Ulu and Chopping Block Rout the block to match the with a simple dishing jig

By Joe Hurst-Wajszczuk

Full disclosure: I collect kitchen the same chef’s knife. The handle’s position above the blade way I do hand tools in my workshop. I bought the ulu knife kit because I was hooked by the shape chopping hard vegetables and frozen foods. of the blade. I'm a little surprised that my ulu has providesTo make a signi�icantfull use of my mechanical new knife, advantage I made a when become my go-to knife for slicing and dicing. double-sided cutting board to match the blade. Designed by the , this little knife has been used for everything from skinning game, to haircuts, to trimming snow blocks for igloos. Seal sideThe concaveserves for face slicing keeps meats �inely-chopped and cheeses. ingredients isn’t a regular part of my daily diet, but I’ve found fromThe spilling knife/block over thepair countertop. is a great excuse The �lat to raid that this curved blade excels at dicing vegetables your scrap bin. With help from a few simple and herbs, and trims meat as well as my pricier jigs, you can make this combo in few hours.

28 woodcraftmagazine.com Oct/Nov 2015 3 Diff erent curves for HANDLE Rout ⁄8" roundover 1 1 × 1 ⁄2 × 5" on top edge aft er blade and board att aching blade. To allow the knife to pivot, the diameter of the block’s concavity is greater than the blade’s arc. The 12"-dia. routed dish works well with 1 Woodcraft ’s 4 ⁄2"-radius knife.

5 3 3 ⁄16" roundover ⁄32 × ⁄4" morti se 1 ⁄8" roundover

Round edges before routi ng bowl. 1 square = 1" Half-sized patt ern; enlarge 200%. 3 ⁄8"

1 1 ⁄8"

CHOPPING BLOCK 1 1 ⁄2 × 8 × 8" Glue up strips to create oversize block, and then trim to size.

Saw-Simple Knife Instead of sandwiching the two tangs between matching wood 3 scales, I plunge-cut the slots with a multi-tool and 8"-wide blade. After layout, I drilled a series of holes, set my saw guide,⁄ and sawed out the waste. I then used a jigsaw blade to clean out the

with epoxy. Temporarily mounting the exposed blade in a holder slot and work up to my line. When the tangs �it, glue them in place

saves time (as possibly �ingers) as you complete the knife.

1 ⁄2" magnet

Rout this way. Clamp the blade 3 between ⁄4"-thick MDF shields to create a holder for routi ng the handle. Keep the scrap in place Taking the plunge. Set shims under the guide and make two plunge cuts. when sanding and fi nishing. A countersunk magnet keeps the blade from jumping off the guide.

Opening photo: Jim Osborn; Project photos: Ralph Lee Anderson; Illustrati ons: Trevor Johnston Oct/Nov 2015 woodcraftmagazine.com 29 Make a dishing jig to rout the block Turning the concavity might be faster, but this jig makes routing a perfectly-sized dish nearly fool- 5 proof. The turntable rotates on a 16"-dia. dowel that's glued into the base. Attaching⁄ sandpaper to the turntable prevents the block from spinning should the bit catch the block. Use double-stick

The short runners and notched platform allow Drill bit/ pivot point. thetape router or pin to nails ride to the af�ix curve the moreblock closely.to the turntable.

Benchtop saver

6" One jig makes another. Cutti ng the dishing jig's 1 9 ⁄2" arced sides with a trammel ensures that the sides 1 7" are smooth and symmetrical. Rout the arc in ⁄4" increments. Tack the sides to a backer so that 3" the parts don’t shift at the end of the cut.

14"

RUNNER 3 3 ⁄8 × ⁄4 × 2" File edge to STOP 3 3 clear side. ⁄4 × ⁄4 × 6"

Center bit above PLATFORM 1 1 1 turntable before ⁄2 × 4 ⁄2 × 17 ⁄2" att aching stops.

SIDE 3 ⁄4 × 7 × 14"

BASE TURNTABLE 3 1 3 ⁄4 × 14 × 12 ⁄2" ⁄4 × 8 × 8"

1 1 1 Doing the dishing. This jig creates a 7 ⁄4" × 1 ⁄8"-deep cavity in 1 ⁄2" thick block. I used a bowl bit, but any 1 roundnose bit will suffi ce. To control chatt er, use a ⁄2"-shank bit and set the speed to 13,000 RPM. To reach the very bott om of the dish, I set bit lower in the collet and fi nished up with super light passes.

30 woodcraftmagazine.com Oct/Nov 2015 Routing in the round Rout the recess from the outside in. To do this, position the platform so that the bit clears the 1 block, adjust the bit for 8"-deep cut, and then pivot the platform until ⁄the bit's bottom edge makes contact. Rotate the turntable 360° before shifting the platform. To minimize cleanup, overlap your passes. After routing, use the jig to hold the block while you clean up scallops left by the bit.

Tilt and spin. Aiming the router bit away directs chips away from you and keeps your fingers a safe distance from the bit. If the block starts spinning, disengage the bit by tilting the platform.

Sand then seal. A multitool equipped with a sanding pad, followed by a mop sander, quickly erase remaining tool marks. Finish-sand through 320 grit, Smooth it out. Use a curved scraper to shave and then seal with your favorite cutting board finish. off any high spots. A wedge-shaped block keeps the turntable from spinning.

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