Category Archives: Chisels

Maple Trestle Table, Session 19 – Refining the Sculpted Base

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2

On the morning of Sunday, April 15th, Morton and I exchanged ideas about trestle tables, spurred on by a recent sketch of a table on which he was working.  That got me yearning to build a trestle table.

I documented my progress live on Twitter which was useful because each update had a time stamp so followers could see the rate at which I progressed.  Here is a list of the previous Sessions:

Session 1 - Flat Boards are Boring;
Session 2 - Playing with Slabs;
Session 3 - From Two Slabs to One Table Top;
Session 4 - Clamping Odd Shapes and Sketching on Wood;
Session 5 - Routing Pockets for Battens;
Session 6 - Making Battens and Installing Countertop Connectors;
Session 7 - Installing Battens and Flattening the Underside;
Session 8 - Make Your Tools Work for You and Flattening the Top;
Session 9 - Mortises the Slow Way (or Why I’m Buying a Domino XL);
Session 10 - Curvy Legs are Always Good;
Session 11 - Straight Lines on Wonky Surfaces;
Session 12 - Fitting the Mother of all Mortise & Tenon Joints;
Session 13 - Making Things Better, Worse, then Better;
Session 14 - Battens and Complicated Tenons, Again;
Session 15 - The Trestle Comes Together Session;
Session 16 - Angled Mortises and Tenons;
Session 17 - Two Feet for Two Legs; and
Session 18 – Attachment Strips and Power Carving.

(If you are not familiar with the format used on Twitter, every update, or “tweet” below starts with a username, being the author of that tweet.  Sometimes, you see two or more usernames in a tweet.  The second (and third, etc) usernames are preceded by a @ symbol and are people to whom the author is talking.  The other symbol you see is #, which serves as a category.  I try to remember to categorize all my tweets pertaining to this project under #flairww.)

FlairWoodworks There will be much sanding today. #flairww -11:56 AM May 19th, 2012

FlairWoodworks I am happy with how this section of the leg looks. #flairww -12:02 PM May 19th, 2012

FlairWoodworks I think I will cut the tenons flush after all. #flairww -12:05 PM May 19th, 2012

FlairWoodworks I cut the tenon off and I’m using my block plane to trim it flush. #flairww -12:18 PM May 19th, 2012

FlairWoodworks I haven’t sharpened my block plane through this whole project. I can’t believe it’s still sharp. #flairww -12:20 PM May 19th, 2012

FlairWoodworks The block plane affords many different grips. #flairww -12:24 PM May 19th, 2012

FlairWoodworks When sanding, my objective is to remove all other existing tool marks. #flairww -12:27 PM May 19th, 2012

FlairWoodworks When shaping, I work the entire piece as one – I don’t let one section get further ahead than another. #flairww -12:29 PM May 19th, 2012

FlairWoodworks I will often make changes to the shape so I only move onto finer grits of sandpaper once I’ve established a shape I like. #flairww -12:30 PM May 19th, 2012

FlairWoodworks This area was too difficult to carve with the angle grinder. I’ll use gouges, rasps and sandpaper. #flairww -12:36 PM May 19th, 2012

FlairWoodworks It can be difficult to remove marks and glue in corners. I use a card scraper at a low angle. #flairww -12:43 PM May 19th, 2012

LornaBourke @FlairWoodworks Good call on trimming the tenon to be flush with leg, looks very nice. -12:45 PM May 19th, 2012

FlairWoodworks Thank you! #flairww RT @LornaBourke: @FlairWoodworks Good call on trimming the tenon to be flush with leg, looks very nice. -12:46 PM May 19th, 2012

FlairWoodworks Since I’m still in the initial refining stage, I am using coarse sandpaper and will sand in all ways regardless of grain direction. #flairww -12:50 PM May 19th, 2012

FlairWoodworks This section is now shaped. It still needs to be refined. #flairww -1:00 PM May 19th, 2012

FlairWoodworks This surface is far from smooth but I am happy with the shape. I’ll move on to the other leg. #flairww -1:14 PM May 19th, 2012

FlairWoodworks This leg needs a lot of refining! #flairww -1:20 PM May 19th, 2012

FlairWoodworks 40-grit makes quick work of the uneven surface. #flairww -1:23 PM May 19th, 2012

FlairWoodworks I’m still using the first 40-grit Abranet HD sanding disc. It’s not worn out, but I’ll change it for a fresh one. #flairww -1:25 PM May 19th, 2012

FlairWoodworks Preliminary sanding with my sander is done. Now I’ll use hand tools to sculpt the tighter areas. #flairww -1:50 PM May 19th, 2012

FlairWoodworks I use a coarse, round rasp to carve until the point of the V disappears. I’m almost there. #flairww -1:55 PM May 19th, 2012

FlairWoodworks Then I use both sides of a half-round rasp to blend the surfaces. #flairww -1:59 PM May 19th, 2012

FlairWoodworks By the way, I neither own, nor have any desire to own any fine rasps. Mine are all very coarse and cost about $20-30 each. #flairww -2:05 PM May 19th, 2012

sharpendwood @FlairWoodworks Really like the shaping you’ve done. Very pleasing lines…at least to me ;) -2:19 PM May 19th, 2012

FlairWoodworks When I power-carved the legs, I left this area square. I want to sculpt it to be more round. #flairww -2:28 PM May 19th, 2012

FlairWoodworks Oh, here is the crotch area completed. #flairww -2:29 PM May 19th, 2012

FlairWoodworks I used a Kutzall burr in my drill to sculpt this tight area. #flairww -2:42 PM May 19th, 2012

FlairWoodworks The end of this leg is much larger than on the other leg. I’m trying to decide if I should change it. #flairww -2:45 PM May 19th, 2012

FlairWoodworks Any guesses as to what I decided to do? #flairww -2:47 PM May 19th, 2012

FlairWoodworks After cutting the bulk of the waste away, I used a gouge to roughly establish the shape. #flairww -2:58 PM May 19th, 2012

FlairWoodworks I used a flat spokeshave to refine the shape. No templates or measurements were used. #flairww -3:04 PM May 19th, 2012

roncbailey @FlairWoodworks really have enjoyed following this build. It looks outstanding! -3:22 PM May 19th, 2012

FlairWoodworks Both legs are sculpted. Before progressing to finer grits I need to decide if I want to do any more shaping. #flairww  -3:21 PM May 19th, 2012

FlairWoodworks Thank you, Ron! #flairww RT @roncbailey: @FlairWoodworks really have enjoyed following this build. It looks outstanding! -3:22 PM May 19th, 2012

FlairWoodworks I don’t like the square edges on the tops of the feet. #flairww -3:53 PM May 19th, 2012

TheWoodBug @FlairWoodworks Now your talking! -3:54 PM May 19th, 2012

FlairWoodworks Whooo! #flairww RT @TheWoodBug: @FlairWoodworks Now your talking! -3:54 PM May 19th, 2012

tulcarvely: @FlairWoodworks what are you thinking of doing? Maybe angle bevel? or rounded? -3:57 PM May 19th, 2012

FlairWoodworks Probably rounded. #flairww RT @tulcarvely: @FlairWoodworks what are you thinking of doing? Maybe angle bevel? or rounded? -3:57 PM May 19th, 2012

TheWoodBug @FlairWoodworks having fun today I can see and making great progress sir -3:58 PM May 19th, 2012

FlairWoodworks @TheWoodBug It is very fulfilling to see it take shape. #flairww -3:59 PM May 19th, 2012

FlairWoodworks I’m not sure how much I want to round over the ends. I’ll start with the area nearest the legs, then work outwards. #flairww -4:01 PM May 19th, 2012

FlairWoodworks Having the right tools to do this type of work is important but trusting yourself is even more important. #flairww -4:04 PM May 19th, 2012

DyamiPlotke: @FlairWoodworks looks great. -4:13 PM May 19th, 2012

FlairWoodworks Thanks, Dyami! #flairww RT @DyamiPlotke: @FlairWoodworks looks great. -4:14 PM May 19th, 2012

FlairWoodworks Have I inspired anybody to try sculpting part of their next piece of furniture? #flairww -4:15 PM May 19th, 2012

FlairWoodworks This angular corner doesn’t look good to me either. #flairww -4:25 PM May 19th, 2012

FlairWoodworks The near-right side is rounded. I can’t stop here. #flairww -4:25 PM May 19th, 2012

FlairWoodworks Again, I used my round rasp to round the V. #flairww -4:31 PM May 19th, 2012

FlairWoodworks Some people like to undercut their tenon shoulders. It’s not a good idea if you will be sculpting the piece. #flairww -4:31 PM May 19th, 2012

gvmcmillan @FlairWoodworksThat joint sure looks nice tho! -4:33 PM May 19th, 2012

FlairWoodworks Thanks, Grant! #flairww RT @gvmcmillan: @FlairWoodworksThat joint sure looks nice tho! -4:34 PM May 19th, 2012

BCcraftmaster @FlairWoodworks that’s a great point [to not undercut tenon shoulders]. Never really thought about that but will have to keep it in mind if I decide to go “round” #flairww-4:36 PM May 19th, 2012

FlairWoodworks I’m happy with the shape of this area and will do the same on the other end of this foot, then the other foot. #flairww 5:04 PM May 19th, 2012

FlairWoodworks At 5:04, I’m going for a lunch break. #flairww -5:04 PM May 19th, 2012

FlairWoodworks I’m very happy with the progress I’ve made so far today. #flairww -5:05 PM May 19th, 2012

SMeekWoodworks @FlairWoodworks Really can’t wait to see this table when it’s finished. It’s amazing. -5:47 PM May 19th, 2012

