Category Archives: Mirka CEROS

Maple Trestle Table, Session 24 – Profiling the Table’s Edge

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7

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;
Session 18 - Attachment Strips and Power Carving;
Session 19 - Refining the Sculpted Base;
Session 20 - A Little Sanding, then Lots More Sanding;
Session 21 – Preparing for a Big Glue-Up;
Session 22 – Fitting and Joining the Table Top; and
Session 23 – The Bottom of the Top.

(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 Welcome to Session 24! I’ll continue work on the Maple Trestle Table by cutting the ends, then working on the edge profile. #flairww -12:48 PM May 27th, 2012

FlairWoodworks I’m ready to make the first cut. #flairww -12:58 PM May 27th, 2012

FlairWoodworks I cut the curve with my jigsaw. Now I’m using my low-angle block plane to clean up and fair the curve. #flairww -1:22 PM May 27th, 2012

FlairWoodworks This joint is nice and tight. #flairww -1:25 PM May 27th, 2012

gvmcmillan @FlairWoodworks Now THAT’S a joint! How thick is the wood there again? -1:29 PM May 27th, 2012

FlairWoodworks It’s 2-1/8″ thick. #flairww RT @gvmcmillan:@FlairWoodworks Now THAT’S a joint! How thick is the wood there again? -1:29 PM May 27th, 2012

gvmcmillan @FlairWoodworks That’s substantial – what did you use to make that much thickness so perfect? Surely not a hand plane? -1:31 PM May 27, 2012

FlairWoodworks @gvmcmillan I used a router to get it close, then a handplane to get it perfect. #flairww -1:32 PM May 27th, 2012

FlairWoodworks The curve looks and feels fair. Therefore, it must be fair. #flairww -1:38 PM May 27th, 2012

FlairWoodworks Now I’ll cut the other end. #flairww -1:39 PM May 27th, 2012

FlairWoodworks Here’s another angle of the cut end. #flairww -1:40 PM May 27th, 2012

FlairWoodworks When using the jigsaw upside-down, I find it helpful to carry the cut line down the edge. #flairww -1:49 PM May 27th, 2012

FlairWoodworks I completed the cut. I have more control with the jigsaw set to not orbit. #flairww -1:58 PM May 27th, 2012

FlairWoodworks Again, I’m using my block plane to fair the curve. The light areas are the low spots. #flairww-2:21 PM May 27th, 2012

FlairWoodworks The end curves are fair. The next step is to lay out the edge profile. #flairww -2:28 PM May 27th, 2012

DyamiPlotke @FlairWoodworks have you figured it out? -2:31 PM May 27th, 2012

FlairWoodworks @DyamiPlotke All the edge profiles in the base are convex, as are the ends of the table. I want to mimic the profile of the legs. #flairww -2:34 PM May 27th, 2012

DyamiPlotke @FlairWoodworks good plan. -2:40 PM May 27th, 2012

FlairWoodworks Before I start profiling the edge, I’m going to tidy up the shop. #flairww -2:47 PM May 27th, 2012

FlairWoodworks I unscrewed the particle board cauls. The materials may be reused or tossed. #flairww -2:48 PM May 27th, 2012

FlairWoodworks I’ve used more than 22 sanding discs so far. They cost about a buck each. #flairww -3:03 PM May 27th, 2012

DyamiPlotke @FlairWoodworks they don’t seem very long lived -3:07 PM May 27th, 2012

FlairWoodworks @DyamiPlotke Some still have life in them, but they do tend to wear quickly when working on sculpted surfaces. #flairww -3:08 PM May 27th, 2012

 Tumblewood @FlairWoodworks @DyamiPlotke Yea, it seems a big difference between finishing a surface and creating a surface, in terms of longevity. -3:09 PM May 27th, 2012

FlairWoodworks To cut the edge profile evenly, I’m going to first cut a wide bevel. #flairww -3:27 PM May 27th, 2012

FlairWoodworks To lay out the bevel, I made two simple jigs. They guide a pencil to draw a line parallel to the edges. #flairww -3:29 PM May 27th, 2012

FlairWoodworks The second jig marks the other guideline. #flairww -3:41 PM May 27th, 2012

FlairWoodworks I’ve started establishing the end bevel with my biggest gouge and a mallet. #flairww -3:51 PM May 27th, 2012

gvmcmillan @FlairWoodworks Yep, that’s a pretty big gouge! My biggest is 1″ -4:00 PM May 27th, 2012

Tumblewood @FlairWoodworks are you still going for a cove vs a bevel? I can’t think of an expedient way to do that. #flairww

FlairWoodworks @gvmcmillan This one is a 9/25 (#9 sweep, 25mm mm wide, for the non-carvers). #flairww -4:03 PM May 27th, 2012

FlairWoodworks @Tumblewood No, I’m doing an elliptical roundover. #flairww -4:03 PM May 27th, 2012

FlairWoodworks @Tumblewood The quickest way to make a large cove on something like this table top would be a series of passes with a router… #flairww -4:04 PM May 27th, 2012

FlairWoodworks @Tumblewood … then sandpaper to finish. #flairww -4:04 PM May 27th, 2012

Tumblewood @FlairWoodworks oh cool. The round over would’ve been my choice, too.  #flairww -4:10 PM May 27th, 2012

gvmcmillan @FlairWoodworks I think I’d be tempted to knock of the largest bits with my jig saw set at a 45 degree angle. #flairww -4:11 PM May 27th, 2012

FlairWoodworks @gvmcmillan The only trouble with that is the bevel angle is a 1:2 rise/run ratio. #flairww -4:11 PM May 27th, 2012

Tumblewood @FlairWoodworks yea with a big cove bit. Would still require a LOT of extra work. #flairww -4:11 PM May 27th, 2012

gvmcmillan @FlairWoodworks Yes, but, ahem, who decided that? ;) #flairww -4:12 PM May 27th, 2012

FlairWoodworks @Tumblewood Some extra work for sure. How would it be compared to the alternatives? #flairww -4:13 PM May 27th, 2012

Tumblewood @FlairWoodworks I think your approach melds w/ the base very well.  #flairww -4:15 PM May 27th, 2012

FlairWoodworks Thanks, Vic! I do too. RT @Tumblewood:@FlairWoodworks I think your approach melds w/ the base very well. #flairww -4:16 PM May 27th, 2012

FlairWoodworks I’ve used the gouge to remove most of the waste. #flairww -4:33 PM May 27th, 2012

FlairWoodworks Now I’m using a coarsely-set block plane across the grain to refine the bevel. #flairww -4:34 PM May 27th, 2012

FlairWoodworks Here’s the first bevel completed. I’ll do the other end next. #flairww -4:45 PM May 27th, 2012

FlairWoodworks As I’m wasting away the bevel with my gouge and mallet, “Wasting Away” by The Northern Pikes started to play! #flairww -4:47 PM May 27th, 2012

Tumblewood @FlairWoodworks SWEET! #flairww -4:50 PM May 27th, 2012

FlairWoodworks When chopping away waste, it does not make sense to be timid. When the chips break free, they fly 4-6′ from the table. #flairww -4:56 PM May 27th, 2012

FlairWoodworks I cannot believe how long this gouge stays sharp. #flairww -5:00 PM May 27th, 2012

FlairWoodworks The second end is shaped. I’m tired and hungry so I’m stopping for lunch. #flairww -5:14 PM May 27th, 2012

DyamiPlotke: @FlairWoodworks what brand? -5:43 PM May 27th, 2012

FlairWoodworks My gouge is a Pfeil (a.k.a. Swiss-Made). #flairww RT @DyamiPlotke: @FlairWoodworks what brand? -5:44 PM May 27th, 2012

FlairWoodworks After a delicious lunch, I’m back at work on the edges of the table. I’m going to work on the long edges next. #flairww -6:19 PM May 27th, 2012

FlairWoodworks The curves present a little bit of a challenge but mostly they will make progress slower. #flairww-6:23 PM May 27th, 2012

FlairWoodworks The difficult figure won’t help either. #flairww -6:24 PM May 27th, 2012

FlairWoodworks My drawknife works quickly to remove most of the waste. #flairww -6:30 PM May 27th, 2012

FlairWoodworks I cleaned up the edge with my flat spokeshave. #flairww -6:40 PM May 27th, 2012

FlairWoodworks As I expected, this section is difficult to work. #flairww -6:43 PM May 27th, 2012

FlairWoodworks The best way I’ve found to work this section is to use the gouge to chop into the edge. #flairww -6:47 PM May 27th, 2012

FlairWoodworks My right arm is sore from swinging my 12oz carver’s mallet but the gouge work is done here. #flairww -6:56 PM May 27th, 2012

FlairWoodworks I’ve got one long bevel done. Next! #flairww -7:29 PM May 27th, 2012

woodshaver101 @FlairWoodworks A draw knife would do wonders on such a large bevel.looking good. -8:04 PM May 27th, 2012

FlairWoodworks Thanks! This is a lot of work! #flairww RT @woodshaver101: @FlairWoodworks A draw knife would do wonders on such a large bevel.looking good. -8:05 PM May 27th, 2012

FlairWoodworks I just finished the difficult (and beautiful) section on this edge. #flairww -8:06 PM May 27th, 2012

BCcraftmaster @FlairWoodworks that looks great with the curve of the flitch -8:07PM May 27th, 2012

Tumblewood @FlairWoodworks looks awesome! #flairww -8:11 PM May 27th, 2012

FlairWoodworks I’m just glad my spokeshaves can handle this grain! #flairww -8:12 PM May 27th, 2012

FlairWoodworks I resorted to the gouge for this heavily-figured section. #flairww -8:25 PM May 27th, 2012

FlairWoodworks When the grain is this figured, is it any wonder it took so long to shape? The bevel is complete. #flairww -8:33 PM May 27th, 2012

FlairWoodworks I’m done work for now. Next, the bevels will turn into gentle curves. #flairww -8:34 PM May 27th, 2012

In the next session, I’ll continue working on the bottom half of the edge profile.  You can leave a comment here.

Maple Trestle Table, Session 23 – The Bottom of the Top

Posted on by
3

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;
Session 18 - Attachment Strips and Power Carving;
Session 19 - Refining the Sculpted Base;
Session 20 - A Little Sanding, then Lots More Sanding;
Session 21 – Preparing for a Big Glue-Up; and
Session 22 – Fitting and Joining the Table Top.

