Porter Cable 890 Plunge Router with Dust Collection Hose

Since I don’t yet own a Festool router, my Porter-Cable 890 Plunge Router showed the most promise of containing the mess.  Dust and chips were drawn into the port built into the base (located behind the depth stop turret) and up through the column.  My only shop vacuum/dust extractor was a Festool CT26 and I had a D27 (27mm diameter) hose attached to it so I set out to make the two work together.  (I also had a high-volume dust collector that is used with my stationary machinery.)

Point of Dust Collection

The Festool D27 hose stretched a little to fit over the very top of the column but it was far from secure and could very easily come free.

Festool D27 Hose and Router's Dust Collection Port

I found a plastic pipe fitting that fit inside the D27 hose nicely and turned a round tenon to fit inside the router’s column.  I chamfered the bottom inside edge to allow the chips and dust to pass through easily.

The adapter press-fits into the top of the column.

Adapter inserted into dust collection column

The D27 hose fit nicely over the adapter.

Hose over adapter

For the most secure fit, I pressed the hose end all the way down onto the top of the router’s column.

Hose fully seated over adapter and dust collection column

Since the Porter-Cable didn’t use the Plug-It system, I used the same Velcro straps that held the Plug-It cord to the D27 hose to hold the cord back and out of the way.

Plug-It Cord tied back

This time, I am giving away one Makita BO3700 Finishing Sander which has seen a minimal amount of use.  It uses 1/3 of a standard 9×11″ sandpaper sheet which is held in place by a spring-loaded clamp at each end of the pad.

The soft pad has eight holes for dust extraction.  The steel plate is used to punch matching holes in the paper.

Dust collection with the bag is not great, but some dust does make it into the bag.  The dust port is round, so it shouldn’t be too difficult to adapt a vacuum to it.

The sander runs on 120 volts, draws 1.3 amps, orbits 10,000 times per minute and is turned on and off with the trigger under the handle (there is a lock-on button as well).  The tool weighs 3.1 pounds and the cord is listed at 6.6 feet.

If you would like this sander, please leave a comment below indicating your interest before February 21, 2012.  I will then draw a winner at random.  Even if you don’t get this sander, remember that this is only some of the MANY things I want to give away.

Review the details of the Overflow program.

There are two types of fools: one says, “This is old, therefore it is good”; the other says, “This is new, therefore it is better.”

- William Ralph Inge

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

To be continued…

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

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

Pattern Study 1 by Jennifer Anderson

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ravinheart @FlairWoodworks there will be no throwing :P

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Elliptori by Jon Siegel

Artist Name:  Jon Siegel
Title:  Elliptori
Details:  circa 2001 - mahogany, glass 56″ wide x 26″ deep x 16″tall

Why It’s Notable:

I like the design, but to me, what is most notable is the process used to make the base.  Instead of laminating the rough shape, then refining it with carving tools, planes, and sanders, Jon Siegel took another approach.

“When I make the turning, which is 4′ in diameter, I am only making 1/2 of the profile, and the back is flat.  Then the ring is cut in half along the diameter and “folded” and glued together to make one table.  This method has two advantages:  it is easy to mount the work on a face plate because the back is flat, and it assures that the form is symmetrical.”

How did Jon develop the process of making the base?

“I never had a drawing of this table – the idea went from my brain directly to a scale model made on the lathe.  My first experiments were in doll-house scale (1:12).  Then when I thought I had the proportions right, I jumped up to 1/4 size scale.  From that model, I measured how I was going to glue up the blank in three layers - three band sawn rings were stacked and glued up.  About a year after I made it I realized that somewhere in the back of my mind I was probably inspired by the work of Stephen Hogbin that I had seen 25 years earlier!”

The glass top makes the table functional without hindering the view of the unique cross-section of the base.  Very interesting!

For the curious, this is the lathe Jon used to turn the table’s base.

Jon Siegel's Putnam Lathe

“Restoring 100 year old machinery (both woodworking and metal working) is a passion of mine – especially lathes.  The lathe was made in Fitchburg, Massachusetts by Putnam who made mostly metal lathes, but they also made some of these pattern maker’s lathes.  These are woodworking lathes that have a carriage.  This type of bed was used on their metal lathes too, which is why they are so heavy.  But the headstock and carriage are greatly simplified from their metal working cousins.  This type of bed is called ‘extension bed’, and by turning the large handwheel that you can see below the bed, the upper half of the bed slides away revealing the large ‘gap’ which is thus adjustable in width for the particular job at hand.  Of course this also extends the length of the bed when needed, hence the name.  It extends to allow 12′ workpiece length.  It swings 24″ over the bed and 50″ in the gap.  I used this lathe to make ‘Elliptori’.  The rough blank weighed over 100 pounds, and the finished turning about 70 pounds.  Work of this size is turned at about 120 rpm (2 revolutions per second).  The largest piece I have turned on this lathe weighed 500 pounds, and it handled it easily because that is only 10% of the weight of the machine.”

I’d like to extend a “thank you” to Jon Siegel for his help writing this article.  Jon has been turning for over 45 years.  He co-founded Big Tree Turnings, LLC., and is a member of the Guild of New Hampshire Woodworkers, New Hampshire Furniture Masters Association, and president of Granite State Woodturners (a chapter of the American Association of Woodturners).

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

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

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

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

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

Why the Change?

Currently, flairwoodworks.com is my official site and flairwoodworks.wordpress.com is my blog.  All my promotional material points to flairwoodworks.com, yet it’s my blog that I update most often.  Ultimately, I want to see more traffic through my site.  This change is one of the first steps in taking Flair Woodworks to the next level.

What is Changing?

This week, I will be merging the two sites into one.  You may have noticed that I’ve been adding new pages to my blog such as a Portfolio and Achievements & Testimonies and that is part of the process.  I’ve also updated the About page.  Check them out if you haven’t already.  Also, the random ads you see will disappear.

When will the Change Occur?

If you are reading this, chances are I’ve already begun or have completed the process of merging the two sites.

What Does This Mean?

Once this change has been completed, my blog and official site will both be at flairwoodworks.com.  The content will not change nor will anything else.  The only difference will be the website address.

I’m hoping it goes more like this:

A Walk in the Park

And less like this:

A Train Wreck

SEE YOU ON THE OTHER SIDE!

Secret Carpentry by Maskull Lasserre

Artist Name:  Maskull Lasserre
Title:  Secret Carpentry
Details:  circa 2011 – 26″ x 6″ x 2″

Why It’s Notable:

An axe, to most people, is an unremarkable object – just an axe.  However, if you take any item and embellish it, it becomes more distinct and meaningful.  This piece reminds me that anything has the potential to be a work of art.

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

Lacquered and Stripped Handles

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

Working on a Chisel Handle

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

Refinished, Faceted Handles

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

Refinished Spokeshave Handle

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