Woodturning Fundamentals
SPECIAL EDITION: Setting Up Your Woodturning Workstation
woodturner.org
SPECIAL EDITION: Setting Up Your Woodturning Workstation Woodturning Fundamentals AAW TABLE OF CONTENTS EDUCATION
2014 – Special Edition: Setting Up Your Woodturning Workstation
Welcome message from AAW Executive Director, 1 Phil McDonald
A Note from the AAW Safety Chair, Rob Wallace 2
Setting Up Your Woodturning Workstation By Rob Wallace
• Part 1: Space planning, lighting, electrical 3 and provision for dust collection
• Part 2: Design and layout of the space, how 9 to evaluate the most efficient and ergonomic placement for storage
• Part 3: Safe operation at the lathe, reaching 16 and repetitive movement, and use of personal Rob Wallace protection equipment
• Video: Adjust the Height of Your Lathe 24
Woodturning Board of Directors Woodturning A Note About Safety: Fundamentals Dale Larson, President Fundamentals An accident at the lathe a bimonthly publication by Kurt Hertzog, VP Committee can happen with blinding suddenness. the American Association of Cassandra Speier, Sec. Denis Delehanty, Respiratory and other Woodturners Philip Hauser, Treas. Chair problems can build over 222 Landmark Ctr. Binh Pho Linda Ferber years. Take precautions 75 5th St W Rob Wallace Beth Ireland when you turn. Safety St. Paul, MN 55102 Lou Williams Rob Wallace guidelines are published phone 651-484-9094 Denis Delehanty John Lucas online at website woodturner.org Art Liestman Alan Zenreich Exec. Director: Phil http://www.woodturner McDonald .org/?page=Safety [email protected] Following them will help Program Director: you continue to enjoy Linda Ferber woodturning. [email protected]
Cover photo: William Meiklejohn
AAW | woodturner.org INTRODUCTION
Note from Phil McDonald, Executive Director
AAW staff and board are pleased to present you with this complimentary special edition of Woodturning Fundamentals. We’ve recently given Woodturning Fundamentals a facelift and have expanded the educational content in each issue. This is an integral part of our ongoing plan to complement our bi- monthly American Woodturner and serve AAW members with a greater variety of woodturning information.
We are introducing more video, with more basic woodturning information. And coming soon, watch soon for the latest installment in our premium- content, Elements of Woodturning project workbook series. The newest title will cover all aspects of sharpening turning tools and will be available for purchase on the AAW website in both a digital download and a print on demand paperback. I would like to express my gratitude to our volunteer member-authors, the Fundamentals Committee and AAW staff for progressively elevating the quantity and quality of our publications.
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1 ABOUT THE AUTHOR
Message from Rob Wallace
Thanks for taking time to read “Setting up Your Woodturning Workstation.”
Every woodturner goes through a learning curve to acquire the knowledge and skills needed to accomplish different turning methods. It is my hope that sharing this series of articles will help you set up a safe and functional workshop.
A great companion to this series is AAW’s Safety for Woodturners book which offers a basic understanding of important safety practices and the need to turn safely. Safety will become second nature to every woodturner who reads it and safety-aware turners are better able to experience the enjoyment and thrill of woodturning, as well as an increased confidence in their abilities. You’ll take comfort in knowing you are doing everything possible to maximize safety of yourself and those around you.
Turn SAFELY! Rob Wallace
Rob Wallace holds a Ph.D. in Botany from Rutgers University, New Jersey and is a biology professor at Iowa State University where he teaches courses in evolution, plant taxonomy and systematics, economic botany, and biogeography. He has been a woodworker since before his teen years and enjoys all aspects of woodworking, especially woodturning. He is a member of the American Association of Woodturners (AAW) and has been an active member and officer of the Ames Woodworkers Club, Iowa for over 16 years. He has coordinated the local group of woodturning enthusiasts, Ames Area Woodturners, since 2005 and has presented demonstrations on various woodturning and woodworking topics to regional and national groups. Wallace is on the AAW Board of Directors and is head of the AAW Safety Committee.
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2 WOODTURNING SHOP
Part 1: Choosing a Location
For the new woodturner, the turning accessories that might cause motivation to “get turning” with you to slow down or stop your your own lathe in your own shop or operation, or identify those things studio is exciting - as it should be. that make you This situation does not lend itself to feel Are you doing deliberate planning in the design and uncomfortable, everything safely? set-up of a woodturning work station, whether Does it feel OK to do but don’t resist the urge to set up the physically or this technique? Are machine and make some shavings. psychologically you experiencing You may already have experience in (i.e., Are you body pain or knowing how much fun woodturning doing muscle strain after can be, and getting some lathe time everything a turning session? right away with a new machine is safely? Does it always special. Even if you only have feel OK to do this technique? Are you your machine set up temporarily, experiencing body pain or muscle take some time to enjoy getting to strain after a turning session?) These know your lathe and how it works. are areas of concern that need to be Do this safely, and if you need advice, addressed when developing the get it. Doing some woodturning on design of your permanent your new lathe is a great way to get a woodturning workstation. You’ll get feel for how much space might be to know what is needed for your own needed around the lathe for your workstation while gaining some body size. It also might give you some useful experience. reference about where your lathe tools and accessories might best be Whether you are a new woodturner, located for your turning style. One or one with considerable experience, point to emphasize here is that you it is always useful to periodically will eventually be creating a evaluate the safety and efficiency of woodturning workstation that is your woodturning station to be sure designed around YOU, and more you are maintaining a healthful, safe, specifically, how you relate to the and enjoyable work environment. I lathe and all of the supporting tools, will review some of the aspects of equipment, and supplies. Setting up a setting up and maintaining a temporary woodturning location will woodturning station that should be enable you to pay special attention to considered as you evaluate and any arrangements of tools, sanding design your own personal turning and finishing supplies, or other space.