FlairWoodworks Wow! That was the most amazing sandwich I’ve had in a long time! Toasted sourdough, guacamole… (back in the shop now). #flairww -8:04 PM May 19th, 2012

FlairWoodworks I’m going to start shaping the left side of this foot. #flairww-8:09 PM May 19th, 2012

FlairWoodworks As always, I started by defining the ankle. #flairww -8:12 PM May 19th, 2012

FlairWoodworks I’ve rounded the leg. Now I’ll work on the foot. #flairww -8:22 PM May 19th, 2012

JC_McGrath @FlairWoodworks add me to the list, this looks great Chris, can’t wait to it done. Inspiring -8:30 PM May 19th, 2012

FlairWoodworks Awesome! Thanks, Jon! #flairww RT @JC_McGrath: @FlairWoodworks add me to the list, this looks great Chris, can’t wait to it done. Inspiring -8:31 PM May 19th, 2012

FlairWoodworks I’ve rounded over the top of the foot as well as the transition into the leg. #flairww -9:10 PM May 19th, 2012

FlairWoodworks I’m happy with the foot for now, but I think the central section is too flat. #flairww -9:12 PM May 19th, 2012

FlairWoodworks One way to quickly (and tidily and quietly) add shape is to carve across the grain with a deep gouge. #flairww -9:18 PM May 19th, 2012

FlairWoodworks My random orbit sander and 40-grit paper quickly evened out the surface. #flairww -9:21 PM May 19th, 2012

FlairWoodworks At the bottom of the last picture, you can see a section that needs to be faired, right at the base of the intersection. #flairww -9:21 PM May 19th, 2012

FlairWoodworks The centre section is a little more rounded now. #flairww -9:44 PM May 19th, 2012

FlairWoodworks Here’s another picture of this end of the base. #flairww -9:50 PM May 19th, 2012

FlairWoodworks I turned the base around. This side does not look nearly as good without the extra sculpting. #flairww -9:55 PM May 19th, 2012

FlairWoodworks I’ve got one side of the foot shaped. #flairww -11:04 PM May 19th, 2012

FlairWoodworks I thought this was a neat picture. The left was sanded with 40-grit, the right side from a spokeshave. #flairww -11:07 PM May 19th, 2012

FlairWoodworks The shaping is done… next comes a lot of sanding to polish the surfaces. #flairww -11:31 PM May 19th, 2012

FlairWoodworks I’m done work in the shop for the day. #flairww -11:31 PM May 19th, 2012

Next time in the shop, there will be a lot of sanding!  Bring your dust mask!  Click here to leave a comment.

Maple Trestle Table, Session 16 – Angled Mortises and Tenons

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4

On the morning of Sunday, April 15th, Morton and I exchanged ideas about trestle tables, spurred on by a recent sketch of a table on which he was working.  That got me yearning to build a trestle table.

I documented my progress live on Twitter which was useful because each update had a time stamp so followers could see the rate at which I progressed.  Here is a list of the previous Sessions:

Session 1 - Flat Boards are Boring;
Session 2 - Playing with Slabs;
Session 3 - From Two Slabs to One Table Top;
Session 4 - Clamping Odd Shapes and Sketching on Wood;
Session 5 - Routing Pockets for Battens;
Session 6 - Making Battens and Installing Countertop Connectors;
Session 7 - Installing Battens and Flattening the Underside;
Session 8 - Make Your Tools Work for You and Flattening the Top;
Session 9 - Mortises the Slow Way (or Why I’m Buying a Domino XL);
Session 10 - Curvy Legs are Always Good;
Session 11 - Straight Lines on Wonky Surfaces;
Session 12 - Fitting the Mother of all Mortise & Tenon Joints;
Session 13 - Making Things Better, Worse, then Better;
Session 14 – Battens and Complicated Tenons, Again; and
Session 15 – The Trestle Comes Together

(If you are not familiar with the format used on Twitter, every update, or “tweet” below starts with a username, being the author of that tweet.  Sometimes, you see two or more usernames in a tweet.  The second (and third, etc) usernames are preceded by a @ symbol and are people to whom the author is talking.  The other symbol you see is #, which serves as a category.  I try to remember to categorize all my tweets pertaining to this project under #flairww.)

FlairWoodworks I’m back in the shop working on a game plan. #flairww -11:21 AM May 15th, 2012

FlairWoodworks I’m going to start by shaping the tenons. #flairww -11:28 AM May 15th, 2012

FlairWoodworks I used a melamine jig to guarantee a straight shoulder.#flairww -11:33 AM May 15th, 2012

FlairWoodworks If I had a tenon saw, I would consider cutting this joint by hand. #flairww -11:34 AM May 15th, 2012

FlairWoodworks Awesome! I just found a dust collection shroud for my Milwaukee routers! #flairww -11:40 AM May 15th, 2012

FlairWoodworks Using a router is awkward. It seems faster and easier to cut the tenon by hand, even without a saw. #flairww -11:56 AM May 15th, 2012

FlairWoodworks One thing I really like about hand tools is how easy it is to be accurate. Hand tools register off knife lines. Power tools don’t. #flairww -11:59 AM May 15th, 2012

TheGravedigger: @FlairWoodworks If you’ve only got one or two to do, it’s definitely faster. -11:59 PM May 15th, 2012

FlairWoodworks Agreed. #flairww RT @TheGravedigger: @FlairWoodworks If you’ve only got one or two to do, it’s definitely faster. -12:00 PM May 15th, 2012

FlairWoodworks The tenons would have been easier to cut before attaching the stretcher… #flairww -12:00 PM May 15th, 2012

FlairWoodworks … but I couldn’t accurately lay out the tenons until after gluing up the stretcher. #Catch22 #flairww -12:01 PM May 15th, 2012

FlairWoodworks I chopped out the bulk of the waste from both edges, working down to the baselines but crowning the centre. #flairww -12:12 PM May 15th, 2012

FlairWoodworks Now I need to flatten the hump. #flairww -12:13 PM May 15th, 2012

FlairWoodworks I’m cutting the tenon close to length. #flairww -12:18 PM May 15th, 2012

FlairWoodworks Cutting the tenon to length allowed me to scribe a line on the end grain. #flairww -12:21 PM May 15th, 2012

FlairWoodworks My medium shoulder plane looks tiny on this big tenon. Even a large shoulder plane would look small. #flairww -12:24 PM May 15th, 2012

FlairWoodworks I can use the shoulder plane to clean up the area next to the shoulder, then any other plane to flatten the rest of the tenon. #flairww -12:26 PM May 15th, 2012

FlairWoodworks I need to clean up the shoulder next. #flairww -12:33 PM May 15th, 2012

FlairWoodworks To start the second cheek, I’m using a Dozuki to cut the shoulder. #flairww -12:42 PM May 15th, 2012

FlairWoodworks Appropriately enough, as I use the handsaw, Rage Against the Machine’s “Take the Power Back” is playing on the @993thefox. #flairww -12:43 PM May 15th, 2012

FlairWoodworks I’m chopping across the grain to avoid causing splits. #flairww -12:49 PM May 15th, 2012

FlairWoodworks Time to flip the leg over and chop from the other side. #flairww -12:58 PM May 15th, 2012

FlairWoodworks There wasn’t much material to remove on this side so it went quickly. I’ll flip it over and finish the cheek. #flairww. -1:04 PM May 15th, 2012

FlairWoodworks I had to take a break to take care of some phone calls and emails. Just two more steps to finish the tenon. #flairww -1:31 PM May 15th, 2012

FlairWoodworks Because the grain would cause the wood to split if I worked from the end, I cut kerfs to control splitting. #flairww -1:38 PM May 15th, 2012

FlairWoodworks You can see that the short segments still wanted to split into the tenon. The kerfs stopped that from happening. #flairww -1:40 PM May 15th, 2012

FlairWoodworks There is just one more shoulder to cut! #flairww -1:45 PM May 15th, 2012

FlairWoodworks Here, the grain runs slightly uphill towards the shoulder so I don’t need the extra saw kerfs (just one at the shoulder). #flairww -1:47 PM May 15th, 2012

FlairWoodworks One tenon is done! #flairww -1:51 PM May 15th, 2012

asliceofwood @FlairWoodworks nice work. Looks really smooth. -1:54 PM May 15th, 2012

FlairWoodworks I’m going to turn on the camera and cut the other tenon. #flairww -1:58 PM May 15th, 2012

asliceofwood: @FlairWoodworks livestream or footage for later? -1:59 PM May 15th, 2012

HalfInchShy Be sure to use a stunt double for safety! RT @FlairWoodworks: I’m going to turn on the camera and cut the other tenon. #flairww -2:00 PM May 15th, 2012

FlairWoodworks If you think your shop is small, try putting a camera in it! #flairww -2:01 PM May 15th, 2012

HalfInchShy switch to a telephoto lens the other is too wide #badjokes MT @FlairWoodworks: If you think your shop is small, put a camera in it! #flairww- 2:06 PM May 15th, 2012

FlairWoodworks Well that was a miserable filming session. I had to work in too many awkward positions to allow a decent view. (The resulting video was not worth editing and publishing.) #flairww -4:12 PM May 15th, 2012

FlairWoodworks As result, it took twice as long as it should have (there was also a phone call in there). I’m going for lunch. #flairww -4:13 PM May 15th, 2012

FlairWoodworks I’m back from lunch. My next task is to cut mortises in the feet. #flairww -5:20 PM May 15th, 2012

FlairWoodworks I drilled out the centre. I’ll chisel the rest. #flairww -5:29 PM May 15th, 2012