(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 at work on the table after a full day working on Time Warp Tool Works projects. #flairww -2:19 PM May 24th, 2012

FlairWoodworks I can finally remove these long clamps under which I’ve been constantly crawling. #flairww -2:21 PM May 24th, 2012

FlairWoodworks An unexpected setback – I killed the output of my stereo. I blame @hailthevillain #flairww -2:29 PM May 24th, 2012

FlairWoodworks I wrapped the shiny red handle with a strip of a bicycle inner tube. Remember: shiny handles suck. #flairww -2:46 PM May 24th, 2012

FlairWoodworks With the pressure of the clamps gone, I can remove the glue squeeze-out and reflatten the surface. #flairww -2:58 PM May 24th, 2012

FlairWoodworks My Stanley Bailey #6 isn’t tuned as well as a smoother but it doesn’t need to be. #flairww -3:02 PM May 24th, 2012

FlairWoodworks I’m using a hand plane to refine the visible surfaces of the battens. #flairww -3:12 PM May 24th, 2012

FlairWoodworks Both battens are nicely refined. Now I’ll sand the underside of the table top to 180-grit before attaching the battens. #flairww -3:20 PM May 24th, 2012

FlairWoodworks I spent an hour on the phone with an engraver friend. (Anybody have an engraved tool?) Now I’ll begin sanding. #flairww -4:37 PM May 24th, 2012

FlairWoodworks The glue-up and handling resulted in a few dings so I went back to 80-grit to remove them. Now I’m uisng 120-grit. #flairww -4:49 PM May 24th, 2012

FlairWoodworks I’ve sanded the surface to 120-grit. I’m not going to go to 180-grit at this point. Now I’ll work on the edge. #flairww -5:19 PM May 24th, 2012

FlairWoodworks I used my jack plane to fair the convex section and spokeshave to fair the concave section of the edge. #flairww -5:22 PM May 24th, 2012

This video shows how I used my low-angle jack plane to fair the convex edge.  (Duration – 0:53)

This movie requires Adobe Flash for playback.

FlairWoodworks This section will make profiling the edge more difficult, but also will make the end result more impressive. #flairww -5:23 PM May 24th, 2012

HalfInchShy That edge will look fantastic with a finish @FlairWoodworks #flairww -5:29 PM May 24th, 2012

FlairWoodworks Unsure of which profile I want, I added a mild chamfer to the edge. Hmm… #flairww -5:34 PM May 24th, 2012

FlairWoodworks The edge definitely needs something to visually lighten it. #flairww -5:34 PM May 24th, 2012

HalfInchShy Maybe sculpt some undulations in place of the chamfer, they can go deep, but not far into the top surface @FlairWoodworks #flairww -5:36 PM May 24th, 2012

HalfInchShy Or maybe the same idea, but the undulations from underneath @FlairWoodworks #flairww -5:36 PM May 24th, 2012

FlairWoodworks I’ve use bevels top and bottom of varying sizes before, like on Table with a Twist. #flairww-5:37 PM May 24th, 2012

BCcraftmaster @FlairWoodworks twist it like the aprons on that other sick table you built! -5:37 PM May 24th, 2012

FlairWoodworks Neat idea. I had thought of a wavy edge. RT @HalfInchShy: Maybe sculpt some undulations in place of the chamfer @FlairWoodworks #flairww -5:38 PM May 24th, 2012

HalfInchShy Something like that would work if the bevels are shallow; don’t think making them steep would do it @FlairWoodworks #flairww -5:38 PM May 24th, 2012

FlairWoodworks I don’t think the slabs suit it. RT @BCcraftmaster: @FlairWoodworks twist it like the aprons on that other sick table you built! -5:39 PM May 24th, 2012

HalfInchShy sorry… ‘something like that’ has ‘Table with a Twist’ as the antecedent @FlairWoodworks #flairww -5:39 PM May 24th, 2012

MansFineFurn: @FlairWoodworks semi-parabolic cove underneath-5:41 PM May 24th, 2012

FlairWoodworks I was thinking of that… #flairww RT @MansFineFurn: @FlairWoodworks semi-parabolic cove underneath-5:41 PM May 24th, 2012

FlairWoodworks @HalfInchShy Careful! I have a piece titled, Something Like That! #flairww -5:42 PM May 24th, 2012

BCcraftmaster @FlairWoodworks how about a bottom bevel to give it a thinner look. Like this  -5:46 PM May 24th, 2012

FlairWoodworks @BCcraftmaster Yes, that’s a possibility. #flairww-5:47 PM May 24th, 2012

FlairWoodworks While I ponder the shape, I’m going to go get some lunch. #flairww -5:48 PM May 24th, 2012

BCcraftmaster @FlairWoodworks I saw T-mac do it on one of his tables and used it on my fireplace mantle and entertainment center – 5:50 PM May 24, 2012

DyamiPlotke @FlairWoodworks I like the chamfer. -6:06 PM May 24, 2012

HalfInchShy Great, you’ll come back and shape it like a burger… RT @FlairWoodworks: While I ponder the shape, I’m going to go get some lunch. #flairww -6:14 PM May 24th, 2012

FlairWoodworks I’m not sure whether I’ll go wth a chamfer or round-over profile. I don’t like the idea of a concave profile. #flairww -6:15 PM May 24th, 2012

MansFineFurn @FlairWoodworks boooooo ;) -6:15 PM May 24th, 2012

FlairWoodworks @MansFineFurn You like the idea of a hollow? #flairww -6:18 PM May 24th, 2012

MansFineFurn @FlairWoodworks yup, underside hollow makes the edge appear thin (lightweight) rather than appearing as a feature in itself…. -6:19 PM May 24th, 2012

FlairWoodworks @HalfInchShy Hmm… a hamburger bun has a nice shape… #flairww -6:19 PM May 24th, 2012

MansFineFurn @FlairWoodworks …you have lots of other features to showcase on that, the edge should be subtle, and lightweight -6:20 PM May 24, 2012

FlairWoodworks @MansFineFurn A bevel on the underside has the same effect without disappearing entirely. #flairww -6:22 PM May 24th, 2012

MansFineFurn @FlairWoodworks yes, but your whole table has curvature, a chamfer doesn’t seem to fit the theme (stands out, and not in a good way IMHO [in my honest opinion]) -6:23 PM May 24, 2012

FlairWoodworks @MansFineFurn So the question is: would a chamfer provide good or bad contrast? #flairww -6:26 PM May 24th, 2012

MansFineFurn @FlairWoodworks I can only say in my opinion, it would stand out. which (I think) is not where you’d like the focus to be on this piece -6:28 PM May 24th, 2012

FlairWoodworks I have some offcuts from the table top on which I can experiment. #flairww -6:28 PM May 24th, 2012

HalfInchShy What about a wavy edge? like Flow. In my mind, it doesn’t look good, though @FlairWoodworks #flairww -6:28 PM May 24th, 2012

FlairWoodworks @HalfInchShy No, I wouldn’t want a wavy edge like on Flow. #flairww -6:30 PM May 24th, 2012

MansFineFurn @FlairWoodworks damn, a design hangout would be awesome right about now. -6:30 PM May 24th, 2012

FlairWoodworks @MansFineFurn You are right – the edge should not compete for attention. #flairww -6:32 PM May 24th, 2012

BCcraftmaster @FlairWoodworks @MansFineFurn @HalfInchShy @DyamiPlotke sure. I’m creating a g+ accredited now -6:37 PM May 24th, 2012

MansFineFurn @FlairWoodworks I may be able to: If I show up, I’ll be there #captainobvious -6:38 PM May 24th, 2012

FlairWoodworks I’m back in the shop and going to cut up an offcut from the table for testing profiles. #flairww -6:47 PM May 24th, 2012

FlairWoodworks Are you on G+? Join my Hangout and help me design an edge profile for the table! Link #flairww -6:54 PM May 24th, 2012

FlairWoodworks I’m going to profile the edges as well as the ends, so I need to cut the ends first. #flairww -7:15 PM May 24th, 2012

FlairWoodworks I also need to fair the other edge of the table. #flairww -7:15 PM May 24th, 2012

FlairWoodworks I had one design Hangout with @MansFineFurn and@DyamiPlotke earlier and one with @BCcraftmaster just now. They were a great help! #flairww -8:07 PM May 24th, 2012

FlairWoodworks I’ve dressed a scrap of maple the same thickness as the table top. I’ll use it as a test for the profile. #flairww -8:08 PM May 24th, 2012

FlairWoodworks This is the profile I want to use on the edge. I’ll rough it out with my table saw. #flairww -8:09 PM May 24th, 2012

FlairWoodworks I redrew the curve with perpendicular lines every 1/4″ to aid in setting the table saw blade height. #flairww -8:18 PM May 24th, 2012

FlairWoodworks Here is the kerfed block. This process is similar to using a rabbet plane before hollows and rounds. #flairww -8:42 PM May 24th, 2012

FlairWoodworks Cutting all the grooves requires getting into a rhythm. If you break the rhythm, you might need to start again. #flairww -8:44 PM May 24th, 2012

FlairWoodworks I broke away most of the waste with a mallet. #flairww -8:50 PM May 24th, 2012

FlairWoodworks I used a gouge to refine the surface. The convex plane will finish the job. #flairww -8:57 PM May 24th, 2012

FlairWoodworks Luckily I have a full set of Time Warp Tool Works moulding planes. The #8 round worked perfectly! #flairww -9:13 PM May 24th, 2012

FlairWoodworks I could use either a scraper or sander to smooth the curve. #flairww -9:17 PM May 24th, 2012

FlairWoodworks The scraper worked quickly to even out the surface. #flairww -9:29 PM May 24th, 2012

FlairWoodworks  As is often the case with mouldings, the last inch or so isn’t as consistent as the rest. #flairww -9:31 PM May 24th, 2012

FlairWoodworks I think this is going to look awesome. Good call, Nick! @mansfinefurn #flairww -9:33 PM May 24th, 2012

FlairWoodworks The last thing I’ll do in the shop tonight is draw the curves along which I’ll cut the table ends. #flairww -9:46 PM May 24th, 2012

FlairWoodworks I drew two lines square to each edge that intersected at an point (where the pencil is). #flairww -10:02 PM May 24th, 2012

FlairWoodworks Then I drew a line between the two ends of the lines. #flairww -10:04 PM May 24th, 2012

FlairWoodworks I’m looking at pictures from Session 4 to figure out what curve I like. #flairww -10:05 PM May 24th, 2012

FlairWoodworks Here are three curves I’d drawn in Session 4. I’m only looking at the curvature, not the positioning. #flairww -10:07 PM May 24th, 2012

HalfInchShy Just got back; would have been a fun hangout. I like the thumbnail cove you decided on @FlairWoodworks #flairww -10:10 PM May 24th, 2012

HalfInchShy Now, to find a router bit that big… =:-O @FlairWoodworks #flairww -10:11 PM May 24th, 2012

FlairWoodworks Thanks! RT @HalfInchShy: Just got back; would have been a fun hangout. I like the thumbnail cove you decided on @FlairWoodworks #flairww -10:12 PM May 24th, 2012

FlairWoodworks This curve has 1-1/2″ of bow. I like it. #flairww -10:14 PM May 24th, 2012

FlairWoodworks I’ve laid out the curve on the other end too. #flairww -10:24 PM May 24th, 2012

FlairWoodworks I added a piece of tape to guide me across the void. #flairww -10:26 PM May 24th, 2012

FlairWoodworks I’m considering making a template to rout the ends evenly because tuning end-grain isn’t much fun. #flairww -10:35 PM May 24th, 2012

FlairWoodworks I used a CAD program to calculate the radius of the arcs which I laid out. They have a radius of 74-7/8″. #flairww -10:35 PM May 24th, 2012

FlairWoodworks I could always cut close to the line and fair the curve. That wouldn’t be that difficult. #flairww -10:39 PM May 24th, 2012

FlairWoodworks Tuning the two cuts with my random orbit sander should be easier than making a template. That’s what I’ll do next time. #flairww -10:41 PM May 24th, 2012

FlairWoodworks I’m done in the shop for today. Thanks for following! #flairww -10:43 PM May 24th, 2012

luggermatt @FlairWoodworks Another fabulous day! Thanks for posting :-) -10:43 PM May 24th, 2012

FlairWoodworks Thanks! I’m appreciative of all the interest that’s been shown. RT @luggermatt: @FlairWoodworks Another fabulous day! Thanks for posting :-) -10:46 PM May 24th, 2012

FlairWoodworks When designing the edge profile, I forgot about the battens. This one is in the way. #flairww-11:19 PM May 24th, 2012

FlairWoodworks I could either shorten the length of the edge profile or shorten the batten. Or I could do both. #flairww -11:20 PM May 24th, 2012

In the next session, I’ll cut the ends of the table and work on profiling the edges.