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The available space – Once the time very hot, considerations of how to deal has come to determine where your with heating and cooling of the lathe will reside long-term, some initial workspace environment are very planning will go a long way in making important, particularly if you intend to sure your woodturning station is set up enjoy woodturning at all times of the as safely and efficiently as the year. There are a number of books resources will allow. A bit of planning available on the process of setting up a for the future growth at your woodworking shop, and with some woodturning station’s location will additional considerations for pay off in creating a more pleasant and specializing the design for the lathe efficient place in the future where you and supporting equipment with undoubtedly will be spending long woodturning as the main focus of the hours of enjoyable time turning wood. operations, many of these same Your space restrictions may dictate principles will apply to setting up a that your turning station may need to safe and efficient woodturning be located in a garage, basement, or shop/studio. other shared-use space. Some will have a dedicated space in a large room, out- building, or other location – each space will be unique. General aspects of the space chosen should include ease of access through doors (you’ll be bringing in wood blanks, hauling out shavings, etc.), space available for support tools (band saw, drill press, dust collector, etc., and if you’re planning to do segmented woodturning, a table saw and/or miter saw, clamps, and benches), and sufficient space for storage of turning stock, drying roughed pieces, and possibly an area for finishing. A bit of Room for the Lathe and uncommitted elbow-room would also Operating Space Around It – be desirable, and given the fact that When choosing the location for the eventually you’ll probably be inviting placement of your lathe, you will need woodturning friends over, the extra to plan for much more space than just space is always welcome. Other the footprint of the machine itself. important things to think about are Obviously, there will need to be space having sufficient lighting, electrical allocated for the operator of the lathe, service and climate control. For those which is typically a minimum of two in regions where winter means cold or to three feet deep along the length of very cold, or summer means hot or the lathe bed. Depending on the
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design of your lathe, access to the perpendicular to a wall, or at some headstock and tailstock ends may be intermediate angle adjacent to a wall is important. For lathes with sliding a matter of personal preference, as is headstocks, or short-bed bowl lathes, the placement of the lathe away from a having extra room at the tailstock end wall. Left-handed woodturners with will improve access to the piece during reversing lathes may wish to set up hollowing operations from the end of their machine with more space at the the lathe. Most turners would also back of the lathe to accomplish more consider the efficient turning (in reverse) to placement of a accommodate the lefty perspective. grinder (or Placement of tool This is an example of adapting the other racks in work station to you, and not you sharpening ergonomically having to adapt to the lathe. The tools) close to compatible places turner can experiment with the the lathe as adjacent to the positioning of the lathe and other essential for operator’s position supporting items to maximize the quick, improves safety, comfort, and efficiency of the efficiency... convenient turning operation – such sharpening experimentation and modification operations, which are a standard part should be encouraged as new of woodturning. In addition to wise techniques are learned, or as new placement of sharpening equipment, it equipment dictates. is important to define a location (or locations) where one’s frequently-used Lighting, Electrical, and Other turning tools are stored. Placement of Considerations – When developing tool racks in ergonomically compatible plans to set up places adjacent to the operator’s your turning position improves efficiency. One station, keep should also ensure that the racks are in mind that stable, easy to use, and do not pose a additional, safety hazard for the turner. The concentrated, presence of items on the floor that and adjustable might pose a tripping hazard (wires, air lighting at the hoses, turning blanks, etc.) must be operator’s avoided, including any form of anti- position is a fatigue floor matting that is used at the significant operator’s location. The positioning of improvement the lathe within the room can be beyond having influenced by the availability of adequate ambient room lighting. electrical outlets, dust collection Many turners value the extra light requirements, and other physical provided by various forms of task aspects of the space. Whether the lathe lighting which can serve to more is set up parallel to a wall,
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intensely illuminate the “field of properly-rated over-current device action” - where the turning operation (circuit breaker) is used in the supply actually takes place on the lathe. panel. If adding electrical circuits for Whether this task lighting is delivered use at the lathe, those that supply by some form of flexible arm light, power to the ambient room lighting track lighting, or other specialty should be on a different branch circuit fixture, this than that used to supply current to the light source lathe, or to other accessories (e.g., should be …light source grinder) if possible. The room should fairly bright should be fairly not go dark as a result of a circuit and bright and tripped by a machine or accessory. adjustable to adjustable to Many turners, particularly those that accommodat accommodate do any kind of hollowing, also feel that e different different needs of having compressed air available at the the turner… needs of the lathe is a necessity. While not turner, essential, it would be prudent to plan including the ability to illuminate to add this utility to the woodturning turned forms of different sizes and station design as a future addition if shapes. It is often helpful to have more desired. than one form of task lighting for additional specialized woodturning Provisions operations – for example, a readily- for Dust positionable light to assist with Collection hollowing operations. As the turner and Floor gains experience and turning methods Clean-up – A change and develop, requirements will very