FlairWoodworks Cutting an angled, 7/8″ x 4″ mortise is slow but I’m getting there. #flairww -5:59 PM May 15th, 2012

FlairWoodworks And the fitting process begins… #flairww -6:13 PM May 15th, 2012

FlairWoodworks I just discovered that the back of one of my most-used chisels is convex. Not cool. #flairww -6:17 PM May 15th, 2012

FlairWoodworks It’ll be footage for later, provided it’s usable. #flairww RT @asliceofwood: @FlairWoodworks livestream or footage for later? -6:24 PM May 15th, 2012

Aolas @FlairWoodworks Loving your stage by stage photos. -6:24 PM May 15th, 2012

FlairWoodworks Thanks for the feedback! #flairww RT @Aolas: @FlairWoodworks Loving your stage by stage photos. -6:24 PM May 15th, 2012

BCcraftmaster @FlairWoodworks is [the bent chisel] really that big of an issue? You’ve built some pretty nice pieces using it! Did you not lap the back when you got it? -6:25 PM May 15th, 2012

FlairWoodworks @BCcraftmaster The convex back made it very difficult to get plumb mortise sidewalls and meant a LOT of extra clean-up. #flairww -6:28 PM May 15th, 2012

FlairWoodworks @BCcraftmaster I did lap the back of the chisel when I got it. I either did a poor job or it has bent/warped since then. Thoughts? #flairww -6:28 PM May 15th, 2012

BCcraftmaster @FlairWoodworks check your stones! They may need to be flattened. -6:29 PM May 15th, 2012

FlairWoodworks I use a diamond stone… #flairww RT @BCcraftmaster: @FlairWoodworks check your stones! They may need to be flattened. -6:30 PM May 15th, 2012

BCcraftmaster @FlairWoodworks sooooo… is it flat? -6:31 PM May 15th, 2012

FlairWoodworks Yes. #flairww RT @BCcraftmaster: @FlairWoodworks sooooo… is it flat? -6:31 PM May 15th, 2012

FlairWoodworks @BCcraftmaster I checked my diamond stone two weeks ago. It is flat. Good question! Never assume! I like it! #flairww -6:32 PM May 15th, 2012

BCcraftmaster @FlairWoodworks maybe you just invented the first “scrub chisel” -6:35 PM May 15th, 2012

FlairWoodworks If only…. It’s a shallow bent-chisel. #flairww RT @BCcraftmaster: @FlairWoodworks maybe you just invented the first “scrub chisel” -6:37 PM May 15th, 2012

BCcraftmaster @FlairWoodworks then, huh! Im clueless. Can steel warp without extreme temps? -6:37 PM May 15th, 2012

FlairWoodworks Perhaps unseasoned steel? #flairww RT @BCcraftmaster: @FlairWoodworks then, huh! Im clueless. Can steel warp without extreme temps? -6:37 PM May 15th, 2012

FlairWoodworks @BCcraftmaster I know that unseasoned cast iron or improperly stress-relieved steel can warp. #flairww -6:38 PM May 15th, 2012

BCcraftmaster @FlairWoodworks save that chisel and reshape it with your grinder into a tiny little dovetail chisel -6:45 PM May 15th, 2012

FlairWoodworks I’ve finally got one foot fitted. #flairww -6:45 PM May 15th, 2012

FlairWoodworks @BCcraftmaster Well, I do need a long marking knife. Maybe I’ll grind a spear-point on the end. #flairww -6:46 PM May 15th, 2012

FlairWoodworks So now I need to cut the mortise in the second foot. #flairww-6:48 PM May 15th, 2012

BCcraftmaster @FlairWoodworks or just re-lap it… -6:49 PM May 15th, 2012

FlairWoodworks @BCcraftmaster Uh… no.  See – it’s really warped. #flairww -6:51 PM May 15th, 2012

BCcraftmaster @FlairWoodworks ohhhh convex, the length of the blade, I thought you meant convex across the blade. I would guess it’s from chopping with it. -6:54 PM May 15th, 2012

FlairWoodworks @BCcraftmaster It would be sad if these chisels were so soft that they bent in use. #flairww -6:55 PM May 15th, 2012

SMeekWoodworks @flairwoodworks How the heck did that happen? You using your chisels to open paint cans again? -6:56 PM May 15th, 2012

FlairWoodworks @SMeekWoodworks My paint can lids aren’t on that tightly ;) -6:56 PM May 15th, 2012

BCcraftmaster“@FlairWoodworks: Cutting an angled, 7/8″ x 4″ mortise is slow  but I’m getting there.” That may have something to do with it… -6:56 PM May 15th, 2012

FlairWoodworks Rather than drill one row of 1/2″ holes, I drilled two rows of 3/8″ holes this time. #flairww -7:12 PM May 15th, 2012

FlairWoodworks I don’t have a bit larger than 1/2″ that is also long enough to pass through the foot. #flairww -7:12 PM May 15th, 2012

FlairWoodworks Oh, how I wish I already had my @FestoolUSA Domino XL. #flairww -7:13 PM May 15th, 2012

BillGriggs @FlairWoodworks I was gonna ask why but you already explained it. -7:17 PM May 15th, 2012

SMeekWoodworks @flairwoodworks You are going to love it! It’s perfect for the furniture you make. -7:18 PM May 15, 2012

FlairWoodworks @SMeekWoodworks Have you used one? #flairww -7:19 PM May 15, 2012

SMeekWoodworks @flairwoodworks We have one at GPD. Used it to make 33 interior doors. Pretty sweet. -7:20 PM May 15, 2012

FlairWoodworks @SMeekWoodworks How long did it take to cut all the joints? I can’t wait to get my Domino XL. But I must. #flairww -7:22 PM May 15th, 2012

SMeekWoodworks @flairwoodworks I think there was at least a day spent cutting all the mortises. Somewhere around 2000 of them. -7:24 PM May 15th, 2012

FlairWoodworks And the fitting of the second foot begins! #flairww -7:53 PM May 15th, 2012

FlairWoodworks Getting closer. #flairww -8:07 PM May 15th, 2012

BCcraftmaster @FlairWoodworks are you going to draw bore? -8:08 PM May 15th, 2012

FlairWoodworks I want to wedge the tenons. #flairww RT @BCcraftmaster: @FlairWoodworks are you going to draw bore? -8:09 PM May 15th, 2012

FlairWoodworks Ha! I got it! #flairww -8:20 PM May 15th, 2012

thewoodbug @FlairWoodworks @BCcraftmaster wedge on Sir. Wedge on -8:22 PM May 15th, 2012

FlairWoodworks Here’s the base put together, inverted on the table top. #flairww -8:23 PM May 15th, 2012

Tumblewood: @FlairWoodworks DAMN!! That looks good!! Great job on this, Chris!! -8:26 PM May 15th, 2012

FlairWoodworks Thanks, Vic! It’s nice to see it taking shape! #flairww RT @Tumblewood: @FlairWoodworks DAMN!! That looks good!! Great job on this, Chris!! -8:26 PM May 15th, 2012

BCcraftmaster“@FlairWoodworks: I want to wedge the tenons. #flairww RT @BCcraftmaster: @FlairWoodworks are you going to draw bore?” Contrasting wood? -8:27 PM May 15th, 2012

FlairWoodworks @BCcraftmaster The wedges will be under the feet, only visible when the table is flipped upside down, so it doesn’t reallly matter. #flairww -8:28 PM May 15th, 2012

FlairWoodworks I use carpenter’s pencils a lot in the shop, mostly for shading material to be removed. #flairww -8:35 PM May 15th, 2012

FlairWoodworks I need to cut reliefs into the undersides of the feet to make the table more stable. #flairww -8:42 PM May 15th, 2012

TheWoodBug @FlairWoodworks I will wait for the big stuff, looking incredible Chris, can I help with the finishing?? -8:51 PM May 15, 2012

FlairWoodworks @TheWoodBug Sure, Dan; I’d love your help. #flairww -8:52 PM May 15th, 2012

FlairWoodworks I used a framing square to mark the feet 2-1/2″ in from the edge of the table. #flairww -8:53 PM May 15th, 2012

TheWoodBug @FlairWoodworks Nice then I get to see the finish project in person, Violet dye might be nice then you can market it as Purple heart -8:58 PM May 15th, 2012

FlairWoodworks A dye might look nice on the table top! #flairww RT@TheWoodBug: Violet dye might be nice then you can market it as Purple heart -9:02 PM May 15th, 2012

FlairWoodworks I cut the ends of the feet at 5 degrees. #flairww -9:03 PM May 15th, 2012

FlairWoodworks Five degrees didn’t look like enough so I recut the ends at 10 degrees. #flairww -9:08 PM May 15th, 2012

Tooltutor @FlairWoodworks Looking pretty sweet. You must be so ripped now. -9:11 PM May 15th, 2012

FlairWoodworks I just want to get the feet glued and go for dinner! #flairww RT@Tooltutor: @FlairWoodworks Looking pretty sweet. You must be so ripped now. -9:11 PM May 15th, 2012

FlairWoodworks My bent chisel works fine for splitting out wedges… #flairww -9:21 PM May 15th, 2012

FlairWoodworks One wedge done… I don’t think I’ll be able to glue up the feet without disturbing the family. #flairww -9:22 PM May 15th, 2012

FlairWoodworks I’ve got the four wedges cut. I’ll cut slots for them and stop there for the night. #flairww -9:40 PM May 15th, 2012

FlairWoodworks Last picture of the day! #flairww -9:53 PM May 15th, 2012

FlairWoodworks I’ll do the glue-up next time. #flairww -9:54 PM May 15th, 2012

FlairWoodworks I just remembered that I have a hollow chisel mortiser with a tilting head that would have worked well for mortising the feet. #flairww -10:23 PM May 15th, 2012

FestoolUSA @FlairWoodworks Yeah, the wait is never the fun part, Chris. Just two more weeks until it’s available. 5:05 AM May 16, 2012

DozersWorkshop @FlairWoodworks fantastic! Coming together fast, now! 7:22 AM May 16, 2012

Do you like how the table is taking shape?  Have you ever seen chisels take curvature over time?  Let me know in the comments section.