What do you think of the profile?  Does it suit the table?  Or do you think a round-over profile or another shape would look better?  Leave me a comment!

Maple Trestle Table, Session 20 – A Little Sanding, then More Sanding

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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;
Session 18 - Attachment Strips and Power Carving; and
Session 19 – Refining the Sculpted Base.

(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 Welcome to Session 20 of the Maple Trestle Table! #flairww -1:05 PM May 20th, 2012

FlairWoodworks Here’s where I left off last night. I first have to decide if I’m happy with the shape or if it needs more. #flairww -1:05 PM May 20th, 2012

FlairWoodworks Have you checked out the slideshow showing the progress on the Maple Trestle Table? #flairww -1:10 PM May 20th, 2012

FlairWoodworks I want to round over the ends more. #flairww -1:19 PM May 20th, 2012

FlairWoodworks Much better! #flairww -1:23 PM May 20th, 2012

FlairWoodworks From Abranet HD 40-grit sanding discs, I’m progressing to HD 60-grit. This should not take long. #flairww -1:36 PM May 20th, 2012

FlairWoodworks I’m halfway done with the Abranet HD 60-grit. The stretcher has some dings so it needs to be sanded too. #flairww -2:03 PM May 20th, 2012

FlairWoodworks Break time! #flairww -2:29 PM May 20th, 2012

FlairWoodworks Okay, back to work after a brief call with @GarthTW2. Yep, the toolmaking business is keeping me busy too! #flairww -2:49 PM May 20th, 2012

FlairWoodworks I’ve sanded this leg with the 80-grit on the sander. Now I need to hand-sand the three tight areas. #flairww -3:03 PM May 20th, 2012

FlairWoodworks I’ve finished sanding the first leg. Now I’m hand-sanding the leg/stretcher joint. #flairww -3:19 PM May 20th, 2012

FlairWoodworks I’ve sanded the stretcher and am now working on the other leg/stretcher joint. #flairww -3:36 PM May 20th, 2012

FlairWoodworks Ok, I’m done sanding the second leg/stretcher transition. I get a hand-sanding break while I use my Mirka CEROS to sand the leg. #flairww -3:56 PM May 20th, 2012

FlairWoodworks Now back to hand-sanding to finish the 80-grit stage. #flairww -4:10 PM May 20th, 2012

GarthTW2 @FlairWoodworks Need another phone chat to keep the momentum going? :) -4:14 PM May 20th, 2012

FlairWoodworks Ha ha! I do hand-sand well when on the phone! #flairww RT @GarthTW2: @FlairWoodworks Need another phone chat to keep the momentum going? :) -4:16 PM May 20th, 2012

FlairWoodworks I’m finished hand-sanding with 80-grit but I found a low spot that was missed. I will use my random orbit sander to level this area. #flairww -4:31 PM May 20th, 2012

FlairWoodworks I’m done sanding with 80-grit. Lunch time now! #flairww -4:43 PM May 20th, 2012

FlairWoodworks Back from lunch, I’ll continue sanding the table’s base, this time with 120-grit Abranet abrasive paper. #flairww -5:41 PM May 20th, 2012

FlairWoodworks For the 80-grit stage, I used one disc on my Mirka random orbit sander and one for hand-sanding. Each has a little more life. #flairww -5:45 PM May 20th, 2012

FlairWoodworks I first sanded the exposed end-grain surfaces using my sander without the interface pad. The interface pad is attached here. #flairww -5:53 PM May 20th, 2012

FlairWoodworks I’m doing some hand sanding while listening to @ravinheart’s live broadcast. #flairww -6:09 PM May 20th, 2012

FlairWoodworks I’ve got one leg sanded with 120-grit abrasive now. Can you see any difference? #flairww -7:04 PM May 20th, 2012

BCcraftmaster @FlairWoodworks love me some maple! -7:06PM May 20th, 2012

FlairWoodworks With which woods do you normally work? #flairww RT @BCcraftmaster: @FlairWoodworks love me some maple! -7:07 PM May 20th, 2012

BCcraftmaster @FlairWoodworks still fairly new so I’ve been mixing it up as much as possible just to get them “under my belt” as of now, walnut is my fav -7:09PM May 20th, 2012

BCcraftmaster @FlairWoodworks readily available and cheap in eastern PA and it looks awesome with oil! -7:10PM May 20th, 2012

FlairWoodworks @BCcraftmaster I’ll trade you maple for walnut! I have access to lots of maple! -7:11PM May 20th, 2012

BCcraftmaster @FlairWoodworks what’s shipping on one of those slabs? Hahhha -7:12PM May 20th, 2012

FlairWoodworks @BCcraftmaster Expensive, probably! -7:12PM May 20th, 2012

BCcraftmaster @FlairWoodworks #crosscountrycolaboration -7:15PM May 20th, 2012

FlairWoodworks Not to mention #CrossBorder @BCcraftmaster #crosscountrycolaboration -7:22PM May 20th, 2012

BCcraftmaster @FlairWoodworks can’t wait to see this table flipped right side up. -7:25PM May 20th, 2012

FlairWoodworks @BCcraftmaster The base is right side up… -7:28PM May 20th, 2012

BCcraftmaster @FlairWoodworks you #flipped it???? -7:32PM May 20th, 2012

BCcraftmaster @FlairWoodworks or is it just not attached to the top yet? -7:32PM May 20th, 2012

FlairWoodworks @BCcraftmaster It’s been upright since I started sanding. It’s sitting on the top instead of the other way around. -7:33PM May 20th, 2012

BCcraftmaster @FlairWoodworks ohhhhhhh.. how many more hours do you think you have left? -7:35PM May 20th, 2012

FlairWoodworks Ha ha ha… lots! RT @BCcraftmaster: @FlairWoodworks ohhhhhhh.. how many more hours do you think you have left? -7:36PM May 20th, 2012

BCcraftmaster @FlairWoodworks well stop tweeting me and get back to work!! :-) -7:43PM May 20th, 2012

FlairWoodworks @BCcraftmaster Well, after 5 hours of sanding, you can understand that I don’t mind taking a few seconds to reply to you! Okay, okay… :) -7:45PM May 20th, 2012

FlairWoodworks I decided to reshape the feet. They are now more rounded on top. #flairww -7:53 PM May 20th, 2012

FlairWoodworks This is why I don’t sand one section to completion before another. #flairww -7:55 PM May 20th, 2012

FlairWoodworks This makes the feet appear to taper when viewed from above. #flairww -8:03 PM May 20th, 2012

FlairWoodworks I shaped the foot with my block plane, then started smoothing the facets with 120-grit paper. See the difference? #flairww -8:19 PM May 20th, 2012

FlairWoodworks The feet are reshaped and sanded to 120-grit. Now for 180-grit. #flairww -8:14 PM May 20th, 2012

FlairWoodworks It’ll be all hand-sanding from here on. #flairww -8:16 PM May 20th, 2012

FlairWoodworks Since I’m not using the random orbit sander anymore, I’m switching to sandpaper folded in quarters. #flairww -8:22 PM May 20th, 2012

FlairWoodworks Norton 3X is as effective as the Abranet and cheaper. #flairww-8:23 PM May 20th, 2012

FlairWoodworks For hand-sanding non-flat objects, I have no at-source dust collection. #flairww -8:36 PM May 20th, 2012

FlairWoodworks I gave away my portable air filtration unit in an early Overflow giveaway because I never needed it. [Subscribe to this blog to be notified when new articles, including Overflow Giveaways, are posted!] #flairww -8:37 PM May 20th, 2012

FlairWoodworks As a result, I’ve moved into the adjacent machine shop equipped with an air filtration unit, windows and doors. #flairww -8:38 PM May 20th, 2012

TheWoodBug thank you :) ! RT @FlairWoodworks I decided to reshape the feet. -9:06

FlairWoodworks This is why I am hand-sanding the rest of the way. #flairww -9:17 PM May 20th, 2012 Tumblewood Your ROS must’ve grabbed some grit. RT @FlairWoodworks: This is why I am hand-sanding the rest of the way. #flairww -9:34

FlairWoodworks I’m very happy to tell you that I am done sanding the base. #flairww -10:00 PM May 20th, 2012

FlairWoodworks You’re welcome? RT @TheWoodBug: @FlairWoodworks thank you :) ! RT @FlairWoodworks I decided to reshape the feet.

woodshaver101 @FlairWoodworks its coming together.are you going to match the radius on the legs on the tops outside edge?looking good.

FlairWoodworks @woodshaver101 I haven’t decided yet! That decision will be coming up shortly though! #flairww -10:11 PM May 20th, 2012

FlairWoodworks Upon close inspection under the good lighting in my bench room, the base still needs more sanding. #flairww -10:31 PM May 20th, 2012

FlairWoodworks I drilled and counterbored a hole in each attachment strip for bolts to secure the base to the top. #flairww -10:39 PM May 20th, 2012

FlairWoodworks I’m thinking about an edge profile for the table right now. #flairww -10:42 PM May 20th, 2012

FlairWoodworks Not happy with my hand-sanding, I decided to try sanding to 320-grit with my random orbit sander. It seems to work well. #flairww -11:00 PM May 20th, 2012

FlairWoodworks However, I’ve had enough sanding for today. It’s time for a shower, then dinner. #flairww -11:00 PM May 20th, 2012

uppercutwood @FlairWoodworks didya have a good one -11:02 PM May 20th, 2012

FlairWoodworks I made a lot of progress. I’ve still got a lot of work to do though! #flairww RT @uppercutwood: @FlairWoodworks didya have a good one -11:03 PM May 20th, 2012

I’m not quite done sanding the base, but most of it is done.  You know there’s more to come!  Care to leave a comment?

Maple Trestle Table, Session 19 – Refining the Sculpted Base

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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 18 – Attachment Strips and Power Carving

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3

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; and
Session 17 - Two Feet for Two Legs.