important change for new forms of lighting, so consideration some flexibility in positioning of extra of any location electrical outlets should be considered that you select near the woodturning station to for your accommodate future requirements. woodturning These extra outlets will also come in station is handy when other electricity-requiring making tools, such as sanders/drills, routers, provisions for carving tools, vacuum pumps, etc. are installing some used while pieces are still mounted on form of dust collection. Whether the the lathe. The service needed to supply actual dust collector unit is located power to the lathe will necessarily be right next to the operating position, or tailored to the electrical requirements if it is located some distance from the of the machine in question – be sure lathe and connected by an efficient that the proper voltage and current ductwork system, every woodturning (amperage) ratings are met with workstation should be equipped with a suitably sized service wire gauge, and a
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method of removing the fine dust Other Resources You Can Use – created during sanding operations. When reviewing the possibilities of Given the nature of the spinning where you will set up your wooden workpiece and its ability to woodturning workstation, it is a great throw fine dust into the air around the idea to visit other turners’ shops or operator, having efficient wood dust studios and see how they have set up extraction should be considered a high their lathe and supporting items. Have priority, mandatory installation for a look at their lighting arrangements, every turner. Remember that it is air where and how they store their flow volume that is the critical feature turning tools, chucks, faceplates, and when selecting a dust collection other accessory items. Where do they system, and that capturing the dust at prepare their turning blanks? Do they the source as it is created is most have adequate dust collection? Don’t desirable. The idea is to capture the be afraid to ask them what they really airborne dust with a machine before like about their set-up, and what they your lungs get filled with it – this is the do not like about it - particularly what most important they would do differently. Invite a thing you can woodturning friend or two over, let do for long- …having efficient them see the space you’re planning, term wood dust and get some additional opinions from respiratory extraction should those who have been down the same health if you be considered a road before; nothing beats experience. high priority, plan on turning You can also make use of the broad mandatory for any length and deep collective experience installation for of time. Your available through Internet discussion every turner… turning space groups, such as on the AAW’s Member should also Forums or the Woodcentral Turning have floor surfaces which are not only Messageboard. Don’t be shy about safe to stand and work on, but also are asking questions about setting up your easy to sweep and keep clean. Periodic work station – there are many cleaning of accumulated shavings is experienced turners eager to help that highly desirable, if not required for fire are only a few mouse-clicks away. safety, and from different woodturners you will receive a range of responses Once you have chosen a location for about what “periodic” means. The area your turning station, the next step is to surrounding the lathe should be design the work space to match your planned so that it can be cleaned body, to the techniques you intend to easily, which means that shavings and use, to the kinds of tools you have (or chip removal is more likely to actually plan to have), and to arrange them for be done on a regular basis. maximum safety, efficiency, and enjoyment.
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In part two of the series, I will discuss the design and layout of the space, including the lathe, supporting tools, storage of turning tools, sanding and finishing supplies, and other items normally used around the lathe, and how to evaluate the most efficient and ergonomic placement for the storage of these items.
(Selection from Woodturning Fundamentals, May 2012, American Association of Woodturners)
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Part 2 – Adjusting Lathe & Workstation Parts
In part one, I reviewed different aspects of selecting an optimal adjustment of the height of the spindle location for your woodturning of the lathe to match the physical body workstation, which included dimensions of the primary operator is considerations of available of critical importance. In general, the shop/studio locations, tool placement, advice has been passed down that the electrical and lighting requirements, optimal dust collection, and cleaning access. spindle height …the optimal spindle Once you have chosen a location for of the lathe for height of the lathe your turning station, the next step is to the operator for the operator adjust the lathe, and to design the should be should be work space to match your body to the approximately approximately the techniques you intend to use, to the the distance distance from the kinds of tools you have (or plan to from the floor floor to the have), and how to arrange them the to the operator’s elbow best way for maximum safety, operator’s when the forearm is efficiency, and enjoyment. elbow when held forward plus an the forearm is inch or two… In this article, I review the basics of held forward adjusting the lathe and other parts of (with the upper arm hanging down in the workstation to your body, so that a relaxed position), plus an inch or you will be relaxed and safe while two, based on personal preference, enjoying efficient woodturning. What type of turning operations done, etc. I outline here should be considered a (See Figure 1). This dimension should starting point for adjustments and serve as a starting point for periodic modifications which ultimately need review and adjustment until one feels to suit you as an individual regarding comfortable (literally) with the lathe adjustment of the lathe and height, as determined through turning surroundings, and placement of tools, experience. When you are first starting supplies, and other support items such out, this adjustment should not be, as lighting, dust collection, and “Set it – and forget it.”, but should compressed air supply. require periodic evaluation and, if necessary, adjustment. For “height Setting up your lathe – In addition challenged” individuals, if the built-in to identifying the position of your height adjustment (if present) on the lathe within the available area lathe cannot be adjusted any lower, discussed in the last installment, the you may need to accommodate your spindle height adjustment by constructing an adequately large