Next time, I’ll glue the feet onto the legs!

Maple Trestle Table, Session 12 – Fitting the Mother of all Mortise & Tenon Joints

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2

On the morning of Sunday, April 15th, Morton and I exchanged ideas about trestle tables, spurred on by a recent sketch of a table on which he was working.  That got me yearning to build a trestle table.

I documented my progress live on Twitter which was useful because each update had a time stamp so followers could see the rate at which I progressed.  Here is a list of the previous Sessions:

Session 1 - Flat Boards are Boring;
Session 2 - Playing with Slabs;
Session 3 - From Two Slabs to One Table Top;
Session 4 - Clamping Odd Shapes and Sketching on Wood;
Session 5 - Routing Pockets for Battens;
Session 6 - Making Battens and Installing Countertop Connectors;
Session 7 - Installing Battens and Flattening the Underside;
Session 8 - Make Your Tools Work for You and Flattening the Top;
Session 9 - Mortises the Slow Way (or Why I’m Buying a Domino XL);
Session 10 - Curvy Legs are Always Good; and
Session 11 - Straight Lines on Wonky Surfaces.

(If you are not familiar with the format used on Twitter, every update, or “tweet” below starts with a username, being the author of that tweet.  Sometimes, you see two or more usernames in a tweet.  The second (and third, etc) usernames are preceded by a @ symbol and are people to whom the author is talking.  The other symbol you see is #, which serves as a category.  I try to remember to categorize all my tweets pertaining to this project under #flairww.)

FlairWoodworks I went for a rollerblade around Lafarge Lake and a great bicycle ride through Ridge Park. And it’s only 12:30. Time to start work! #flairww -12:38 PM May 6th, 2012

FlairWoodworks This is how I left the shop after the last session. #flairww -12:51 PM May 6th, 2012

luggermatt @FlairWoodworks *Passes you a broom* ;-) -12:52 PM May 6th, 2012

FlairWoodworks I need more than a broom! #flairww RT @luggermatt: @FlairWoodworks *Passes you a broom* ;-) -12:52 PM May 6th, 2012

luggermatt @FlairWoodworks Haha! :-) -12:52 PM May 6th, 2012

FlairWoodworks An excavator might the the right tool for the job. #flairwwRT @luggermatt: @FlairWoodworks Haha! :-) -12:53 PM May 6th, 2012

luggermatt @FlairWoodworks I can create more waste than that in a morning when I get going at the mo!

FlairWoodworks A couple days ago my wood guy, Dave, stopped by to see the table. He was thoroughly impressed. #flairww -12:57 PM May 6th, 2012

FlairWoodworks Nickelback’s “Burn it to the Ground” is playing on @993thefox. Is that a bad omen? Nah, I don’t believe that. #flairww -12:58 PM May 6th, 2012

FlairWoodworks I want to cut the mortise in this leg and then fit the tenon to it. #flairww -1:00 PM May 6th, 2012

mtvtdmsfts RT @FlairWoodworks: I want to cut the mortise in this leg and then fit the tenon to it. #flairww -1:01 PM May 6th, 2012

FlairWoodworks Great. Now it’s Foo Fighters’ “Bridge Burning” on @993thefox as I work on my Trestle Table. #flairww -1:03 PM May 6th, 2012

FlairWoodworks I laid out the shoulder cuts for the tenon with a square. #flairww  -1:04 PM May 6th, 2012

FlairWoodworks @mtvtdmsfts Thanks for the RT. I hope you’re enjoying the build! #flairww -1:04 PM May 6th, 2012

luggermatt: @FlairWoodworks I’d turn the tunes off! -1:04 PM May 6th, 2012

FlairWoodworks Noooo! #flairww RT @luggermatt: @FlairWoodworks I’d turn the tunes off! -1:04 PM May 6th, 2012

FlairWoodworks @993thefox Can I hear Matt Mays & El Torpedo’s Building a Boat? #flairww -1:05 PM May 6th, 2012

HalfInchShy I agree, music is the hamster on my brain’s treadmill! RT @FlairWoodworks: Noooo! #flairww RT @luggermatt: I’d turn the tunes off! -1:06 PM May 6th, 2012

luggermatt @HalfInchShy @FlairWoodworks Maybe just change the titles ;-) -1:06 PM May 6th, 2012

FlairWoodworks This stretcher is a real challenge to clamp. I should reinstall my Tucker vise. #flairww -1:09 PM May 6th, 2012

FlairWoodworks I could use a bigger joinery saw. #flairww -1:12 PM May 6th, 2012

HalfInchShy You could put a pull-saw in the kerf to finish it RT@FlairWoodworks: I could use a bigger joinery saw. #flairww -1:13 PM May 6th, 2012

LornaBourke @FlairWoodworks Or a backless japanese saw -1:14 PM May 6th, 2012

FlairWoodworks @HalfInchShy My only spineless fine-toothed saw is a flush-cut. #flairww -1:14 PM May 6th, 2012

FlairWoodworks I used my flushcut saw to finish the cut, then a chisel and float to fine-tune it. #flairww -1:19 PM May 6th, 2012

FlairWoodworks Because of the grain angle, I couldn’t pare towards the shoulder so I used a pull float. #flairww -1:20 PM May 6th, 2012

FlairWoodworks Both end shoulders are cut. I’ll have to modify the middle “shoulders” too. #flairww -1:27 PM May 6th, 2012

FlairWoodworks I think I should maintain the angles. But I’ll need to clean up the raw surfaces. #flairww -1:28 PM May 6th, 2012

FlairWoodworks My work is, like the beer commercial says, “miles away from ordinary”. #flairww -1:28 PM May 6th, 2012

ChrisHasFlair RT @FlairWoodworks: My work is, like the beer commercial says, ”miles away from ordinary”. #flairww -1:28 PM May 6th, 2012

FlairWoodworks This is a very awkward cut. I wish I had a coping saw or fret saw with a longer blade. #flairww -1:33 PM May 6th, 2012

FlairWoodworks My stroke is limited to 1/8″. A keyhole saw would probably be a better tool here. It’s a tool I’ve NEVER used. #flairww -1:34 PM May 6th, 2012

FlairWoodworks I didn’t find my keyhole saw but I did find an edge float @GarthTW2 made. Thanks Garth! #flairww -1:39 PM May 6th, 2012

FlairWoodworks @GarthTW2 is, of course, my partner in Time Warp Tool Works #flairww -1:40 PM May 6th, 2012

FlairWoodworks One inside shoulder is done. #flairww -1:43 PM May 6th, 2012

FlairWoodworks To cut the second inside shoulder, I clamped the stretcher in my Moxon vise. #flairww -1:46 PM May 6th, 2012

DyamiPlotke @FlairWoodworks why’d you uninstall it? -1:47 PM May 6th, 2012

FlairWoodworks I use cedar shims a lot in my shop. They are convenient and soft enough to not damage my workpiece. #flairww -1:48 PM May 6th, 2012

FlairWoodworks @DyamiPlotke I was supposed to be building a new bench a month ago… still haven’t gotten around to it. #flairww -1:48 PM May 6th, 2012

FlairWoodworks The Moxon vise is very versatile and useful… but not quite as good as a patternmaker’s vise. It’s a close second. #flairww -1:50 PM May 6th, 2012

FlairWoodworks The rough shaping of the tenon is done. Next – lay out the mortise. #flairww -1:53 PM May 6th, 2012

FlairWoodworks These acute angles could be interesting. #flairww -2:06 PM May 6th, 2012

HalfInchShy See, now you’re doing crazy angles :) it’s contagious! RT @FlairWoodworks: These acute angles could be interesting. #flairww -2:07 PM May 6th, 2012

FlairWoodworks I’m going to drill out the bulk of the waste with my largest brad-point bit. #flairww -2:08 PM May 6th, 2012

FlairWoodworks Ack! RT @HalfInchShy: See, now you’re doing crazy angles :) it’s contagious! #flairww -2:08 PM May 6th, 2012

FlairWoodworks I just applied some DriCote to the bit to see if it will eliminate that annoying squealing. #flairww -2:10 PM May 6th, 2012

HalfInchShy Wish that worked on people too MT @FlairWoodworks Applied some DriCote 2 the bit 2 see if it will eliminate that annoying squealing.#flairww -2:12 PM May 6th, 2012

FlairWoodworks Er… I meant the squealing from the bit, not from people like @HalfInchShy :) #flairww -2:13 PM May 6th, 2012

FlairWoodworks And yes, it works. Somewhat. #flairww -2:13 PM May 6th, 2012

FlairWoodworks Could this mortise be cut with the Domino XL? Clamp a fence to the face of the leg and slide it along and plunge? #flairww -2:20 PM May 6th, 2012

HalfInchShy @FlairWoodworks Definitely; I’m sure you’ve made oversized mortises with your 500 that same way; plunge depth of 700 makes it easier. #flairww -2:22 PM May 6th, 2012

FlairWoodworks Let the chopping begin! I’ll do half from this side, then flip over the leg. #flairww -2:24 PM May 6th, 2012