(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 And… into the shop I go! First thing I do: turn on the lights; then remove the clamps! #flairww -1:33 PM May 17th, 2012

FlairWoodworks I’ll cut the tenons flush. #flairww -1:38 PM May 17th, 2012

FlairWoodworks Because I want to do other things today, I’m not using my small, fine-toothed flush-cut saw. #flairww -1:41 PM May 17th, 2012

FlairWoodworks I then used a block plane to set the tenon flush. #flairww -1:43 PM May 17th, 2012

FlairWoodworks The base is assembled. It still needs to be sculpted. #flairww -1:50 PM May 17th, 2012

FlairWoodworks I cut two attachment strips which will be fastened to the legs and mortised into the battens. #flairww -2:11 PM May 17th, 2012

FlairWoodworks The purpose of these strips is to secure the base to the top and conceal the centre two bolt holes. #flairww -2:12 PM May 17th, 2012

FlairWoodworks In the finished table, only the two outermost bolts will be used. #flairww -2:12 PM May 17th, 2012

FlairWoodworks It took some careful layout to position the battens. Next, I’ll fasten them with screws. #flairww -2:39 PM May 17th, 2012

FlairWoodworks I used a 17/64″ transfer punch to mark the location of the 9/32″ clearance holes. #flairww -2:59 PM May 17th, 2012

FlairWoodworks The smaller punch is easier to use because there is no friction between it and the hole. #flairww -2:59 PM May 17th, 2012

FlairWoodworks The mark could be out by 1/128″ but I don’t care. #flairww -3:00 PM May 17th, 2012

FlairWoodworks To guide the drill bit, I used my drill press to drill through a block of scrap wood. #flairww -3:08 PM May 17th, 2012

FlairWoodworks E-mails are coming in non-stop today. #flairww -3:10 PM May 17th, 2012

FlairWoodworks One attachment strip is mounted. #flairww -3:12 PM May 17th, 2012

FlairWoodworks I use my cordless drill/driver to install the screws most of the way but always finish by hand. #flairww -3:17 PM May 17th, 2012

FlairWoodworks Here’s a picture of the base for you to look at while I tidy up my shop a little. #flairww -3:19 PM May 17th, 2012

CashFromCraft @FlairWoodworks I find setting the cluch to be helpful when driving a number in the same operation. -3:22 PM May 17th, 2012

FlairWoodworks @CashFromCraft The drill’s clutch can be helpful, but I don’t find it accurate enough due to density variances. #flairww -3:24 PM May 17th, 2012

FlairWoodworks @CashFromCraft I have a much greater sensitivity when using a screwdriver than a power tool. #flairww -3:25 PM May 17th, 2012

DyamiPlotke @FlairWoodworks why not adjust the torque setting on the screw gun? -3:31 PM May 17th, 2012

FlairWoodworks A screwdriver allows greater sensitivity. RT @DyamiPlotke: @FlairWoodworks why not adjust the torque setting on the screw gun? -3:31 PM May 17th, 2012

FlairWoodworks Next, I’ll trace the position of the attachment strips onto the battens. #flairww -3:41 PM May 17th, 2012

FlairWoodworks I’ll remove the two centre bolts which are no longer needed and rout the pocket for the attachment strip. #flairww -3:46 PM May 17th, 2012

FlairWoodworks Ready to rout! #flairww -3:57 PM May 17th, 2012

FlairWoodworks My router fence slipped and caused this gouge. I’ll have to patch it. #flairww -4:21 PM May 17th, 2012

FlairWoodworks To fix the gouge, I first routed a straight-edged pocket. #flairww -4:31 PM May 17th, 2012

FlairWoodworks I turned the head of my marking gauge around to scribe a straight line. #flairww -4:33 PM May 17th, 2012

FlairWoodworks I cut a patch and scribed it onto the batten. #flairww -4:45 PM May 17th, 2012

FlairWoodworks I fit and glued the patch in place. After the glue dries, I’ll trim it flush. #flairww -4:59 PM May 17th, 2012

FlairWoodworks I need to finish the patch before starting the sculpting of the base. I’ll sand the underside of the table in the meantime. #flairww -5:15 PM May 17th, 2012

FlairWoodworks I simply unbolted the battens to allow uninhibited sanding of the surface. #flairww -5:26 PM May 17th, 2012

FlairWoodworks The first Abranet HD 80-grit disc lasted for almost half of the surface. The one on the bench is dull. #flairww -5:33 PM May 17th, 2012

FlairWoodworks This is the first time I’ve used the Abranet HD discs aside from testing. What’s nice about them is they’re either sharp or not. #flairww-5:42 PM May 17th, 2012

FlairWoodworks That means there is no doubt about whether the discs need to be changed. #flairww -5:42 PM May 17th, 2012

FlairWoodworks I consumed three 80-grit Abranet HD discs smoothing the bottom. #flairww -5:49 PM May 17th, 2012

DyamiPlotke @FlairWoodworks that doesn’t seem like long. Mine last multiple projects. -5:49 PM May 17th, 2012

DyamiPlotke @FlairWoodworks wait, isn’t abranet the mesh ones? That’s what I was referring to. -5:49 PM May 17th, 2012

FlairWoodworks @DyamiPlotke The regular Abranet discs are mesh and seem to last longer but don’t cut as quickly as the Abranet HD. #flairww -5:50 PM May 17th, 2012

FlairWoodworks If I only did horizontal, flat surfaces, I would have bought a Festool sander because they have less vibration. #flairww -5:52 PM May 17th, 2012

FlairWoodworks But I find the size and balance (and weight) of the Festool sanders not as conducive to sculpting, especially with one hand. #flairww -5:53 PM May 17th, 2012

FlairWoodworks The Abranet HD discs are more agressive than regular Abranet discs. From the HD 80-grit, I could go to regular 80 or regular 120. #flairww -5:54 PM May 17th, 2012

FlairWoodworks According to this twitter feed, it’s now been one hour since I glued in the patch so I’ll go back and finish the job. #flairww -6:00 PM May 17th, 2012

FlairWoodworks I used my side rabbet plane to clean up the inside edge of the patch. My #4 bench plane flushed the surface. #flairww-6:06 PM May 17th, 2012

FlairWoodworks Do you know what comes next? #flairww -6:08 PM May 17th, 2012

FlairWoodworks Yep! The attachments strips fit in the mortised battens! #flairww -6:11 PM May 17th, 2012

FlairWoodworks Sculping comes next! #flairww -6:12 PM May 17th, 2012

FlairWoodworks I need to trim the end of this leg so that it does not cover the bolt. #flairww  -6:14 PM May 17th, 2012

FlairWoodworks Cancel plans for tonight – I’m power carving! #flairww -6:29 PM May 17th, 2012

FlairWoodworks I’m wearing a long-sleeved jacket, gloves, goggles, ear muffs, and a dust mask. #flairww -6:33 PM May 17th, 2012

MansFineFurn @FlairWoodworks tweet-along’s hidden side benefit: work timer -6:36 PM May 17th, 2012

FlairWoodworks Sculpting is going well so far. #flairww -6:51 PM May 17th, 2012

FlairWoodworks The legs are rounded at the top and transition into a rectangular cross section at the bottom. #flairww -7:42 PM May 17th, 2012

FlairWoodworks I’ve finished power carving outside so I brought the base back inside where I’ll refine the shape with rasps and sandpaper. #flairww -7:57 PM May 17th, 2012

DyamiPlotke @FlairWoodworks what did you power carve it with? -8:02 PM May 17th, 2012

FlairWoodworks @DyamiPlotke I was just thinking that I should take a picture of my grinder and Arbortech disc. #flairww -8:05 PM May 17th, 2012

DyamiPlotke @FlairWoodworks How is it to control? Taking a grinder to wood has always intimidated me (concrete & metal I grind away on). -8:07 PM May 17th, 2012

FlairWoodworks @DyamiPlotke It is certainly easier to dig into wood and cause a catch (than with concrete or metal) but I have great control. #flairww -8:09 PM May 17th, 2012

FlairWoodworks The surface left by the Arbortech disc is far from smooth. #flairww -8:12 PM May 17th, 2012

DyamiPlotke @FlairWoodworks I’ll have to pick up an arbortec blade and try it out. Can you recommend one? -8:12 PM May 17th, 2012

FlairWoodworks @DyamiPlotke Arbortech and King Arthur’s Tools are two makers of power carving wheels. #flairww -8:16 PM May 17th, 2012

FlairWoodworks @DyamiPlotke I use THIS ONE. The carbide cutters last a really long time! #flairww -8:17 PM May 17th, 2012

FlairWoodworks @DyamiPlotke If you’re serious about power carving, it’s a great way to go. It cuts in all directions. #flairww -8:18 PM May 17th, 2012

FlairWoodworks The Lancelot and Squire wheels don’t cut well on the draw stroke using the cutter’s face.  The edge of the cutter does the cutting. #flairww -8:19 PM May 17th, 2012

FlairWoodworks Ready to refine… with 40-grit! #flairww-8:25 PM May 17th, 2012

FlairWoodworks This sharp 40-grit paper doesn’t make dust – it makes little shavings! #flairww -8:28 PM May 17th, 2012

This video shows how I use my 6″ Mirka CEROS (Compact Electric Random Orbit Sander) and a 40-grit Abranet HD disc  to sand the sculpted legs.  I normally wear a dust mask while sanding, but I I forgot while thinking about camera angles.  Use a dust mask!  The CEROS is very good at collecting dust when used on flat surfaces but not as good when sanding rounded surfaces.  The Abranet HD discs are less effective at catching dust from the regular Abranet discs.

This movie requires Adobe Flash for playback.

DyamiPlotke @FlairWoodworks I’ll check on a PC [power carver] later, but is there a particular model (grit?) good for a newb? -8:30 PM May 17th, 2012

DyamiPlotke @FlairWoodworks excellent! -8:30 PM May 17th, 2012

FlairWoodworks @DyamiPlotke As far as an angle grinder, look for one that is compact and lightweight. Power isn’t really a factor. #flairww -8:54 PM May 17th, 2012

FlairWoodworks @DyamiPlotke Paddle switches are suppoed to be more reliable than sliders which can get clogged with dust. #flairww -8:54 PM May 17th, 2012

woodshaver101 @FlairWoodworks things are coming together nicely. keep it up. -8:56 PM May 17th, 2012

FlairWoodworks The sander does not do well on more severe convex sections. #flairww -9:01 PM May 17th, 2012

FlairWoodworks The foam interface pad allows the sander to handle curves like this but doesn’t fair the surface as well and is less aggressive. #flairww-9:01 PM May 17th, 2012

FlairWoodworks I’ll first fair the concave sections with a rasp, then use the sander with the 3/8″ foam interface pad and finer sandpaper. #flairww -9:03 PM May 17th, 2012

FlairWoodworks When it comes to rasps, I like them as coarse as they come. I rely on them to establish shape, not for smoothing. #flairww -9:08 PM May 17th, 2012

FlairWoodworks I don’t use templates or layout lines. Instead, I trust my eye and sense of touch. #flairww -9:11 PM May 17th, 2012

FlairWoodworks All I had for lunch was a slice of tiramisu, so I think I’ll need to stop for food soon. #flairww -9:14 PM May 17th, 2012

FlairWoodworks A round spokeshave would work well to fair this concave curve. #flairww -9:26 PM May 17th, 2012

FlairWoodworks Here’s where I’ll leave it for the night. #flairww -10:21 PM May 17th, 2012

Next comes more sculpting.  Care to leave a comment?

Maple Trestle Table, Session 9 – Mortises the Slow Way (or Why I’m Buying a Domino XL)

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16

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; and
Session 8 - Make Your Tools Work for You and Flattening the Top.