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sturdy platform which raises you to the operator’s body position should be correct spindle height. One way or maintained in a neutral posture for the another, this important adjustment of majority of time for the work spindle height should be made and operation being performed at the evaluated carefully as you get used to workstation. This your lathe. Take the time early in the means that a lathe set-up process to make sure the woodturner Having to lean spindle height is set correctly and it working at their over or lean back will pay dividends long into the future lathe should be to accommodate an incorrect in long periods of relaxed, fatigue-free standing (or spindle height woodturning. And don’t forget about sitting) in a adds muscular the resilient “anti-fatigue” matting, if comfortable, strain to the body you intend to use it, and its effect on relaxed, upright which, over time, the measurement of your optimal position which can create spindle height – this should be taken does not require fatigue, muscular into consideration when the desirable leaning, pain, stress, and spindle height is being measured. stretching, or other discomfort. Make your measurement from expenditure of whatever floor surface you will be any additional standing on. muscular exertion while the work is done. Having to lean over or lean back Figure 1: to accommodate an incorrect spindle Determining the proper spindle height adds muscular strain to the height dimension. body which, over time, can create The lathe’s spindle fatigue, muscular pain, stress, and height should be other discomfort. Having to reach roughly equivalent repeatedly out of the neutral comfort to the “R7” zone when doing standard operating dimension, as measured from the tasks should also be avoided. Assuming floor surface to the you intend to spend many long, base of the elbow enjoyable working at your lathe, you when the forearm is should frequently evaluate your body positioned up as posture as you work, and make shown. Some prefer the spindle height corrections as necessary to be neutral an inch or two for the majority of the time spent above this turning. If you find yourself measurement. developing pain in the lower back, the hamstring region of your upper legs, or The Importance of Being Neutral in the calf of the lower leg, you should – Although this might sound like a evaluate whether the spindle height is great title for a book written on the too low or you are assuming a body history of Switzerland, in actuality it is working position which requires an ergonomic concept where the leaning forward repeatedly. Should
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you experience muscular discomfort in these, and what kinds of relaxed the abdomen, or have tense, fatigued reaching possibilities there are for the upper arms, neck, and shoulders, the particular operator to access all of these spindle height may be too high for needed things. The concept of you. It is important that you evaluate determining one’s reach envelope these situations and take appropriate includes the assessment of the physical steps so you can turn from a neutral, dimensions of the operator’s body and relaxed position. If necessary, have an arms to see how far from the main experienced turner watch you as you operating position the limits of easy do routine turning operations and see reach (without undue stretching, if they can identify problems with your jumping, leaning, or using aids to posture or body position while you reach) can be found. Figure 2 illustrates turn; then take corrective measures. the general concepts of determining an Your turning experience will be much operator’s reach envelope to determine more enjoyable and safer for you and primary, secondary, and tertiary work your body. zones, based on the body’s dimensions. The take- home message is that the Your Relationship to the most frequently used tools (for Operating Space – Understanding example, your “go-to” gouge, your how the body relates to its work main skew or parting tool, your environment is one of the main favorite scraper, etc.) should be located concepts behind ergonomic design. within or near a primary reach Since every operator’s body has its own envelope zone, since you use it unique dimensions, a design that frequently, and you should expend the might work well for one individual least amount of energy trying to access may be entirely inefficient (or perhaps it every even dangerous) for another. time you ...turning tool Evaluating your own situation and need it. For placement at the lathe how the size and scale of your body that workstation should be compared to your lathe and the space oddball established by priority around it that you are dedicating to scraper or and frequency of tool your woodturning activities is an specialty use, on a tool-by-tool important part of making your tool that basis. workstation work best for you. A big you use component of this is determining how very rarely, these should be located in your operating position needs to the secondary or tertiary reach interface with actual turning envelope zone, since you won’t lose operations at the lathe, as well as the too much time or energy reaching for placement of all of the “support these because they’re not used very infrastructure” (tool racks, lighting, often. In short, turning tool placement sanding and finishing supplies, dust at the lathe workstation should be collection, compressed air, etc.), which established by priority and frequency are the most frequently used among of tool use, on a tool-by-tool basis.
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Positioning of the rack or table where with the non-dominant hand and then the tools are kept adjacent to the transferring the tool to the dominant operator at the workstation should also hand. In either case this is an inefficient be determined by use priority, within situation and adds extra unnecessary the desired reach envelope, as well as muscular expenditure of energy and considering the right or left movement. Thinking through the handedness of the operator. turning process, knowing what “hand” you are, and positioning your tools within (or close to) the reach envelope on your dominant side will improve the efficiency of your woodturning operation. We turners pick up and put down turning tools very frequently, and it makes sense to maximize the efficiency of this process whenever possible.
