing hard metal in the hold the abrasive sheets onto the surface. medium/fine grits (~220 – 600). Alumina- Machinists frequently use granite surface plates zirconia tends to combine the best qualities of for layout and jigging in metalworking. Tool the other two materials, but it is more room, or Grade B, 12” x 18” surface plates with expensive. It provides particularly fast material overall accuracies of ±0.0001” can be purchased removal in the coarser grits (~80 – 220) and, for about $30 plus shipping (~$35). While this therefore, it is recommended for this use. It is surface is relatively expensive, it is very durable only available in coarser grits because these and could be used for other things that may grits offer a cost-effective advantage over require an exceptionally flat surface. Finally, a aluminum oxide not found with the finer grits. flat machinery surface can be used for experimenting. Jointer beds and iron table saw Grit Grade Choice tops are good surfaces to use, but not very It is often possible to proceed from a convenient for a long-term sharpening setup. coarse ground surface to a polished surface with Ideally, one would like to have the whole series as little as 5-10 strokes on each grit size when of abrasive sheets attached to a readily the sizes are wisely chosen. Abrasive sheet accessible surface so that touch-ups are quick sharpening can be very fast because it is and easy. possible to start sharpening with coarse, aggressive grits and proceed in small steps to Abrasive Sheets – The Nitty Gritty smaller grits and their corresponding small Recently, one of us (BT) had a scratches. The abrasive sheets cost pennies conversation with an abrasive specialist about each, so unlike stones, it is practical to have at sharpening with abrasive sheets glued to a flat hand the optimum progression of grit sizes so surface. While this individual’s company does that each smaller grit has but a small task to not conduct research on sharpening, they do remove the previous scratch size. study smoothing and polishing metals. Making For metal finishing, or wood finishing the assumption that smoothing and polishing are for that matter, abrasive companies typically functionally the same as sharpening, in that two recommend skipping not more than one grit size surfaces are smoothed and polished in in the smoothing and polishing process.
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