(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 haven’t worked on the table for four days and I’m finally getting a chance to get back at it today! Follow along with #flairww. -2:24 PM Apr 30th, 2012

FlairWoodworks When I left off, I had just finished flattening the table top. Joinery between the two slabs comes next. #flairww -2:26 PM Apr 30th, 2012

FlairWoodworks I’ve laid out on the faces where I want the mortises to be located. There will be three 3″-long mortises. #flairww -2:38 PM Apr 30th, 2012

FlairWoodworks Since I can use the same layout for the other side, I put pencil marks on my aluminum ruler. #flairww -2:41 PM Apr 30th, 2012

FlairWoodworks The layout of the second half was ridiculously easy. Now I need to flip over the top and separate the two halves. #flairww -2:44 PM Apr 30th, 2012

FlairWoodworks Maybe I should clean up some of these plane shavings first… #flairww  -2:48 PM Apr 30th, 2012

FlairWoodworks Two bags of shavings! #flairww -2:55 PM Apr 30th, 2012

FlairWoodworks In the shavings, I found the transfer punch I’d used when I installed the battens. #flairww -2:57 PM Apr 30th, 2012

FlairWoodworks Well, that was kind of exciting. I didn’t break a horse, but I did knock over one. #flairww -3:02 PM Apr 30th, 2012

FlairWoodworks I’m using a socket adapter in my drill to quicky remove the lag bolts. #flairww -3:05 PM Apr 30th, 2012

FlairWoodworks They’re free! #flairww -3:09 PM Apr 30th, 2012

FlairWoodworks I’ll be using a plunge router to cut the mortises. This is easiest with the surface being mortised in the horizontal position (and the slab vertical). #flairww -3:13 PM Apr 30th, 2012

FlairWoodworks Had I been able to get a @FestoolUSA Domino XL, I could have easily cut the mortises with the slabs in the horizontal position. #flairww -3:14 PM Apr 30th, 2012

FlairWoodworks I cannot imagine using a stationary machine such as a horizontal boring machine/slot mortiser to mortise these slabs. #flairww -3:15 PM Apr 30th, 2012

FlairWoodworks I want really deep mortises and my Milwaukee plunge router has a greater plunge capacity than my Porter Cable. #flairww -3:17 PM Apr 30th, 2012

FlairWoodworks I used my saddle square to transfer the layout lines from the face to the edge. #flairww -3:21 PM Apr 30th, 2012

FlairWoodworks I use a large X to clearly mark which sections receive mortises. #flairww  -3:22 PM Apr 30th, 2012

FlairWoodworks I clamped a straight piece of wood to the router’s base to act as a fence. #flairww -3:25 PM Apr 30th, 2012

FlairWoodworks Why? I’m not positive that the slabs are of even thickness so I am using the face as a reference surface. #flairww -3:26 PM Apr 30th, 2012

FlairWoodworks It’s the distance from the face to the mortise that is important. I used the CS-2 because I’d like them to be roughly centred.#flairww -3:27 PM Apr 30th, 2012

HalfInchShy @FlairWoodworks THAT’S where my CS-2 went! :-P Nice build; I’m having popcorn playing with Domizilla thinking how useful it would be #flairww -3:27 PM Apr 30th, 2012

FlairWoodworks @HalfInchShy Thanks :) I hope @BridgeCityTools makes you a new CS-2 soon! #flairww -3:28 PM Apr 30th, 2012

FlairWoodworks Because of the live edge, I moved the edge of one mortise. #flairww -3:40 PM Apr 30th, 2012

HalfInchShy @FlairWoodworks I like how you Xed out the X for the mortise. Is that a woodworking double negative? #flairww -3:53 PM Apr 30th, 2012

HalfInchShy @FlairWoodworks More seriously, are you going to use the router horizontally or have you mounted the slab vertically like you did before? #flairww-3:53 PM Apr 30th, 2012

FlairWoodworks @HalfInchShy I’ve got the slab clamped vertically to a sawhorse. #flairww -3:59 PM Apr 30th, 2012

FlairWoodworks I’ve routed the first set of mortises. They are 2-1/2″ deep which is the capacity of my router bit. #flairww -4:00 PM Apr 30th, 2012

FlairWoodworks Unfortunately, my Milwaukee plunge router requires me to hold down a stiff plunge lock lever with my thumb in order to release the plunge lock. #flairww -4:01 PM Apr 30th, 2012

FlairWoodworks My thumb is quite sore after just three mortises… #flairww -4:01 PM Apr 30th, 2012

FlairWoodworks It was a fairly slow process to cut a mortise, too. #flairww -4:02 PM Apr 30th, 2012

FlairWoodworks And now I need to set up to rout the set of mortises on the other end of this slab. #flairww -4:05 PM Apr 30th, 2012

FlairWoodworks You can smell burnt wood from the friction of the non-fluted shank against the mortise walls. #flairww -4:06 PM Apr 30th, 2012

FlairWoodworks Oh, I forgot to mention that I’m using a 1/2″ diameter up-spiral router bit. I wouldn’t want to use a straight bit for deep mortises because they don’t clear chips as well. #flairww -4:07 PM Apr 30th, 2012

FlairWoodworks It took me over 2 minutes to rout each of the three mortises. #flairww -4:08 PM Apr 30th, 2012

FlairWoodworks I guess I’ll rout this set of mortises on my knees. #flairww -4:11 PM Apr 30th, 2012

FlairWoodworks I applied some DriCote to the router bit. It’s supposed to reduce friction and keep the bit clean. #flairww -4:15 PM Apr 30th, 2012

FlairWoodworks I’m going to see if I can defeat the sprung plunge lock on my router. #flairww -4:17 PM Apr 30th, 2012

FlairWoodworks There’s the culprit! Remove the spring and I’m a happy woodworker! #flairww -4:19 PM Apr 30th, 2012

FlairWoodworks I bolted the lever back on, positioned where it is comfortable to operate. Here the plunge is locked. #flairww -4:22 PM Apr 30th, 2012

FlairWoodworks And I push the lever down to plunge freely! #flairww -4:23 PM Apr 30th, 2012

FlairWoodworks I might have broken this handle when I knocked over the saw horse. #flairww -4:27 PM Apr 30th, 2012

FlairWoodworks Hmm… when the plunge mechanism is unlocked, there is noticeable play in one column. Before… #flairww -4:32 PM Apr 30th, 2012

FlairWoodworks … and after. I don’t know if you can see it, but I can see and feel it. Not good. #flairww -4:33 PM Apr 30th, 2012

FlairWoodworks My Porter Cable has some wiggle too. It’s not as much but still significant at the end of a bit protruding 2-1/2″ from the collet. #flairww-4:34 PM Apr 30th, 2012

malphrusoxide: if you want a better way to measure runout, chuck up a piece of round stock. less tricky to see/measure than a bit. -4:35 PM Apr 30th, 2012

FlairWoodworks @malphrusoxide Good idea, but it’s plenty clear when you see it in person. I’m evaluating my options right now. #flairww -4:37 PM Apr 30th, 2012

malphrusoxide @FlairWoodworks gotcha. got very little experience with rebuilding routers, but i know the feeling. good luck! -4:38 PM Apr 30th, 2012

FlairWoodworks @malphrusoxide I’m thinking upgrade, not rebuild. I don’t think it’s a wear issue becuse it has so little use. Blame tolerances. #flairww -4:39 PM Apr 30th, 2012

malphrusoxide @FlairWoodworks i did the same thing. went from old craftsman to new bosch. = night & day. -4:40 PM Apr 30th, 2012

FlairWoodworks Nice. #flairww RT @malphrusoxide: @FlairWoodworks i did the same thing. went from old craftsman to new bosch. = night & day. -4:41 PM Apr 30th, 2012

FlairWoodworks @malphrusoxide I have a Bosch 1617EVS plunge router somewhere… gonna find it and see how it feels. #flairww -4:42 PM Apr 30th, 2012

malphrusoxide @FlairWoodworks cool. forget which model bosch i ended up with. was working against a deadline so i didn’t get to shop around like i prefer. -4:43 PM Apr 30th, 2012

FlairWoodworks I have no idea where the plunge base is. I never change the Bosch 1617 bases because it is very difficult. #flairww-4:46 PM Apr 30th, 2012

DyamiPlotke: my local tool monger has a number of used 3HP PC plunge routers in stock now if you need a new one. -4:52 PM Apr 30th, 2012

FlairWoodworks I found the plunge base and managed to swap over the router without any drama. The plunge feels good! #flairww -4:53 PM Apr 30th, 2012

FlairWoodworks Are they good? #flairww RT @DyamiPlotke: my local tool monger has a number of used 3HP PC plunge routers in stock now if you need a new one. -4:54 PM Apr 30th, 2012

FlairWoodworks The Bosch 1617EVS plunges about 2-3/8″ so it might work.#flairww -4:56 PM Apr 30th, 2012

FlairWoodworks This table will be for sale when it is complete. E-mail me if you are interested. #flairww -5:03 PM Apr 30th, 2012

FlairWoodworks So far the cost is a Domino XL and OF1400 :) #flairww -5:04 PM Apr 30th, 2012

DyamiPlotke @FlairWoodworks I have 1 I bought used & like it equal 2 my Festool OF2000 Different feel but both very nice The PC is big & well balanced -5:05 PM Apr 30th, 2012

malphrusoxide @FlairWoodworks dominoXL v. domino… thoughts? worth the extra coin? -5:05 PM Apr 30th, 2012

FlairWoodworks @malphrusoxide Totally different applications. For me, the XL makes more sense. But I already have the DF-500. #flairww -5:08 PM Apr 30th, 2012

FlairWoodworks @malphrusoxide So for me, yes. #flairww -5:08 PM Apr 30th, 2012

FlairWoodworks To ensure the fence is positioned the same on my Bosch router, I first plunged the bit into an existing mortise. #flairww -5:16 PM Apr 30th, 2012

FlairWoodworks Ok… my Bosch router is now set up. Next question: does the switch work? #flairww -5:18 PM Apr 30th, 2012

FlairWoodworks Yes, it does work. #flairww -5:21 PM Apr 30th, 2012

FlairWoodworks Here goes… mortise set 2… #flairww -5:23 PM Apr 30th, 2012

This video showed how I routed the mortises.  In this real-time video, I routed one of three mortises in this end of the slab.  There were 12 mortises in total.  (Duration – 3:07)

This movie requires Adobe Flash for playback.

woodshaver101 @FlairWoodworks routing bits limit depth,but are precise,I tend to cut deep mortises with a mortise chisel. good luck -5:31 PM Apr 30th, 2012

FlairWoodworks … and… done that set of mortises! #flairww -5:34 PM Apr 30th, 2012

FlairWoodworks @woodshaver101 How long would a 3″ long, 1/2″ wide, and 2-1/2″ deep take you to chop by hand? #flairww -5:36 PM Apr 30th, 2012

FlairWoodworks So the second set of mortises took 10 minutes… about 30% longer than the first set. #flairww -5:38 PM Apr 30th, 2012

FlairWoodworks Before routing this mortise, I should check that it won’t go into this cavity. #flairww -5:43 PM Apr 30th, 2012

FlairWoodworks I moved the mortise in by 3/4″ to be safe. #flairww -5:48 PM Apr 30th, 2012

FlairWoodworks Since these pieces are a little awkward to turn upside-down to knock the sawdust out of the mortises, I’m using a stick to scoop chips towards the vacuum hose. #flairww -6:02 PM Apr 30th, 2012