Figure 2: Illustration showing the concept of reach envelopes based upon the arm lengths Design of the Lathe Workstation – and arm movement areas of the operator. Borrowing from research in the design of Placement of tools, supplies, and support efficient operator positions in such equipment should be determined by diverse applications as emergency evaluating the primary types of work performed at the workstation, and then communications consoles, aircraft pilot prioritizing the locations for the most positions, nuclear power plants, frequently used tools and other items within industrial machine control positions, primary and secondary work zones, or within and other efficiency-important work easy reach of them when necessary. locations, the design of a lathe workstation can follow the same basic The Concept of Handedness – Most principles of matching the environment humans have definite preferences to the operator, the work needs, and regarding tool use being more frequent efficiencies gained in proper positioning with one hand than the other – i.e. of tools and support equipment and they can identify with being right- materials. A common feature of these handed or left handed. This preference work environments is that the various needs to be incorporated into the equipment and controls are arranged in design and layout of positioning lathe a “U” configuration (inverted) which tool positioning for selection and use makes optimal use of the operator’s by the turner while working at the reach envelope, handedness, and ability lathe. Locating tool racks for to have visual access to the variously frequently used turning tools on the located items that enables maximum non-dominant side of the operator space efficiency use around the operator. would necessitate twisting or moving the body to pick up a tool with the dominant hand, or picking up a tool
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Taking into account the operator’s reach turning tools. Having the grinder close- envelope and handedness while by the operator means that it will more standing at the primary work position likely be used to near the lathe, the arrangement of tool quickly and If the operator racks, grinder and sharpening frequently touch- must repeatedly equipment, supplies, and specialty up dulling tools leave the equipment should be determined by while turning, workstation to priority of tool use, safety, and available with little effort, sharpen dull tools, space surrounding the lathe. Since resulting in more there will be a visually locating, reaching for, and efficient turning tendency to not picking up a particular tool are among operations. If the sharpen as frequently, with the most important repetitive processes operator must negative results... done at the lathe (as well as returning repeatedly leave tools to these same locations) for most the workstation turning methods, these operations to sharpen dull tools, there will be a should take place within a relatively tendency to not sharpen as frequently, close reach envelope distance on the with negative results on woodturning operator’s dominant side. Less quality and efficiency. I would suggest frequently used tools can be located at a that the grinder/sharpening station be somewhat farther distance from the located in a close, relatively high-priority operator on the dominant side, but region on the operator’s non-dominant should be placed where they can be side, or (depending on shop layout) easily located visually. located behind them when facing the lathe, so that little extra expenditure of energy or time is required to sharpen a tool while at the lathe In my opinion, the grinder should never be more than a step or two away from the main operator position at the lathe. Furthermore, it is also recommended that the shaft height of the grinder be at the same height as the lathe for the same reasons outlined above. The body has muscle memory, and accurate manual operations being performed at a particular spindle height at the lathe while turning can also translate into accurate manual Sharpening also plays a major role in operations at the grinder when typical woodturning activities, and sharpening. selection of the location for a grinder or
other sharpening station needs to be also Turning supplies such as abrasive disks, considered for a priority location at the finishes, and the like, need to share the workstation, although perhaps not as workspace for your convenience, as do high as the location for the “go-to”
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other priority items such as chucks, tool and cuts from lathe tools) among the rests, power sanders, calipers, and other highest priorities in your work station related lathe accessories. Every turner design. will need to assess their own priorities as to how the valuable near-lathe real estate Spend some time investigating your own is shared to develop a safe and efficient turning habits and identify what tools work station. In Figure 3, I present a you use most frequently. Ask yourself simple diagram of what I consider an often if the things you have located close efficient lathe workstation, where hand to the lathe dominance, reach envelope, and the deserve to have woodturning-specific, unique add-ons to that space. Do Don’t be afraid to the lathe area such as the placement of they contribute re-prioritize and vacuum chuck equipment, storage of efficiently to your re-position your tools as your coring or hollowing tools, etc. are turning needs change! considered, along with placement of tool operations? I have racks for primary and secondary priority seen one turner’s turning tools, location of compressed air operating position where an array of and specialty lighting equipment, dust faceplates adorned the valuable wall space collection hoods and ducting, and other right in front of the operator. All of them necessary items found at an efficient obviously hadn’t been used in years, woodturning station. given the layers of dust and rust on them. This wall space could likely be much more I suggest that while developing your own efficiently used to store tools and supplies design for how you position all of the that are frequently part of the turning various turning-related components that process. When asked about the faceplates, go into what you want at your he said that he never used them, and workstation, you keep the concepts of actually preferred using scroll chucks reach envelope, handedness, and instead. I then asked him why he had maintaining a these faceplates all stored in that neutral posture ...minimizing particular place, his answer was simply, in mind. Also, expenditure of extra “They went with the lathe.” Whether you minimizing energy is also are a production turner where time is expenditure of important, as is money, or an occasional turner where extra energy keeping operator time may not be much of an issue, safety (particularly safety among the and efficiency still should be considered through highest priorities in very high priorities in the design of your repetitive your work station lathe work station. You want to have the movement) is design. most enjoyable time possible at your also important, lathe, while maintaining your safety and as is keeping operator safety (from health in doing so. Good workstation physical injury due to wood blank design goes a long way in making sure rotation, flying shavings and other large you get the most out of your woodturning particles, airborne dust and other debris, experience.
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A “U” Concept Diagram of a Lathe Work Station
Wall Less frequently used tools mounted on wall Abrasives, power sander, finishes Vacuum Pump, and vacuum chucking equipment Misc. Task & Specialty Lighting Dust Collection Hood, hosing, blast gate Compressed Air Hose/Nozzle
Headstock Lathe Tailstock Dominant side or Table Toolrack Primary Work Position
Adequate Anti-Fatigue Matting dominant side dominant - Grinder
Specialty tools; hollowing, coring Non
Low-Priority.Long Term Storage Waste can for shavings, etc. (Assumes a right-hand dominant operator)
Figure 3: A simple illustration of an efficient lathe workstation which incorporates the “U-Concept” of gathering tools, equipment, and supplies around the primary operating position, taking into account the concepts of reach envelopes and handedness. Although this illustrates the workstation with the lathe parallel with the wall, the same concepts apply wherever the lathe is positioned in the available work area.