FlairWoodworks By the way, I would recommend DriCote to minimize drill bit squeal. Duct tape seems to work for people :) #flairww -2:25 PM May 6th, 2012

LaMacchiaDesign: @FlairWoodworks which patternmaker’s vice do you have? It’s on my list. I’m entering into the research phase. -2:27 PM May 6th, 2012

FlairWoodworks Tucker! #flairww RT @LaMacchiaDesign: @FlairWoodworkswhich patternmaker’s vice do you have? -2:27 PM May 6th, 2012

FlairWoodworks @LaMacchiaDesign It’s a big investment, but worth every penny to me. #flairww -2:28 PM May 6th, 2012

FlairWoodworks I scored the outline of the mortise using my heavy steel straight edge and marking knife made by Derek Cohen. #flairww -2:36 PM May 6th, 2012

HalfInchShy I think that’s called a diet patch as well :) MT @FlairWoodworks: Duct tape seems to work for people :) #flairww -2:36 PM May 6th, 2012

TheWoodBug Diet patch now that is funny, sorry for butting in @ Hafinchshy #flairww -2:38 PM May 6th, 2012

HalfInchShy haha, not butting in at all; had a ‘diet patch’ flyer on my cube wall and put a ‘free sample’ of duct tape @TheWoodBug: Diet patch #flairww -2:40 PM May 6th, 2012

HalfInchShy Awesome, your tweet flushed out a bot that subscribed to me :) RT @TheWoodBug: Diet patch now that is funny, sorry for butting in #flairww-2:42 PM May 6th, 2012

TheWoodBug one thing I never have in my shop -Duct tape , maybe I should get some, good for everything but “duct work” lol @HalfinchShy #flairww -2:44 PM May 6th, 2012

TheWoodBug Hey Chris your Table is coming along pretty nicely, For me out of shop off to bike mountain w Hounds Cheers guys @FlairWoodworks #flairww-2:46 PM May 6th, 2012

HalfInchShy The blue and green are good for chroma-key masks, too MT @TheWoodBug: Duct tape: good for everything but “duct work” lol #flairww -2:47 PM May 6th, 2012

FlairWoodworks Half-way there! These acute corners are a trick. They are too acute for my dovetail chisel. #flairww -2:55 PM May 6th, 2012

FlairWoodworks Thanks, Dan! RT @TheWoodBug: Hey Chris your Table is coming along pretty nicely. Cheers guys @FlairWoodworks #flairww -2:56 PM May 6th, 2012

FlairWoodworks I’ve transferred the layout lines to the other side. #flairww -3:07 PM May 6th, 2012

FlairWoodworks The mortises are almost done in this leg. I just need to do a little clean-up where the two cuts meet. #flairww -3:27 PM May 6th, 2012

FlairWoodworks I used my fret saw to clean out the acute corner. #flairww -3:36 PM May 6th, 2012

FlairWoodworks Those cuts were barely within the capacity of my 5″ fret saw, but I was able to complete them without using a larger saw. #flairww -3:41 PM May 6th, 2012

FlairWoodworks Now to make the tenons fit into the mortises! #flairww -3:48 PM May 6th, 2012

FlairWoodworks Again, I’m using a float to adjust the tenons. I use the back of the float to check that the surfaces are flat. #flairww -3:55 PM May 6th, 2012

FlairWoodworks This is one heck of a joint. So far, so good! #flairww -4:01 PM May 6th, 2012

FlairWoodworks I drove the leg on until it stopped dead, then marked its position on the tenon. #flairww -4:05 PM May 6th, 2012

FlairWoodworks Then I figure out what is causing the binding and work to remove the hump. #flairww -4:06 PM May 6th, 2012

FlairWoodworks Then I test the fit again and repeat. #flairww -4:08 PM May 6th, 2012

FlairWoodworks Good news: I’m making progress. Bad news: I cut the tenon over-length so I have a fair ways to go still. #flairww -4:35 PM May 6th, 2012

FlairWoodworks Where the mortise is tight on the tenon, it burnished the surface. It’s these areas I need to remove. #flairww -4:44 PM May 6th, 2012

FlairWoodworks Well, I’m not there yet, but I’m going to take a break for some food. #flairww -4:56 PM May 6th, 2012

Tumblewood @FlairWoodworks Nice honkin’ mortise! #flairww -7:15 PM May 6th, 2012

HalfInchShy @FlairWoodworks Wow, dude, you’re gone for a LOT of food…#flairww -9:00 PM May 6th, 2012

FlairWoodworks Ha ha… back now. RT @HalfInchShy: @FlairWoodworks Wow, dude, you’re gone for a LOT of food… #flairww -9:01 PM May 6th, 2012

FlairWoodworks When working on something like this where patience is key, it can help to take breaks. #flairww -9:12 PM May 6th, 2012

FlairWoodworks The last thing I want to do is rush this joint and either split the mortised piece or end up with a loose joint. #flairww -9:12 PM May 6th, 2012

FlairWoodworks I’m getting close! #flairww -9:23 PM May 6th, 2012

Tumblewood @FlairWoodworks Go Chris, go! -9:27 PM May 6th, 2012

FlairWoodworks :D #flairww -9:29 PM May 6th, 2012

Tumblewood Indeed!! Big :oD !! RT @FlairWoodworks: :D #flairww -9:30 PM May 6th, 2012

FlairWoodworks The show side is quite respectable too. #flairww -9:30 PM May 6th, 2012

FlairWoodworks Thank you! #flairww RT @malphrusoxide: @FlairWoodworks well done! -9:31 PM May 6th, 2012

FlairWoodworks To save lifting the stretcher and leg out the top if the vise, I simply removed the vise chop. #flairww -9:35 PM May 6th, 2012

FlairWoodworks You betcha! RT @Tumblewood: Indeed!! Big :oD !! RT@FlairWoodworks: :D #flairww -9:37 PM May 6th, 2012

FlairWoodworks Now, how to lay out the mortise in the other leg… #flairww -9:37 PM May 6th, 2012

FlairWoodworks I’m getting ahead of myself. I first need to finish the installation of the battens. #flairww -9:45 PM May 6th, 2012

FlairWoodworks I first surfaced the face of the batten so it was parallel with the tabletop. #flairww -10:02 PM May 6th, 2012

FlairWoodworks I want to use my router to create a parallel surface for the batten to rest. #flairww -10:09 PM May 6th, 2012

FlairWoodworks I’ll start with that tomorrow. I’m calling it a day. I’m happy with how I got the mortise and tenon to fit. #flairww -10:10 PM May 6th, 2012

I’ll fire up the router and finish installing the battens in Session 13.  What did you think of that mortise and tenon joint?  Let me know in the comments section!

Maple Trestle Table, Session 3 – From Two Slabs to One Table Top

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5

On the morning of Sunday, April 15th, Morton and I exchanged ideas about trestle tables, spurred on by a recent sketch of a table on which he was working.  That got me yearning to build a trestle table.

I documented my progress live on Twitter which was useful because each update had a time stamp so followers could see the rate at which I progressed.  Here is a list of the previous Sessions:

Session 1 - Flat Boards are Boring; and
Session 2 - Playing with Slabs.

(If you are not familiar with the format used on Twitter, every update, or “tweet” below starts with a username, being the author of that tweet.  Sometimes, you see two or more usernames in a tweet.  The second (and third, etc) usernames are preceded by a @ symbol and are people to whom the author is talking.  The other symbol you see is #, which serves as a category.  I try to remember to categorize all my tweets pertaining to this project under #flairww.)

FlairWoodworks I’m back in the shop! #flairww -10:39 AM Apr 19th, 2012

FlairWoodworks I swept the shavings from my surfacing session into a pile.#flairww -11:09 AM Apr 19th, 2012

FlairWoodworks I started laying out possible feet for the trestle table, but I need to first determine the width of the top. #flairww -11:24 AM Apr 19th, 2012

FlairWoodworks It’s no fun lifting the slabs onto sawhorses by myself so I cleared the floor. #flairww -11:28 AM Apr 19th, 2012

FlairWoodworks I laid down strips of wood on which to lay the slabs and allow clearance for my fingers! #flairww -11:29 AM Apr 19th, 2012

FlairWoodworks I must be crazy to be building such a large table in my shop.#flairww -11:33 AM Apr 19th, 2012

FlairWoodworks I need to cut the pieces to join them together so they look something like this. #flairww -11:39 AM Apr 19th, 2012

FlairWoodworks As much as I like the continuation of the main bole, it would make seating awkward. #flairww -11:43 AM Apr 19th, 2012

FlairWoodworks The drawing bow is a great tool. The strap holds the curvature. I just wish I had a longer one. #flairww -11:44 AM Apr 19th, 2012

FlairWoodworks I hold down the drawing bow with one hand and transfer its shape with a pencil in the other. #flairww -11:47 AM Apr 19th, 2012

FlairWoodworks I work one short section at a time to avoid flexing the drawing bow with pressure from the pencil. #flairww -11:48 AM Apr 19th, 2012

FlairWoodworks A pencil line can be hard to see so I draw a squiggly line on the waste side using the drawing bow as a stop. #flairww -11:49 AM Apr 19th, 2012

FlairWoodworks Standard jigsaw blades aren’t long enough to cut these 2-1/2″-thick slabs so I bought longer blades. #flairww -11:56 AM Apr 19th, 2012

FlairWoodworks The black blade is about 1/4″ too short. I have to use the loooong blade which is 6-3/4″ long overall. #flairww -11:59 AM Apr 19th, 2012

FlairWoodworks I elevated the slab using I-beams (H-beams if you’re French) to provide clearance for the blade. #flairww -12:05 PM Apr 19th, 2012

FlairWoodworks I got the idea of I-beams from my buddy Serge. He’s said to be the most prolific tipster! Serge’s blog. #flairww -12:07 PM Apr 19th, 2012

FlairWoodworks I’m not sue why, but I’m a little nervous about this cut. Here goes! #flairww -12:10 PM Apr 19th, 2012

FlairWoodworks I decided to redraw the cut line with a black marker before making the cut. I feel a little less nervous now. #flairww -12:16 PM Apr 19th, 2012

FlairWoodworks One cut down… #flairww -12:24 PM Apr 19th, 2012

FlairWoodworks I pretty much ignored my layout lines and just cut a smooth curve. #flairww -12:27 PM Apr 19th, 2012

(I recorded this video to show what a cut in 2-1/4″ thick Western maple is like.  I used a Festool Trion PS 300 EQ Jigsaw which draws 6 amps with a Trion S145/4FSG blade set for a maximum orbital stroke for a quick cut.  Duration – 0:55)

This movie requires Adobe Flash for playback.