FlairWoodworks Here’s the third set of mortises done. I added a 1/2″ deep haunch and will do the same with the others. #flairww -6:06 PM Apr 30th, 2012

BCcraftmaster @FlairWoodworks I have that same set up. Do you have problems getting the motor into the bases? Is the side of your motor all scratched up? -6:06 PM Apr 30th, 2012

FlairWoodworks @BCcraftmaster Yes and yes! I took some fine wet/dry paper (dry) and sanded the body smooth. It’s better but not great. #flairww -6:07 PM Apr 30th, 2012

FlairWoodworks The last mortise has been routed. Now I need to clear out the mortises and make floating tenons! #flairww -6:40 PM Apr 30th, 2012

FlairWoodworks My crevice nozzle, very conveniently, is a friction fit in the 1/2″ wide mortises. #flairww -6:41 PM Apr 30th, 2012

FlairWoodworks So the mortises I cut with my Milwaukee were 2-1/2″ deep and the mortises cut with my Bosch were only 2-1/8″ deep. #flairww -6:50 PM Apr 30th, 2012

FlairWoodworks I’m going to extend the bit further out of the collet (still with a full 1″ in the collet) and make the mortises deeper. #flairww -6:51 PM Apr 30th, 2012

FlairWoodworks Okay, NOW the routing is done. #flairww -7:05 PM Apr 30th, 2012

FlairWoodworks Like my Milwaukee, my Bosch also has a spring-loaded plunge lock. It’s not as stiff as the Milwaukee, but my thumb’s still sore.#flairww -7:06 PM Apr 30th, 2012

FlairWoodworks I found some maple for the floating tenons. The next step is to plane it to the correct thickness. #flairww -7:12 PM Apr 30th, 2012

FlairWoodworks To ensure the floating tenons were the right thickness, I planed a test piece ahead of the good stock. #flairww -7:59 PM Apr 30th, 2012

FlairWoodworks I then used the bandsaw to define the tenons. I’ll use a fret saw to finish the job. #flairww -8:00 PM Apr 30th, 2012

FlairWoodworks But first… dinner! #flairww -8:00 PM Apr 30th, 2012

woodshaver101 @FlairWoodworks that should hold good.  -8:32 PM Apr 30th, 2012

woodshaver101 @FlairWoodworks about 5 min I’m a mortise cutting mad man -8:33 PM Apr 30th, 2012

FlairWoodworks That is really fast! Can you take a video? RT @woodshaver101: @FlairWoodworks about 5 min I’m a mortise cutting mad man -8:38 PM Apr 30th, 2012

FlairWoodworks I’m back in the shop finishing off the floating, haunched tenons. #flairww -9:04 PM Apr 30th, 2012

FlairWoodworks Here is one tenon complete and partially dry-fit. It’s a friction fit and will be a struggle to remove. #flairww -9:24 PM Apr 30th, 2012

FlairWoodworks I’ve got the second floating haunched tenon cut as well. I think they need to be a bit thinner though. #flairww -9:39 PM Apr 30th, 2012

FlairWoodworks I ran the tenons through the thickness sander a few times to get it to the perfect thickness. #flairww -9:55 PM Apr 30th, 2012

FlairWoodworks That’s a big tenon! It makes XL Dominos look diminutive.#flairww -10:03 PM Apr 30th, 2012

FlairWoodworks Now I get to put the two halves back together for a dry fit with the tenons! This is EXCITING! #flairww -10:07 PM Apr 30th, 2012

gvmcmillan @FlairWoodworks I always like dry fitting time – it’s when you really get to see if it’s going to work and what it will look like. #flairww -10:09 PM Apr 30th, 2012

FlairWoodworks @gvmcmillan I’m excited and nervous. Will my deadblow hammer be seeing a lot of work? #flairww -10:11 PM Apr 30th, 2012

HalfInchShy @FlairWoodworks you even make tenons outta slabs! :) nah no heavy work with the deadblow… you’ve thought of everything (I think :) #flairww -10:13 PM Apr 30th, 2012

FlairWoodworks @HalfInchShy Hey – this isn’t doll furniture! #flairww -10:15 PM Apr 30th, 2012

FlairWoodworks The deadblow hammer is for scale. If this doesn’t impress you, I want to see what you do! #flairww -10:17 PM Apr 30th, 2012

FlairWoodworks The first joint went together easily…. #flairww -10:19 PM Apr 30th, 2012

FlairWoodworks The second side is going to need some clamping pressure.#flairww -10:21 PM Apr 30th, 2012

FlairWoodworks I wish I had some really big clamps right now. #flairww -10:23 PM Apr 30th, 2012

luggermatt @FlairWoodworks Ratchet strap around the end? -10:24 PM Apr 30th, 2012

FlairWoodworks If it comes to that, maybe… #flairww RT @luggermatt:@FlairWoodworks Ratchet strap around the end? -10:25 PM Apr 30th, 2012

luggermatt @FlairWoodworks I use them a lot on the boat. Good for ‘encouraging’ big joints into place ;-) -10:26 PM Apr 30th, 2012

FlairWoodworks With one slab butted against my workbench which was butted against the wall, I was able to use my deadblow to close the joint. – 10:29 PM Apr 30, 2012

FlairWoodworks Next, the countertop connectors are installed and tightened.#flairww -10:35 PM Apr 30th, 2012

FlairWoodworks Then the battens are reinstalled… #flairww -10:40 PM Apr 30th, 2012

FlairWoodworks I feel like a kid on Christmas day! #flairww -10:40 PM Apr 30th, 2012

FlairWoodworks The dry-fit tenons worked brilliantly. There’s no more than a paper’s thickness in deviation between the two slabs on the surface. #flairww-10:45 PM Apr 30th, 2012

FlairWoodworks Now… should I glue it? #flairww -10:45 PM Apr 30th, 2012

FlairWoodworks I’m going to clean up the shop while I ponder that. #flairww-10:46 PM Apr 30th, 2012

HalfInchShy @FlairWoodworks yes :) #flairww -10:46 PM Apr 30th, 2012

FlairWoodworks You’re probably right. Might be an intense glue-up! I’ll have to get some slow-cure glue. RT @HalfInchShy: @FlairWoodworks yes :)#flairww -10:47 PM Apr 30th, 2012

HalfInchShy @FlairWoodworks Oh definitely a slow cure; do you have a slow-cure epoxy? #flairww -10:48 PM Apr 30th, 2012

FlairWoodworks 5-minute? Um… no. RT @HalfInchShy: @FlairWoodworks Oh definitely a slow cure; do you have a slow-cure epoxy? #flairww -10:49 PM Apr 30th, 2012

HalfInchShy @FlairWoodworks Glue the tenons into one slab then you can take your time to get the other in position; wet w/glue slab 2s mortises #flairww-10:56 PM Apr 30th, 2012

HalfInchShy @FlairWoodworks once in position but before pushing together, apply glue to the tenons then push like hell, man! #flairww -10:56 PM Apr 30th, 2012

FlairWoodworks @HalfInchShy That’s definitely how I’d do it! #flairww -10:58 PM Apr 30th, 2012

HalfInchShy @FlairWoodworks I hear my neighbors chanting ‘Chris!’ ‘Chris!’ ‘Chris!’ I think they want to see glue-up. Man up. :) #flairww -10:59 PM Apr 30th, 2012

FlairWoodworks @HalfInchShy Oh, you…. #flairww -10:59 PM Apr 30th, 2012

HalfInchShy @FlairWoodworks It was either that or a Canucks joke… #flairww-11:00 PM Apr 30th, 2012

FlairWoodworks @HalfInchShy I don’t think I actually need a slow-curing glue, thought it could make it less stressful if I have trouble. #flairww -11:01 PM Apr 30th, 2012

FlairWoodworks On edge, the table is up to my chest! #flairww -11:03 PM Apr 30th, 2012

luggermatt @FlairWoodworks Jolly good :-) -11:03 PM Apr 30th, 2012

HalfInchShy @FlairWoodworks Then do your other idea and mix your own TB Extended; first slab do as usual; second wet mortises with TB-Ex #flairww -11:03 PM Apr 30th, 2012

HalfInchShy @FlairWoodworks When you wet the tenons just before pushing it together, use normal TB; home-brew extended wont skin in the mortise#flairww -11:04 PM Apr 30th, 2012

HalfInchShy @FlairWoodworks Get your brother to snap a pic of the table on edge with you behind it or peeking through the center #flairww -11:04 PM Apr 30th, 2012

FlairWoodworks It’s not so easy to get this spring-loaded plunge-lock lever back reinstalled! #flairww -11:34 PM Apr 30th, 2012

FlairWoodworks Okay, it wasn’t that hard – it just took some lateral thinking.#flairww -11:36 PM Apr 30th, 2012

FlairWoodworks I’m done in the shop for the night. Now for some video and blog editing. #flairww -11:45 PM Apr 30th, 2012

The top is nearing completion.  The legs and feet have yet to be started.  What’s next?  In Session 10, I began work on the legs!

I would be delighted if you left a comment.

Maple Trestle Table, Session 2 – Playing with Slabs

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11

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 link to the previous session.

Session 1 - Flat Boards are Boring

(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 like the split but it’s best shown on the side where the lower half protrudes further. #flairww -11:18 AM Apr 16th, 2012

FlairWoodworks The split is barely noticeable on this side. I’m going to change that by reducing the thickness of the top. #flairww -11:21 AM Apr 16th, 2012

cobwobbler @FlairWoodworks why do defects look so cool? -11:23 AM Apr 16th, 2012

FlairWoodworks I’m going to use mu angle grinder with an Arbortech wood-carving wheel. #flairww -11:23 AM Apr 16th, 2012

FlairWoodworks Because they are unique! RT @cobwobbler: @FlairWoodworks why do defects look so cool? -11:26 AM Apr 16th, 2012

FlairWoodworks I would normally do the outside but it’s raining today. I put up tarps to contain the mess. #flairww -11:26 AM Apr 16th, 2012

FlairWoodworks I wear tight-fitting gloves, goggles, ear protection and a dust mask when power carving. #flairww -11:27 AM Apr 16th, 2012

FlairWoodworks Here you can see the effect that I’m going for. #flairww -11:40 AM Apr 16th, 2012

Morton @FlairWoodworks Tarp doesn’t look like it’s doing much ;) -11:48 AM Apr 16th, 2012

FlairWoodworks The shape is established. Now for sanding. #flairww -11:54 AM Apr 16th, 2012

FlairWoodworks Here’s the pile of shavings I produced. #flairww -11:57 AM Apr 16th, 2012

FlairWoodworks Notice that they are shavings, not dust. #flairww -11:58 AM Apr 16th, 2012

FlairWoodworks They actually worked perfectly! RT @Morton: @FlairWoodworks Tarp doesn’t look like it’s doing much ;) -11:59 AM Apr 16th, 2012

BillGriggs @FlairWoodworks Clean it up with a Dust Deputy. -12:01 PM Apr 16th, 2012

FlairWoodworks Nah. One scoop with the dust pan and it’s gone. RT @BillGriggs: @FlairWoodworks Clean it up with a Dust Deputy. -12:03 PM Apr 16th, 2012