In part three, I will discuss several other design factors that might also be considered for efficient and safe operations at your lathe’s workstation. Not only does this involve maintaining minimal reaching and repetitive movement, use of personal protection equipment, and other operator safety practices at the turner’s position, but also the design and placement of tool racks and other storage options.
(Selection from Woodturning Fundamentals, June 2012, American Association of Woodturners)
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Part 3 - Tool Racks & Storage
In part three of the series, I include efficiently. In every case, the design of some food for thought about how the the turning tool rack (or racks) is a woodturner should set up the tool combination of specific requirements racks and other storage at the lathe that include the physical space workstation for safety and for available and ergonomics of the maximum efficiency. There are many operator and the lathe, as well as the ways of accomplishing the goal of requirement to store a certain number having your turning tools readily of lathe tools safely and conveniently. available at the time when they are There are probably as many designs as needed during the woodturning there are turners, but thinking about process, so some creativity here is how to make your own turning tool needed to allow the turner to adapt rack should be part of the overall their workstation to their specific workstation design process. The tool situation, to fit the available space, and rack design can and usually does to consider the various turning evolve over methods being used. I will also include time, given a few brief comments on use of that the personal protection equipment, tool storage although much more could be written requiremen on this topic than I can do in this ts change series. (almost always in Recall that in all cases of setting up an the “need ergonomically-designed efficient more tool workspace, the concepts of reach storage” envelope, prioritization of tool use, direction) and handedness (discussed in part two) as the also come into play with regard to how turner to store one’s turning tools and develops supplies. different skills, tries new techniques, or follows Design of Tool Racks – In each the woodworking adage that “he who turner’s lathe workstation, there is a dies with the most tools wins.” need to bring the lathe, the operator, Developing a good design for your tool and the turning tools together into the rack can pay off in future efficiency same space, and to make sure that this and enjoyment of your turning “merging of the forces” results in a activities, as well as contributing to the place where turning can be done overall safety conditions of your safely, with consideration of how the woodturning work station. Having a turning operation can also be done look at how some of your woodturning
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friends have solved their tool storage together, all scrapers together, all situations, and perusing images of skews together, etc. by “type of tool.” other turners’ shops/studios can Others place all tools necessary to provide a wealth of ideas for designing complete specific tasks together, e.g. your own tool rack that fits your all tools needed to finish bowl unique situation. Whether you have bottoms, all tools needed for shelves, hang tools from nails by holes hollowing, those needed for turning in the handles (or from screw eyes), spindles, etc. The concept of "most build vertical racks of different designs, frequently used tools being placed put together carousel tool holders, or within the highest priority reach develop your own ideas on how to envelope zone" applies here, as does present and store your turning tools at the complementary idea of storing less your lathe workstation, I would like to frequently used tools farther away pass on a few basic design from the turner. Rack design can (and considerations that you might think should) reflect these priorities. about when building (or re-designing) your tool rack(s). 3. Turning tools should be accessible both VISUALLY and by REACH, Some Desirable Characteristics of usually in that order. You should be Tool Racks – Having looked at the able to identify the tool needed by design of many different woodturners' sight first, tool racks over the years, both in before person and via images seen in on-line reaching for woodturning discussion groups and the tool. other resources on the Internet, and Having to having undergone three different re- check the designs of my own racks used for profile of the storing my turning tools, I have found tool after you that there are some common features have picked it that I feel are useful to incorporate in a up is not very good tool rack design for both safety efficient, and efficiency: particularly if it isn’t what 1. In no case should you ever have to you wanted. reach past the sharpened (“business”) I like to be end of one turning tool to reach able to see another tool. This sets up future injury the cutting end of every tool I need “by design.” DON’T DO IT. before I reach for it. Some turners make different handles for every tool and 2. Tools placed in racks should be can determine what tool they need spatially separated by tool type or by either by handle recognition (visually process – whatever works for you, or by feel), or by location. The latter logically. Some turners place all gouges requires diligent replacement of the
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tool back to the same spot every time it have previously used what I call the is used. Remember that an array of “thread the needle” style tool holders turning tools purchased from one where it is necessary to slide one or more manufacturer are likely to all have the parts of the tool through an opening or same handle, so there is a need to see into a hole of some kind in order to what tool you are selecting by looking replace the tool, and don’t find this style at its cutting end – a dozen Sorby of rack very efficient for my use. This is a turning tools all look the same from personal preference. Some turners are the handle end. very happy with this kind of rack design, but it does not work for me. Regardless, 4. Turning racks should be equally as turning tools should be held securely for convenient for returning tools to the safety of both the operator and the during the turning operation as they tool. are when picking them up to use once they are 6. For turning tools stored at or below selected. Easy access for tool waist height, the tool’s cutting ends Easy access selection and return should be adequately protected to avoid for tool to