FlairWoodworks This is the bade after one cut. The teeth at the very top are a little blue from heat build up. #flairww -12:30 PM Apr 19th, 2012

FlairWoodworks The saw seemed to cut more slowly with it set for a full orbital stroke than none at all. #flairww -12:32 PM Apr 19th, 2012

FlairWoodworks My curve was pretty even except for this bump. #flairww -12:35 PM Apr 19th, 2012

FlairWoodworks It was at the bump that my cut was the most out of square. I’m not sure what happened there. #flairww -12:37 PM Apr 19th, 2012

FlairWoodworks I broke a blade. I have no idea why I broke. The cut seemed to be going fine. Any ideas? #flairww -12:55 PM Apr 19th, 2012

BCcraftmaster @FlairWoodworks your lucky you have a festool jigsaw, if you had a normal one that “out of square” would have looked like a 30 degree bevel! -12:50 PM Apr 19th, 2012

FlairWoodworks @BCcraftmaster My old jigsaw didn’t even have enough power to cut 2″ maple. #flairww -12:57 PM Apr 19th, 2012

FlairWoodworks Ha ha ha!! I take back my comment about the saw cutting more slowly on full orbital than none… I read the scale backwards. #flairww-12:59 PM Apr 19th, 2012

BCcraftmaster @FlairWoodworks heat weakened metal? -1:05 PM Apr 19th, 2012

FlairWoodworks I don’t think so. It didn’t bend, it broke. It’s still as straight as an arrow. RT @BCcraftmaster: @FlairWoodworks heat weakened metal? -1:06 PM Apr 19th, 2012

BCcraftmaster @FlairWoodworks why does it look so black right above the break -1:08 PM Apr 19th, 2012

FlairWoodworks I believe that is from the carbide guides. #flairww RT @BCcraftmaster: @FlairWoodworks why does it look so black right above the break -1:09 PM Apr 19th, 2012

BCcraftmaster @FlairWoodworks ohhhh… then I’m clueless -1:11 PM Apr 19th, 2012

BCcraftmaster @FlairWoodworks so does this mean your S.O.L until you get a new one? -1:12 PM Apr 19th, 2012

FlairWoodworks I bought a pack of 5 for $30. #flairww RT @BCcraftmaster: @FlairWoodworks so does this mean your S.O.L until you get a new one? -1:16 PM Apr 19th, 2012

BCcraftmaster @FlairWoodworks Im that Guy that would only buy 1 and then be running back out after it broke #lame -1:20 PM Apr 19th, 2012

FlairWoodworks I got interrupted by a half-hour phone call. Back at work now.#flairww -1:40 PM Apr 19th, 2012

FlairWoodworks This is coming along nicely! #flairww -1:48 PM Apr 19th, 2012

FlairWoodworks I’m working on designing and building a jig to cut the joints. The plywood pieces will serve as the guides. #flairww -2:03 PM Apr 19th, 2012

FlairWoodworks Pretty nice-looking for a quick and dirty jig. #flairww -2:15 PM Apr 19th, 2012

FlairWoodworks I’m set up to joint the first mating surface of this slab.#flairww -2:35 PM Apr 19th, 2012

FlairWoodworks This is a better angle at which to work. #flairww -2:37 PM Apr 19th, 2012

FlairWoodworks Oops. I forgot that I had planned to use the jig and a template bit in a router to joint the mating surfaces. #flairww -2:49 PM Apr 19th, 2012

FlairWoodworks My biggest template bit isn’t long enough to make the cut in one pass. #flairww -2:56 PM Apr 19th, 2012

FlairWoodworks This is as far as I can work with the router. I’ll finish by hand. #flairww -3:02 PM Apr 19th, 2012

FlairWoodworks I could remove the plywood to gain more depth, but it is my reference surface and the angle of the router might change without it. #flairww -3:03 PM Apr 19th, 2012

FlairWoodworks I forgot to close the drawer before routing. I also “forgot” to use a Festool router with dust collection. #flairww -3:05 PM Apr 19th, 2012

FlairWoodworks I’m using a chisel to pare away the waste. The routed area provides solid registration. #flairww -3:09 PM Apr 19th, 2012

HighRockWW @FlairWoodworks I can laugh only because I have done the same thing before… -3:12 PM Apr 19th, 2012 RT FlairWoodworks I forgot to close the drawer before routing.

FlairWoodworks One surface done. #flairww -3:15 PM Apr 19th, 2012

FlairWoodworks The second surface is now jointed as well. #flairww -3:26 PM Apr 19th, 2012

FlairWoodworks Lunch time! #flairww -3:27 PM Apr 19th, 2012

Keep reading!  Session 4 is the next instalment.

How to Listen to the Wood – Carving, Day 2

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Sunday afternoon, I started a project with a board of butternut (I thought it was walnut at first).  The idea was to let the wood dictate the end result.  I documented the process of building and mounting wall brackets live on Twitter and what you see below are the updates from Day 2: Monday (you can read the first day of this project in How to Listen to the Wood – Carving, Day 1).  This was useful because each update had a time stamp so followers could see the rate at which I progressed.

(If you are not familiar with the format used on Twitter, the @ symbol indicates a username.  Every update, or “tweet” below starts with a username, being the author of that tweet.  Sometimes, you will see two or more usernames in a tweet.  The second (and third, etc) usernames are people to whom the author is talking.  The other symbol you will see is #, which serves as a category.  I tried to remember to categorize all my tweets pertaining to this project under #flairww.)

FlairWoodworks So this is where I left off yesterday. Follow along with #flairww  -12:24 PM Feb 13th, 2012 pic.twitter.com/8mmHxwDo FlairWoodworks In this tight area I’m able to hold the chisel like this and move it diagonally in the direction of the arrow. #flairww -12:55 PM Feb 13th, 2012

ravinheart @FlairWoodworks LOL .. hey, I see him now -12:25 PM Feb 13th, 2012

FlairWoodworks Working in restricted spaces is one of the biggest challenges. #flairww -12:50 PM Feb 13th, 2012

pic.twitter.com/syXu4Cxj

FlairWoodworks This section is now shaped. #flairww -1:07 PM Feb 13th, 2012

pic.twitter.com/JSgxj3ug

FlairWoodworks If a curve feels fair, it’s fair. I use my sense of touch to judge my progress. #flairww -1:12 PM Feb 13th, 2012

FlairWoodworks As I work on this carving, I feel the need to add some colour. What do you think? Paint? Dye? Stain? Nothing? #flairww -2:24 PM Feb 13th, 2012

pic.twitter.com/6gVugXA5

asliceofwood @FlairWoodworks maybe a little darker or something to make the grain “pop” -2:28 PM Feb 13th, 2012

FlairWoodworks You think that’s all it needs? #flairww RT @asliceofwood: @FlairWoodworks maybe a little darker or something to make the grain “pop” -2:35 PM Feb 13th, 2012

asliceofwood @FlairWoodworks yeah. I’m a fan of natural. The design looks great. -2:37 PM Feb 13th, 2012

FlairWoodworks Thanks, Tim. #flairww RT @asliceofwood: @FlairWoodworks yeah. I’m a fan of natural. The design looks great. -2:37 PM Feb 13th, 2012

FlairWoodworks I have to figure out what to do about this crack which is about 3/4″ deep at the near end and gets shallower. #flairww -2:45 PM Feb 13th, 2012

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FlairWoodworks I love textures. #flairww -2:50 PM Feb 13th, 2012

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FlairWoodworks This crack just won’t work. I’m going to cut it out and reassemble the two pieces. #flairww -3:04 PM Feb 13th, 2012

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FlairWoodworks Here is the result of one cut on the bandsaw.#flairww -3:08 PM Feb 13th, 2012

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FlairWoodworks I’m taking advantage of the easy access with the bottom removed and carving the otherwise restricted areas. #flairww -3:13 PM Feb 13th, 2012

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FlairWoodworks The trick with the ribbon is to make it look delicate without being delicate. I bevelled the ends. #flairww -3:24 PM Feb 13th, 2012

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FlairWoodworks I use my thumb and finger to gauge the thickness. If it feels right, it’s right. #flairww -3:26 PM Feb 13th, 2012

FlairWoodworks Because the ribbon is fragile, I used a piece of plywood to support it while carving the back. #flairww -3:55 PM Feb 13th, 2012

pic.twitter.com/B8rzMMQ8

gvmcmillan @FlairWoodworks Good idea – the grain direction looks like it would make it even more fragile. #flairww What’s the project? -3:57 PM Feb 13th, 2012