FlairWoodworks I put the round blade of my convex palm plane in my flat palm plane to quickly even the surface. #flairww -12:08 PM Apr 16th, 2012

FlairWoodworks To work a concave surface, either a short-soled plane works well. For more severe concave areas, I’d use the round plane. #flairww -12:09 PM Apr 16th, 2012

FlairWoodworks A plane works more quickly than a sander and does a better job of fairing the curve. #flairww -12:12 PM Apr 16th, 2012

FlairWoodworks With a sharp blade set for a fine cut, the plane even handles knots with ease. #flairww -12:19 PM Apr 16th, 2012

FlairWoodworks I have no problem working to within 1/16″ with the angle grinder which means less cleanup later. #flairww -12:22 PM Apr 16th, 2012

FlairWoodworks I follow up with 80-grit on the sander to further refine the surface and remove any tearout. #flairww -12:32 PM Apr 16th, 2012

FlairWoodworks It doesn’t look right. More shaping is required. #flairww -12:49 PM Apr 16th, 2012

BCcraftmaster @FlairWoodworks I like your saw horse set up. -12:50 PM Apr 16th, 2012

FlairWoodworksI can’t say enough about them. They are so versatile. RT @BCcraftmaster: @FlairWoodworks I like your saw horse set up. -1:00 PM Apr 16, 2012

FlairWoodworks My palm plane is too short to remove this hump so I’m switching to a longer plane. #flairww -1:17 PM Apr 16th, 2012

FlairWoodworks Perfect! #flairww -1:20 PM Apr 16th, 2012

FlairWoodworks If it feels fair, it’s fair. #flairww -1:37 PM Apr 16th, 2012

FlairWoodworks I use a thin-bladed knife to clear loose material out of the cracks. #flairww -1:39 PM Apr 16th, 2012

FlairWoodworks I broke off the end of a hacksaw blade to clean out the cracks. It’s longer and more flexible than my knife. #flairww -1:48 PM Apr 16th, 2012

FlairWoodworks I’m using this wooden block plane. It’s less fatiguing to use than metal planes, especially one-handed. #flairww -2:00 PM Apr 16th, 2012

FlairWoodworks It was the first plane I’d ever made. It works well, but the body needs some shaping. #flairww -2:01 PM Apr 16th, 2012

FlairWoodworks You should never hesitate to modify your tools if it makes them work better for you. #flairww -2:09 PM Apr 16th, 2012

FlairWoodworks I also rounded over one edge of the sole where my fingers curl over. #flairww -2:10 PM Apr 16th, 2012

CashFromCraft RT @FlairWoodworks: You should never hesitate to modify your tools if it makes them work better for you. #flairww -2:11 PM Apr 16th, 2012

FlairWoodworks That feels so nice! #flairww -2:11 PM Apr 16th, 2012

CashFromCraft @FlairWoodworks especially shop made tools! – 2:11 PM Apr 16th, 2012

FlairWoodworks Especially! But by no means only. RT @CashFromCraft: @FlairWoodworks especially shop made tools! - 2:12 PM Apr 16th, 2012

FlairWoodworks I used my block plane to begin rounding over the edges. I’m using my sander with foam interface pad to finish. #flairww -2:47 PM Apr 16th, 2012

FlairWoodworks The stretcher is done… at least for now. #flairww-3:04 PM Apr 16th, 2012

FlairWoodworks And here’s a look at the other side. #flairww -3:04 PM Apr 16th, 2012

FlairWoodworks Time for a lunch break. #flairww -3:05 PM Apr 16th, 2012

FlairWoodworks Any comments or questions so far? #flairww -3:06 PM Apr 16th, 2012

Tumblewood They are tools, after all!! RT @FlairWoodworks: You should never hesitate to modify your tools if it makes them work better for you. #flairww

FlairWoodworks Now that lunch is finished, I’m looking for materials for the rest of this table now that the stretcher is done. #flairww -4:54 PM Apr 16th, 2012

FlairWoodworks Playing with bookmatches for the top (like @Mansfinefurn). I have three slabs with which to work. #flairww -5:21 PM Apr 16th, 2012

FlairWoodworks Here’s one idea. All the outside edges are cut ad the inside edges are live. #flairww -5:37 PM Apr 16th, 2012

FlairWoodworks I’d probably cover the gap in the centre with glass. #flairww-5:39 PM Apr 16th, 2012

FlairWoodworks Yikes – where’d all the space I had go? #flairww -6:07 PM Apr 16th, 2012

FlairWoodworks Three more pieces of maple for other table parts. #flairww -6:16 PM Apr 16th, 2012

MansFineFurn @FlairWoodworks I won’t ask where you had to stand to get that pic -6:31 PM Apr 16th, 2012

FlairWoodworks Not on the roof! RT @MansFineFurn: @FlairWoodworks I won’t ask where you had to stand to get that pic -6:34 PM Apr 16th, 2012

FlairWoodworks And I begins… #flairww -6:21 PM Apr 16th, 2012

paulchinetti  Digging that! @FlairWoodworks: Here’s one idea. All the outside edges are cut ad the inside edges are live. #flairww -6:43 PM Apr 16th, 2012

FlairWoodworks @paulchinetti Thanks for the feedback! That’s what I’m going with for now. #flairww -6:45 PM Apr 16th, 2012

FlairWoodworks Does anybody know if there is a term form this kind or arrangement? It’s not a bookmatch or slipmatch. #flairww -6:56 PM Apr 16th, 2012

Brygidocious @FlairWoodworks kiss match? -6:58

FlairWoodworks I think I know what you want to say. RT @Brygidocious: @FlairWoodworks kiss match? -6:58

Brygidocious @FlairWoodworks haha shush! i remember seeing the term “kiss match” in my IP [Inside Passage School of Fine Woodworking] handout, but it was never explained -6:59

FlairWoodworks Tip: bring a water bottle to the shop and take a sip whenever you take a pause. #flairww -6:59 PM Apr 16th, 2012

FlairWoodworks @Brygidocious Really? I’ve never heard the term. -7:01

Brygidocious @FlairWoodworks its some skull and bones krenov talk that no one knows outside of those circles… -7:02 PM Apr 16th, 2012

Brygidocious @FlairWoodworks i think its a slip match, then flip one sheet end for end – 7:03 PM Apr 16th, 2012

FlairWoodworks @Brygidocious From my understanding, a slip match is just sliding the slices apart with no rotation or flipping. -7:04 PM Apr 16th, 2012

Brygidocious @FlairWoodworks yeah but this is a kiss match! -7:05 PM Apr 16th, 2012

Brygidocious @FlairWoodworks like a dis… -7:06 PM Apr 16th, 2012

FlairWoodworks Okay – I’m with you now! That “other” name is more exciting though. ;) RT @Brygidocious: @FlairWoodworks like a dis -7:08 PM Apr 16th, 2012

FlairWoodworks Surfacing lumber is a great core and upper-body workout. It even works your legs. #AllInOneGym #flairww -7:26 PM Apr 16th, 2012

FlairWoodworks @Brygidocious Scott Grove calls it spin matching. -7:27 PM Apr 16th, 2012

FlairWoodworks One side of one slab is roughly surfaced. #flairww -7:41 PM Apr 16th, 2012

FlairWoodworks Now I need to find a way to rotate these massive and heavy slabs in my small shop. #flairww -7:42 PM Apr 16th, 2012 PM Apr 16th, 2012

Tumblewood I don’t know, but it’s what i’ve been planning for the conversion table. RT @FlairWoodworks: Does anybody know if there is a term form this kind or arrangement? It’s not a bookmatch or slipmatch. -7:49 PM Apr 16th, 2012

Tumblewood 69 bookmatch? If it wasn’t, it is now!! ;oD RT @FlairWoodworks: Does anybody know if there is a term form this kind or arrangement? It’s not a bookmatch or slipmatch. -7:51 PM Apr 16th, 2012

FlairWoodworks Oh! The cat’s out of the bag now! RT @Tumblewood: 69 bookmatch? If it wasn’t, it is now!! ;oD -7:52 PM Apr 16th, 2012

FlairWoodworks I crosshatched the surface with chalk. Now I’ll start planing.#flairww -8:03 PM Apr 16th, 2012

FlairWoodworks Only traces of blue chalk remain. Dinner time. #flairww -8:35 PM Apr 16th, 2012

I set up my video camera to record in time-lapse the flattening of the two slabs by hand (nothing too exciting).  Watch the video below.  (Duration –  4:18)

This movie requires Adobe Flash for playback.

Keep going and read about Session 3!

Maple Trestle Table, Session 1 – Flat Boards are Boring

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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.

(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 Does this (the right side) look like a nice stretcher? #flairww @Morton -3:43 PM Apr 15th, 2012

WatkinsWoodWork @FlairWoodworks @Morton It definitely has potential -3:51 PM Apr 15th, 2012

sharpendwood @FlairWoodworks I like it. Is the crack near the center a problem? @Morton -3:58 PM Apr 15th, 2012

BCcraftmaster @FlairWoodworks @Morton the whole thing looks like a giant pump. (A women’s high heel) -4:00 PM Apr 15th, 2012

FlairWoodworks Hmm. I am not seeing it. RT @BCcraftmaster: @FlairWoodworks @Morton the whole thing looks like a giant pump. (A women’s high heel) -4:01 PM Apr 15th, 2012

BCcraftmaster @FlairWoodworks @Morton it also has the shape/curvature of the back leg of a chair. -4:04 PM Apr 15th, 2012

FlairWoodworks Now, THAT, I see. RT @BCcraftmaster: @FlairWoodworks @Morton it also has the shape/curvature of the back leg of a chair. -4:05 PM Apr 15th, 2012

BCcraftmaster @FlairWoodworks @Morton good, I’m not crazy… -4:13 PM Apr 15th, 2012

FlairWoodworks It’s often good to be crazy. RT @BCcraftmaster: @FlairWoodworks @Morton good, I’m not crazy… -4:14 PM Apr 15th, 2012

BCcraftmaster @FlairWoodworks you could make a chair/throne for enjoying all of those giant pieces of cake you eat!:-) -4:26 PM Apr 15th, 2012

FlairWoodworks @BCcraftmaster Actually, I have a piece of spalted maple reserved for that, tucked away in the corner of my shop since 5 years ago. -4:27 PM Apr 15th, 2012

FlairWoodworks I faired the curve with my low angle jack plane. #flairww -4:36 PM Apr 15th, 2012

FlairWoodworks I smoothed one side with my jack plane followed by my random orbit sander. #flairww-5:18 PM Apr 15th, 2012

BCcraftmaster @FlairWoodworks is that split going to stay attached or will it spit off? Hopefully you can incorporate it… -5:23 PM Apr 15th, 2012

FlairWoodworks @BCcraftmaster It’s going to stay attached. -5:26 PM Apr 15th, 2012

Morton @FlairWoodworks I think so. Assuming the blue line is a cut-line, I would have the closer end be symmetrical (same width) around the crack. -5:34 PM Apr 15th, 2012

FlairWoodworks @Morton Symmetry was not going to happen. It wasn’t in the cards. -5:36 PM Apr 15th, 2012

Morton @FlairWoodworks Is that stretcher vertical (as shown in latest photo) or horizontal? -5:37 PM Apr 15th, 2012