the same spot accidental contact by the operator, selection and increases operator particularly if the operator slips or falls return to the efficiency over the into the rack. I do not like to see vertical same spot long term. tool holders used if there is a chance that increases an accidental slip or fall could mean operator becoming impaled on a turning tool. efficiency over the long term. If you What’s worse is that I have seen a few use a carousel-type tool rack, be turners use a 5-gallon plastic bucket and prepared to “do the spin” to get the stand their turning tools in the bucket, tools back to their home position. If sharp side up, which is then placed on you hang tools vertically, upside down the floor. One bucket-based tool holder by nails or screw-eyes, be prepared to even had PVC pipe sections arranged in slow down each time when returning the bucket to ensure that the tools were the tool to its home location, and spaced away from one another nicely. In expect the occasional crash to the my opinion, this type of tool “rack” is floor, usually with the sharp end simply a recipe for disaster. Be your own hitting first, requiring re-sharpening. judge, but think safety first. Been there, done that. 7. Tool racks should not be designed 5. Tools should be held in place securely such that any parts of the stored tools to prevent falling from the rack. I extend into the operator’s work space personally prefer using tilted racks and and could lead to tripping or other bar magnets to hold my tools both by accidental body contact. The work space gravity and metal attraction, as I find should be free of obstructions that might this design very efficient to see, select, create safety hazards of any kind. grab, use, and replace the tool easily. I
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Placement of Tool Racks at the Near-Lathe Storage – Most Operating Position – It is a fairly woodturners require storage for easy decision to place your tool rack(s) essential, non-tool items and supplies at your dominant hand side of the that are used during the woodturning lathe within your reach envelope. Use process, such as abrasives, finishes, of available cabinet, wall, or other measuring items such as calipers, space to set rulers, etc., and other items. There up your tool should be a landing place for chucks rack must be …the highest priority and centers when removed from the determined in selecting the lathe, and a place to store extra jaw location of the tool on an sets, faceplates, mounting screws, and rack should be individual other high priority items that a turner determined by basis, but you would need while working at the lathe. ensuring operator do want your Making use of high priority "Reach safety and freedom most Envelope Zone Number 1” space from the risk of should be reserved for those lathe tools frequently accidental injury due used tools to to tool rack and support items that are used most be located placement. frequently in the majority of within an woodturning operations. Other arm’s length potential storage areas at lower priority of your dominant side. Many of the positions around the lathe can be used considerations regarding tool rack creatively to store necessary items for design also apply to locating your tool convenient and efficient use. I have rack(s) adjacent to your operating seen numerous examples of cabinetry position. Before determining a final built to use the relatively large amount position for your tool rack, it may be of close space under the lathe bed, as helpful to temporarily position your well as on-wall cabinets and shelves tool rack at different places and then that allow storage of accessories close do some turning – you will soon see to the operator position. Each which position works best for you workstation and each operator is regarding tool selection, use, and unique, and carefully evaluating what return. In any case, the highest priority space is available, plus applying some in selecting the location of the tool creativity in design can result in rack should be determined by ensuring developing storage space at your lathe operator safety and freedom from the workstation that increases risk of accidental injury due to tool productivity and enjoyment of your rack placement. Increasing woodturning. woodturning efficiency is an important, but secondary, priority relative to operator safety.
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favoring the use of face shields instead of goggles. I have seen turners use BOTH forms, either simultaneously, with goggles worn under a face shield, or successively, with the full face shield used while roughing and the turner switching to goggles when the turning operation becomes “safer” during refinement stages of completing the piece. It should be noted that this may be a false sense of safety generated if the “dangerous operations” are completed and you can let down your guard, put on the goggles and grab the Personal Protection Equipment finishing tool and have at it. Regardless (PPE): Vision and “Flying of the stage of turning, the full face Objects” – Among the most shield should be worn throughout the important things all woodturners need turning operation. to hear over and over again is the requirement that eye protection must be used by the operator for each and every turning operation, without exception. That should probably be extended to FACE and HEAD protection as well. The woodturning operation, by its very nature, generates projectiles of different sizes that are often thrown directly at the operator’s face, head and upper body. Having at least minimal protection in place to reduce the chances that these projectiles will reach and damage the What does give me some concern is eyes should be a common sense no- the quality of face shields I see some brainer for ANYONE who intends to turners use. Although there may be a stand at the lathe, spin wood, and put plastic face cover that might protect a cutting tool into the wood to shape against small chips, shavings, and dust it. Unfortunately, simple goggles are generated by the turning process, some often inadequate to extend that of these “bottomless” face shields are protection to larger sized projectiles rather flimsy and would not provide such as chunks of bark, cracked much protection against larger portions of the object, whole blanks, projectiles that might be launched which would suggest that turners from the piece. should opt for full-face protection,
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It is advisable to select a face shield that is not simply a piece of plastic hanging from a headband, but one which also includes lower face and jaw protection as well.