FlairWoodworks @gvmcmillan The project has been evolving since the get-go. Right now, it looks like a runner crossing the finish line. #flairww -3:59 PM Feb 13th, 2012

FlairWoodworks @gvmcmillan I’m just carving and letting the piece lead the way. #flairww -4:00 PM Feb 13th, 2012

gvmcmillan @FlairWoodworks Cool! I’ve never tried that before (abstract isn’t my gift). -4:07 PM Feb 13th, 2012

FlairWoodworks When using a gouge across the grain, one side of the cut is always with the grain and the other side against. #flairww -4:15 PM Feb 13th, 2012

pic.twitter.com/2wrhj7go

FlairWoodworks When shaping convex surfaces, often a wide, flat chisel (and not a carving gouge) is the best tool. #flairww -4:16 PM Feb 13th, 2012

pic.twitter.com/W0rBOx5M

FlairWoodworks I removed most of the material from the back of the ribbon then glued the two pieces back together. #flairww -4:55 PM Feb 13th, 2012

pic.twitter.com/ugzQaCJD

FlairWoodworks I have to wait for the glue to cure, so It’s a good place to stop for the day. #flairww -4:58 PM Feb 13th, 2012

To be continued…

How to Listen to the Wood – Carving, Day 1

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Sunday afternoon, I started a project with a board of butternut (I thought it was walnut at first).  The idea was to let the wood dictate the end result.  I documented the process of building and mounting wall brackets live on Twitter and what you see below are the updates from Sunday (the project wasn’t completed in one day and so there will be more to come).  This was useful because each update had a time stamp so followers could see the rate at which I progressed.

(If you are not familiar with the format used on Twitter, the @ symbol indicates a username.  Every update, or “tweet” below starts with a username, being the author of that tweet.  Sometimes, you will see two or more usernames in a tweet.  The second (and third, etc) usernames are people to whom the author is talking.  The other symbol you will see is #, which serves as a category.  I tried to remember to categorize all my tweets pertaining to this project under #flairww.)

“The inspiration for me was this irregular butternut board and a table by Jennifer Anderson called Pattern Study 1 but I was willing to listen to what the board I had on hand wanted me to do.  By the end of day one, it was clear that I was not making a table.”

Pattern Study 1 by Jennifer Anderson

FlairWoodworks I’ve got this walnut board that tapers in thickness and has a live edge. Follow my inspired process with #flairww -12:29 PM Feb 12th, 2012

pic.twitter.com/dZUHiczC

FlairWoodworks I’ve surfaced one face which revealed long checks (cracks) on it. Cutting them out would be wasteful. #flairww -12:31 PM Feb 12th, 2012

pic.twitter.com/RRT34FVl

FlairWoodworks This is going to be a carving exercise to incorporate the checks into the design. There are no defects. #flairww -12:35 PM Feb 12th, 2012

pic.twitter.com/FaTbA3Wv

FlairWoodworks I started by defining the edges with a V-gouge. #flairww -12:38 PM Feb 12th, 2012

pic.twitter.com/Dl56OB5n

FlairWoodworks I used a series of gouges to excavate between the V cuts. From left to right: 5/12, 7/10 and 9/10 gouges. #flairww -12:45 PM Feb 12th, 2012

pic.twitter.com/DZ8b8v0o

FlairWoodworks My 9/10 gouge is used extensively for roughing – much like a scrub plane. #flairww -12:58 PM Feb 12th, 2012

pic.twitter.com/WjOOcIc3

WatkinsWoodWork @FlairWoodworks Very cool…can’t wait to see the finished product of your inspiration. -12:59 PM Feb 12th, 2012

FlairWoodworks Same here! RT @WatkinsWoodWork: @FlairWoodworks Very cool…can’t wait to see the finished product of your inspiration. -1:00 PM Feb 12th, 2012

FlairWoodworks I had intended to have more cuts terminating in wide curves at the near edge but it’s already quite busy. #flairww -1:20 PM Feb 12th, 2012

pic.twitter.com/ERPufyTT

FlairWoodworks Here’s my new plan. #flairww -1:24 PM Feb 12th, 2012

pic.twitter.com/n6R2tAKK

FlairWoodworks This deep relief visually reduces the thickness of the board. I think I still need to go deeper though. #flairww -1:36 PM Feb 12th, 2012

pic.twitter.com/uTe2aCgX

WatkinsWoodWork @FlairWoodworks Yup…I agree. A bit more depth should give a nice flow. -1:39 PM Feb 12th, 2012

FlairWoodworks My 9/25 gouge is for when I’m serious about stock removal. My 9/10 is in the background. #flairww -1:39 PM Feb 12th, 2012

pic.twitter.com/IQUU03yK

FlairWoodworks I think this looks awesome! Notice the shine on the carved surface. #flairww -1:46 PM Feb 12th, 2012

pic.twitter.com/LZ3JzV7C

FlairWoodworks This end is done for now. I think I need to make the other end scoops deeper now. #flairww -1:56 PM Feb 12th, 2012

pic.twitter.com/UKiQQv3w

TomsWorkbench @FlairWoodworks Is this a new Br’all design? -1:58 PM Feb 12th, 2012

FlairWoodworks No sir! RT @TomsWorkbench: @FlairWoodworks Is this a new Br’all design? #flairww -1:59 PM Feb 12th, 2012

FlairWoodworks Parts of this walnut are surprisingly hard! Sections feel like hard maple. #flairww -2:00 PM Feb 12th, 2012

FlairWoodworks I’m not really happy with this scoop. I want the curve to be steeper but don’t have the required thickness. #flairww -2:07 PM Feb 12th, 2012

pic.twitter.com/xSn6uQ4N

WatkinsWoodWork @FlairWoodworks Very nice -2:20 PM Feb 12th, 2012

FlairWoodworks Okay – I’m back after getting a bite to eat. The carving is certainly lacking but I’m not sure what it needs. #flairww -3:17 PM Feb 12th, 2012

FlairWoodworks It’s coming along but I’m still trying to figure out where it’s going. #flairww -3:46 PM Feb 12th, 2012

pic.twitter.com/JOeupuve

“At this point, I was not at all happy with how it was turning out.  To me, it looked like a board with one live edge, a big crack, and a whole bunch of random scoops taken out of it.  Yuck.  If I hadn’t been documenting the progress live on Twitter all along, I might have tossed it in the firewood box.  But I kept working on it, hoping that something would emerge.  Eventually something did emerge.”

FlairWoodworks I rounded over the shoulders of the cracks that I was unable to carve out. #flairww -3:57 PM Feb 12th, 2012

pic.twitter.com/TI3pwDks

cobwobbler @FlairWoodworks I like this process, letting the project evolve organically. -3:59 PM Feb 12th, 2012

cobwobbler @FlairWoodworks That’s looking good. How easy was it to cut? -4:01 PM Feb 12th, 2012

FlairWoodworks I don’t think enough people allow it to happen. RT @cobwobbler: @FlairWoodworks I like this process, letting the project evolve organically -4:02 PM Feb 12th, 2012

FlairWoodworks @cobwobbler Some parts are easy, some areas are harder and challenging. -4:02 PM Feb 12th, 2012

cobwobbler @FlairWoodworks Now it’s flowing like a river bed. Nice. -4:04 PM Feb 12th, 2012

cobwobbler @FlairWoodworks yes that works, it’s got a real flow and almost a sense of movement. -4:06 PM Feb 12th, 2012

WatkinsWoodWork @FlairWoodworks I like it. The check was distracting. -4:09 PM Feb 12th, 2012

FlairWoodworks I used a wide chisel, bevel-down, to extend the rounded corners. #flairww -4:09 PM Feb 12th, 2012

pic.twitter.com/2cPDz7CV

FlairWoodworks I like the part I just did but the rest looks lacking. I might use a saw to cut more “checks” into the board. #flairww -4:19 PM Feb 12th, 2012

pic.twitter.com/aiNAWllf

FlairWoodworks Pay attention to the wood. This little knot is a signal that the grain may change direction. #flairww -4:26 PM Feb 12th, 2012

MichaelAgate @FlairWoodworks Chris, perhaps it is fine just like it is. Sometimes knowing where to stop is the challenge :) We all like it here :) -4:26 PM Feb 12th, 2012

FlairWoodworks @MichaelAgate Thanks for the input, Michael and company. However, I feel it is not done yet. Onwards! #flairww -4:28 PM Feb 12th, 2012

FlairWoodworks I feel that I am on the right track. That’s good because it’s very difficult to undo carving ;) #flairww -4:33 PM Feb 12th, 2012

pic.twitter.com/nvsPlYA3

asliceofwood @FlairWoodworks looking good! Like all these little tips. -4:39 PM Feb 12th, 2012

FlairWoodworks It was still looking too blocky so I went to the bandsaw and made a series of cuts. Now I’ll refine it with carving tools. #flairww -4:58 PM Feb 12th, 2012

FlairWoodworks For unrestricted access to the edge, I clamped a short 2×4 in my vise and clamped the workpiece to it. #flairww -5:04 PM Feb 12th, 2012

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FlairWoodworks I’m really not happy with how uniform it looks. Time for some adjustments on the bandsaw. #flairww -5:09 PM Feb 12th, 2012

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FlairWoodworks When I come across an inconsistency like this I have to decide whether to incorporate or eliminate it. #flairww -5:19 PM Feb 12th, 2012

pic.twitter.com/6STDj9CM

HighRockWW @FlairWoodworks I like the looks of the rest that I can see. -5:24 PM Feb 12th, 2012