FlairWoodworks @Morton I think it will be vertical. -5:38 PM Apr 15th, 2012

Morton @FlairWoodworks Ah, cool. Like that better. Symmetry doesn’t matter (to me) then ;) -5:38 PM Apr 15th, 2012

FlairWoodworks Glad to have you on-board! RT @Morton: @FlairWoodworks Ah, cool. Like that better. Symmetry doesn’t matter (to me) then ;) -5:39 PM Apr 15th, 2012

FlairWoodworks I just stopped and took a minute to resharpen my low-angle jack plane’s O1 blade. #flairww -5:47 PM Apr 15th, 2012

FlairWoodworks I used my 1200x diamond stone on the hollow-ground blade, then stropped it. Quick and effective. #flairww -5:48 PM Apr 15th, 2012

FlairWoodworks Side 2 took a long time to smooth. I started with my low-angle jack and finished with my random orbit sander. #flairww -6:37 PM Apr 15th, 2012

WatkinsWoodWork @FlairWoodworks looks good. Can’t wait to see the finished piece. -6:38 PM Apr 15th, 2012

FlairWoodworks I used three 80-grit Abranet sanding discs to smooth the two sides of this piece of maple. #flairww -6:39 PM Apr 15th, 2012

FlairWoodworks You can use a handscrew to help hold a board vertically.#flairww -6:43 PM Apr 15th, 2012

FlairWoodworks I think that the cut edge will be the top. I’m unsure what to do with the square edge. Two wide chamfers? #flairww -6:48 PM Apr 15th, 2012

FlairWoodworks Any ideas or suggestions of what to do with the edge?#flairww -6:51 PM Apr 15th, 2012

MansFineFurn @FlairWoodworks carved ‘twist’ -6:52 PM Apr 15th, 2012

FlairWoodworks It’s almost 7pm. I need to get some dinner before the#Canucks game at 7:30. #flairww -6:51 PM Apr 15th, 2012

FlairWoodworks On the edge? Hmmm. Thinking…. still thinking… RT @MansFineFurn: @FlairWoodworks carved ‘twist’ -6:53 PM Apr 15th, 2012

MansFineFurn @FlairWoodworks face to top, then top to opposite face, um, not sure how else to describe it -6:54 PM Apr 15th, 2012

WatkinsWoodWork @FlairWoodworks I like the bulk of it. I say leave it. -6:54 PM Apr 15th, 2012

FlairWoodworks @MansFineFurn I think I understand what you mean. I know how I would do it. -6:54 PM Apr 15th, 2012

MansFineFurn @FlairWoodworks show me -6:55 PM Apr 15th, 2012

FlairWoodworks @mansfinefurn Have a look at this – the apron of Table with a Twist. #flairww -6:55 PM Apr 15th, 2012

FlairWoodworks @WatkinsWoodWork Something about live edges and square corners doesn’t sit right with me. -6:58 PM Apr 15th, 2012

MansFineFurn @FlairWoodworks yeah, more or less like that, but with a faster transition. -6:59 PM Apr 15th, 2012

FlairWoodworks @mansfinefurn Here’s another pic of the other side. #flairww -6:59 PM Apr 15th, 2012

FlairWoodworks Exactly! #flairww RT @MansFineFurn: @FlairWoodworks yeah, more or less like that, but with a faster transition. -7:00 PM Apr 15th, 2012

MansFineFurn @FlairWoodworks or get wild to a twist, to the middle, then twist it back -7:00 PM Apr 15th, 2012

FlairWoodworks @MansFineFurn I’ve experimented with reversing twists but didn’t like the effect. #flairww -7:02 PM Apr 15th, 2012

Morton @FlairWoodworks For me – I’d keep the wide, flat edge. I like how it looks smooth and flat compared to the side. #flairww -8:11 PM Apr 15th, 2012

FlairWoodworks Hmm. Contrast. RT @Morton: For me – I’d keep the wide, flat edge. I like how it looks smooth and flat compared to the side. #flairww -8:12 PM Apr 15th, 2012

Morton @FlairWoodworks Wow – that is really cool (twisted apron). Thx for the pic. -8:12 PM Apr 15th, 2012

FlairWoodworks Thanks for the compliment. RT @Morton: @FlairWoodworks Wow – that is really cool (twisted apron). Thx for the pic. -8:13 PM Apr 15th, 2012

DyamiPlotke @FlairWoodworks abranet is great, isn’t it? 8:16 PM Apr 15th, 2012

FlairWoodworks Love it. RT @DyamiPlotke: @FlairWoodworks abranet is great, isn’t it. 8:16 PM Apr 15th, 2012

Keep going and read about Session 2!

Review of the Mirka CEROS

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Background

I have had the 6″ Mirka CEROS (Compact Electric Random Orbit Sander) for about a year.  Although I have not used it in a production shop environment, I used it extensively for sanding sculptural work and, to a lesser degree, for flat surfaces.  I have had absolutely no issues with it.

When I purchased the Mirka CEROS, it was only available as a 5″ or 6″ sander with a 5 mm orbit.  The 5 mm orbit is for general work.  Since then, Mirka has released two more 6″ CEROS models – one with a 2.5 mm stroke for finish sanding and one with an 8 mm stroke for more aggressive sanding.  I do not believe these are currently available in North America.

Mirka CEROS in Systainer

Details

The sanding action is very smooth and the DC motor is powerful and reasonably quiet (68 dB, which is similar to a piano practice).  It is lightweight and well-balanced, making it comfortable to use with either one hand or two.  The power cord is quite flexible and permanently attached to the sander.  Mirka sells a hose for the sanders, which is more flexible and lighter (for improved ergonomics) than the Festool Anti-Static D27 hose.  The Mirka CEROS has a round dust port with female threads to accept a 1-1/4″ diameter threaded hose.

Although the Mirka sanders closely resemble pneumatic ones, they are powered by a maintenance-free, brushless DC motor and do not require a large air compressor.  The sanders have a 14′-long power cord that plugs into one end of a 8-1/2″ x 5-1/2″ x 3-1/4″ transformer.  A 6′-long power cord runs from the other end of the transformer into a standard AC outlet.

Mirka CEROS Package

Sizes

The Mirka CEROS is available with either a 125mm (5″) or 150mm (6″) diameter pad.  The smaller sander weighs 870 grams (1.9 pounds) and the larger weighs 920 grams (2 pounds).  I think the 6″ version is more practical not only because it can sand a larger area more quickly, but because the larger pad has a greater distance between the edge of the pad and its body which is useful when working in tight quarters.

5" and 6" Mirka CEROSs

Speed Control

The speed of the sanding pad can be adjusted from 4,000-10,000 RPM in 1,000 RPM increments using the buttons on the top-rear of the sander.  Between the speed control buttons is a power button for safety to prevent the sander from starting accidentally.  The paddle switch on top is pressed and held down to operate the tool.  By feathering the paddle, you can control the speed as well but it is very sensitive and not a very reliable way to run the sander at a lower speed.  Instead, it functions as a soft-start feature, of sorts.

Mirka CEROS, Top View

Critique

One addition that I would like to see is a pad brake.  After releasing the paddle switch with the pad turning at 10,000 RPM, the pad continues to spin for about 19 seconds.

Video Review

This first video explains and demonstrates some of the features of the Mirka CEROS.  (Duration: 10:19.)

In these two posts, you can read more about how I:

  1. combined the Mirka CEROS’s transformer with my Festool CT26 Dust Extractor; and
  2. modified the Festool D27 hose’s tool end to fit the Mirka CEROS’s dust collection port.

Video Demonstration

This second video is a demonstration of the Mirka CEROS.  In the first part, I sand the flat top of a bench with 80, 120, 180, 220, and 320-grit Abranet discs.  In the latter part of the video, I demonstrate how I sand contoured parts with and without the foam interface pad.  (Duration: 13:43.)

Summary

Consider this sander because it:

  1. is powerful and easy to control;
  2. runs quietly and smoothly;
  3. feels good because it is compact and well-balanced;
  4. requires very little maintenance because it has few wearing components; and
  5. does not require a large air compressor to run (as a pneumatic sander does).

Warranty

The Mirka CEROS comes with a 3-year warranty.  You can download the warranty information as well as manual from the Mirka CEROS website.

Accessories

Also, check out the Abranet abrasive discs made by Mirka.  The discs last a long time and don’t require alignment of any dust collection holes.  I would recommend getting the 80-, 120-, and 180-grit sanding discs as well as a Pad Saver (I called it a platen protector in the video).  If you work with non-flat surface, I would also recommend looking at the 10 mm (3/8″) Multi Interface Pads

Suppliers

(I do not receive any compensation for what I write and the list of suppliers is by no means an exhaustive one; I’ve simply listed some to get you started.)

Mirka Part Numbers

*Some dealers sell these parts individually.
**8295610111     150 mm (6″) 67-Hole Pad Savers, Package of 5 work with the 150 mm CEROS as well

Poll:  Videos

I’d like to know what you think of videos as method of communication.  Please cast your vote in this poll.

Hand-Carving Threads (to Connect a Mirka CEROS to a Festool 27mm Hose)

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This article shows how to layout and carve threads in a rubber hose end-piece.  However, the same techniques can be used to carve male threads in wood or another material.

Mirka CEROS (Photo from Ultimate Tools)

The Mirka CEROS (Compact Electric Random Orbit Sander) has a dust extraction port with internal threads that screw directly onto the end of a Festool 27mm hose to prevent it from dislodging accidentally.  However, that means the tapered rubber connector on the end of the hose needs to be removed.  This is not a difficult procedure but it is not something I want to do every time I switch between the sander and another tool.

Photo by Matthew Schenker

I know of four solutions to avoid having to install or remove the connector when using it with the CEROS:

  1. Jam the connector in and hope it stays;
  2. Buy another hose and dedicate it to the CEROS;
  3. Make an adapter using a short length of 27mm hose and some fittings; or
  4. Cut threads on the connector.
For the first few months of use, I simply jammed the connector into the dust collection port of the CEROS.  I tapered the end to make it easier to insert. However, it would pop out occasionally.  I couldn’t justify buying another hose and didn’t like the adapter.
Tired of fighting to get it to stay connected with just a press-fit, I decided to carve threads on the adapter to secure it into the port.  I used two carving tools, a rule (double square) and black electrical tape.
The first critical step was layout.  I wrapped tape around the connector, ensuring that the distance from the edge of the previous layer to that of the next layer matched the pitch of the port’s internal threads (which also matched the external threads of the 27mm hose).  I double-checked that the spacing was consistent and that I’d laid out the thread with the correct direction of rotation.

Next, I used a V-shaped carving gouge (#12 sweep, 2mm wide) along the edges of the tape to transfer the layout lines through to the connector.  Then I peeled off the tape so I could better see the V-cuts.

Following the V-cuts, I used a veining tool (#11 sweep, 3mm wide) to cut the threads.

Finally, I tried to thread the connector into the port.  When simply press fit, there was 7/8″ of exposed connector between the first shoulder and port.

Once threaded in fully, only 1/2″ of the connector was exposed between the first shoulder and port.  The threads mated very well and there was no chance of the hose disconnecting accidentally.  And I was able to still use the hose with other tools without a problem.