I am not ashamed to say that I am a member of the “Flying Bowl It is advisable to Club,” and that select a face shield I have that is not simply a previously piece of plastic launched a few hanging from a blanks off of a headband, but one lathe in the past which also includes (even one or lower face and jaw Personal Protection Equipment – two during protection as well. Respiratory Protection – Another demonstrations safety issue involving the use of .), and I have personal protection equipment been lucky so far that no injuries have involves ensuring that the operator is occurred. That does not mean that no adequately protected from fine wood matter how experienced I become as a dust carried in inhaled air. Since turner, that it can’t or won’t happen inhaled fine particulates can represent again in the future. I would hope that a significant health risk, particularly in learning from each unfortunate repeated exposures over extended experience can improve my turning periods of time, it is particularly technique so that I can avoid a similar important that situation as I continue to turn. Having this aspect of ...it is particularly adequate personal protection that I use woodturning regularly increases the chances that I important that this safety be treated aspect of can continue turning without serious very seriously. woodturning safety injury. This DOES NOT mean that I This, of course, be treated very should develop a false sense of security is a huge topic, seriously. that “my face shield will protect me,” deserving of its and more importantly, it SHOULD own article, but I NOT be an excuse to use unsafe do want to include Respiratory PPE as turning methods, put yourself in the an essential component of a well- line of fire, use unstable wood, etc., designed woodturning workstation. simply because you are protected with This PPE does not include the related, good PPE. Operator safety practices but separate, installation of an efficient just don’t work that way. dust collection capability at the workstation. Respiratory PPE involves
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specific devices that are used on the filter, and fan components. As one operator to eliminate or reduce the would expect, the costs of these devices possibility of inhaling fine air-suspended go up with greater filtering efficiency particles deep into the lungs. There are and operator convenience. The turner several different kinds of equipment that needs to assess for himself which level of provide various levels of respiratory respiratory PPE should be added to the protection. The simplest of these (and turning workstation in addition to dust least effective) are “nuisance dust” type collection, to provide the best available masks, worn over nose and mouth, and affordable protection from long- which provide minimal (if any) term inhalation of wood (and other) protection from the very small (5 dust. microns or less) wood dust generated during sanding that is the greatest health risk. More efficient are half-face or full face masks that use Wood dust generated various during sanding that cartridges to is the greatest filter out respiratory health particulates risk. that are suspended in the air, but given the number of bearded turners I see at symposia, such contact- mask types are not very effective for the “facially hirsute” among us. Other powered-type PPE devices that provide respiratory protection are those that provide filtered air over the face, nose, and mouth, creating a positive pressure Personal Protection Equipment – within a gasketed, full-face mask that Hearing Protection – In general, excludes contaminated air from the woodturning at the lathe is a fairly quiet possibility of being inhaled. Many of endeavor, especially when compared to these types have helmet-mounted or running other woodshop machinery belt-mounted battery packs and air- such as surface planers, jointers, miter filtering devices that generate the saws, and table saws. There is a growing pressurized, filtered air that can then be group of quite sophisticated breathed safely. There are other versions woodturners who use these other tools of a “PAPR” (Powered Air-Purifying regularly, in addition to their lathe, as Respirator) apparatus that provide part of their woodturning activities – filtered, pressurized air via long tubes segmented woodturners (the “seggies”). connected to the mask apparatus, They routinely use these flatwork tools instead of having on-operator battery, and should certainly heed warnings
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about repetitive exposure to high decibel work with off-lathe embellishment sound levels that they might be exposed to techniques using high-speed or other air- while they work. Additionally, those driven tools that turners who accompany their turning generate high sound levels (both in sound damage to your ears’ hearing apparatus. Be pressure and frequency) need to also be sure the hearing PPE you get is rated aware that they should have adequate appropriately for the amount and kind of hearing protection while they use these noise you expect to encounter; most of tools. HEARING LOSS IS CUMULATIVE these devices are rated with a Noise throughout one’s lifetime, and regaining Reduction Rating (NRR). There is quite a lost hearing ability due to excessive, bit of information available on-line repetitive damage to various parts of the regarding selecting appropriate hearing inner ear is not very likely. You have ONE protection devices, and I encourage you to set of ears (I hope.) that you need to protect investigate this if you use such noise- throughout your lifetime. generating devices in your turning activities. There are numerous kinds of hearing protection (Hearing Protection Devices, Conclusion HPD) I hope that this contribution to available of The goal here is to Woodturning FUNdamentals has different reduce the sound provided you with enough basic design. Some pressure level across information to get a good start in assessing prefer an the range of your own individual woodturning station, earmuff style frequencies to an whether you are building one anew, or hearing acceptable level that might want to re-design one that you have protector, will not cause been using for some time. You will find with a spring- permanent and that if you include many of the design tension band cumulative damage principles I have outlined here, your result that can be to your ears’ hearing will be a safe and efficient workstation that worn over the apparatus. will be enjoyable to use. Remember that top of the periodic re-assessment and evaluation of head, behind the layout of your woodturning station the head, or even under the chin. Others should be part of the normal growth and prefer hearing protection that inserts into development of your skills as a the outer ear canal as an ear plug which woodturner. Please feel free to contact me attenuates high noise levels before they if you have specific questions or need reach the ear drum and inner ear anatomy. further clarification on items I have The goal here is to reduce the sound discussed in these three installments. pressure level across the range of frequencies to an acceptable level that will (Selection from Woodturning Fundamentals, September not cause permanent and cumulative 2012, American Association of Woodturner)
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23 LATHE ADJUSTMENTS
Adjust the Height of Your Lathe
http://vimeo.com/100176408 (If you have trouble opening the video when clicking the link, please copy the link and paste it into your browser.)
Every woodturner goes through a learning curve when acquiring the knowledge and skills needed to accomplish various turning methods. It is our hope that watching this video will help you set up your lathe – and a safe and functional workshop environment.
Rob Wallace serves on the Board of Directors of the American Association of Woodturners (AAW) and is head of the AAW Safety Committee.
AAW | woodturner.org
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