MansFineFurn @FlairWoodworks character -5:24 PM Feb 12th, 2012

FlairWoodworks I’m starting to see something! Can you see it? This is #exciting! #flairww -5:27 PM Feb 12th, 2012

pic.twitter.com/8bgYIh99

ravinheart @FlairWoodworks Yup I can see it it’s in there just keep letting it out -5:30 PM Feb 12th, 2012

MansFineFurn @FlairWoodworks yes -5:34 PM Feb 12th, 2012

FlairWoodworks I’ve learned to embrace sanding as sometimes it, just like any other technique, has its place. 1 side sanded. #flairww -5:46 PM Feb 12th, 2012

pic.twitter.com/l7eSW02H

FlairWoodworks Having dust collection nearby doesn’t catch all the dust but it gets most, if not all, of the airborne dust. #flairww -5:54 PM Feb 12th, 2012

pic.twitter.com/NLXct8rk

ravinheart: @FlairWoodworks a tree within a tree, water, and motion #flairww -5:56 PM Feb 12th, 2012

FlairWoodworks We must remember to be patient with the creative process. #flairww -6:00 PM Feb 12th, 2012

MansFineFurn @FlairWoodworks A highway interchange, Dr Seuss’s horns from the Grinch, fine carving work, your mad skills, and my lack of artistry -6:14 PM Feb 12th, 2012

MansFineFurn @FlairWoodworks I keep asking myself: “but what’s it DO?” #TheEngineerLooksAtArt -6:17 PM Feb 12th, 2012

FlairWoodworks Ha ha ha! I was doing that too. #flairww RT @MansFineFurn: @FlairWoodworks I keep asking myself: “but what’s it DO?” #TheEngineerLooksAtArt -6:17 PM Feb 12th, 2012

FlairWoodworks Would anyone else care to share what they see here? #flairww  -6:19 PM Feb 12th, 2012

pic.twitter.com/bLPZRsJT

ravinheart @FlairWoodworks a running man would be in motion :) -6:22 PM Feb 12th, 2012

Flairwoodworks If you were closer I might throw him at you! ;) RT @ravinheart: @FlairWoodworks a running man would be in motion :) -6:23 PM Feb 12th, 2012

FlairWoodworks @ravinheart sees a tree, water and motion. @MansFineFurn sees a highway interchange or Grinch horns. I see a runner. #flairww -6:25 PM Feb 12th, 2012

ravinheart @FlairWoodworks there will be no throwing :P

FlairWoodworks Ok. Dinner break. #flairww -6:29 PM Feb 12th, 2012

Tooltutor @FlairWoodworks Looks like a tree on its side being struck by a meteorite…or a flowing river being hit by a meteorite =P -6:40 PM Feb 12th, 2012

Seanw78 @FlairWoodworks something between antlers and a blowing wind -7:15 PM Feb 12th, 2012

FlairWoodworks Thanks for sharing! #flairww RT @Seanw78: @FlairWoodworks something between antlers and a blowing wind -7:18 PM Feb 12th, 2012

FlairWoodworks So I’m back after dinner and thinking about some major material removal, as indicated by the scribble. #flairww -8:19 PM Feb 12th, 2012

pic.twitter.com/BZaZJD6Z

FlairWoodworks I think Andrew @RavinHeart may have inspired me to make this cut by hand instead of the bandsaw. #flairww -8:35 PM Feb 12th, 2012

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FlairWoodworks Two cutouts complete. I’m going to do some shaping next. #flairww -8:44 PM Feb 12th, 2012

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FlairWoodworks The correct sweep of gouge is determined by which part of the edge engages. The corners should not engage. #flairww -8:56 PM Feb 12th, 2012

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FlairWoodworks Out damned crack! I know it doesn’t go through but I can’t tell how deep it is. I’ll keep going… #flairww -9:03 PM Feb 12th, 2012

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FlairWoodworks I’m defining what I think is a ribbon running horizontally across what I think is the waist of the runner. #flairww -9:33 PM Feb 12th, 2012

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FlairWoodworks I’m using a 15/6 (60-degree V) gouge to undercut the ribbon. #flairww -9:49 PM Feb 12th, 2012

FlairWoodworks I want to remove this narrow bit that I’ve shaded but I know it will mean a lot more work. It’s worth it. #flairww -10:12 PM Feb 12th, 2012

FlairWoodworks A good tool solves problems without causing any. This Knew Concepts fret saw is certainly a good tool. #flairww -10:16 PM Feb 12th, 2012

Tumblewood @FlairWoodworks fun to watch your creative improvisation. -10:34 PM Feb 12th, 2012

FlairWoodworks Thanks, Vic! #flairww -10:37 PM Feb 12th, 2012

FlairWoodworks I finished roughing the cutout. Now to refine that confined space. Not fun. #flairww -10:42 PM Feb 12th, 2012

FlairWoodworks Time for another break! #flairww -11:00 PM Feb 12th, 2012

The carving is continued in How to Listen to the Wood – Carving, Day 2.

Every Workshop Needs a Br’all

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This post is part of Get Woodworking Week, an initiative started by Tom Iovino of Tom’s Workbench, to build interest and participation in woodworking.

I know that every one of my readers except for Paul-Marcel, for whom I made the first one, is scratching their head wondering what the heck a Br’all is, what it does, and why they haven’t heard of it.

A Br’all is a shop accessory that I think every shop should have.  I designed it to do one thing and one thing only.  It does not require a great investment in either time, tools or materials to make, so it is a great Get Woodworking Week project.

The first video is the one you should definitely watch.  I show you how to make a Br’all using different hand tools, techniques and the purpose of the Br’all.  (Duration: 13 minutes, 14  seconds; the high-speed segments are 2x speed.)

The second video shows the letter carving I added.  (Duration: 7 minutes, 12 seconds; the high-speed segments are 4x speed.)

Here are some pictures of my bench-clearing Br’all.

Shiny Handles Suck

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Many wooden-handled tools that you can buy come covered in a tough, shiny finish.  These tools look so perfect and pretty and would look right at home in a glass display case under a spotlight in the Museum of Modern Art.  While the shiny handles are pretty and easy to wipe clean, they are slippery and not very comfortable to hold.

One day, I got fed up with the lacquered handles on my chisel handles.  I took a piece of coarse sandpaper (80-grit, I think) and removed the shiny finish.  I palmed the handle and knew immediately that I had done the right thing.  I was able to grip the chisel with more control than ever before, and with less effort.

Lacquered and Stripped Handles

Later, when I decided to strip the finish off the remaining chisel handles, I decided to try something different.  Instead of using sandpaper, I used a spokeshave.  The result was a faceted handle that felt better in my hand.

Working on a Chisel Handle

Although I could have left the naturally-oily rosewood handles bare, I chose to add a coat of oil finish.

Refinished, Faceted Handles

I also removed the finish from the handles of my spokeshave and finished them in a similar fashion.

Refinished Spokeshave Handle

With the slick, glossy finishes removed, the tools were much more comfortable to use and looked even better, in my opinion.

Slicks and Handles for Socket Chisels

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A slick is essentially a large chisel that can be used to pare or trim projections in the middle of a large surface.  Many slicks have cranked handles (angled upwards) to provide the necessary clearance.  They are often used in timber framing but their size makes the overkill in the shop.  Useful or not, it’s a neat curiosity.

A few weeks ago, I arranged a trade with Tom Iovino of Tom’s Workbench.  I sent four assembly squares his way in exchange for a slick he didn’t need.  It arrived with the short, squarish handle shown in the middle.  (The full-size carving gouge is for scale.)

In use, I wanted to be able to brace the butt end of the handle against my shoulder and the old handle wasn’t long enough to be comfortable so I decided to turn a longer one.  I started by removing the old handle so that I could take measurements off it as I shaped the taper.  Since this is a socket chisel (meaning that there is a socket in the metal that the wooden handle fits into), removal was easy with the right technique.  I gripped the blade, with the edge safely away from myself, and whacked the handle against my bench a couple of times and the handle popped out.

I found a suitable piece of wood for the handle (Western maple) and installed it between centers on my lathe.  I first turned the blank round, then used a parting tool to define the size and shape of the taper using the old handle as a guide.  A tight fit is important, so I intentionally left the taper slightly oversized.  I went ahead and shaped and sanded the rest of the handle.

The handle-to-blade connection is purely mechanical (a friction-fit) so I wanted to make sure I got a good, solid fit.  Back at the bench, I test-fitted the handle in the socket.  It didn’t fit that well, but I twisted it around a few times before removing the handle.  A discoloration was left where the wood rubbed against the metal and I used a rasp to remove the marks, then tried again.  When I got an even wear pattern, I fully seated the chisel by driving the butt end of the handle down on my benchtop and inertia secured the blade.

I would have left the handle unfinished, but the curly maple I pulled from my firewood box was begging for a finish so I applied a light coat of an oil/varnish blend to showcase the figure.

If you look closely at the joint between the handle and blade, you will see a slight gap between the blade and shoulder of the handle.  This is important as without that gap, the blade could bottom out on the should and not fully engage with the socket.  That means the handle could separate from the blade.  Not good.  Fortunately, if care is take to ensure a good fit, the handle should lock on very securely.

Before starting work for the day, it’s good practice to rap the butt end of the handle on the bench to ensure that it is indeed fully seated.  If this seems like too much bother, you could apply some shellac to the taper just before you install the handle.  When the shellac hardens, it will lock the handle in place but it can still be removed by applying heat to soften the shellac.  Thanks to Jeremy Tomlinson of Lie-Nielsen Toolworks Inc. for this tip.