Knotty Pine

This question kept me awake in the wee hours one morning:

What would it look like if I carved a knot in a piece of wood?

I lay in bed trying to visualize it, and figure out how best to attempt it… Start by finding a fairly thick piece of rope, tie a knot, use it to layout the carving, rough-out the carving with a saw, then finish carving with a knife and/or gouges.

Tracing the imaginary path of the rope with my index finger while laying on my back, I rehearsed the carving over and over, over and over.

At the first semi-reasonable hour, I got out of bed and went down to the shop to find an appropriate piece of wood to carve. I found a clear piece of Austrian pine, salvaged from a piece of 6×8 dunnage in a container of Felder machines.

I tied a knot in a short length of 3/8” rope and used a pen to roughly indicate the path of the rope on each of the four faces of the blank.

Using a jigsaw and long blade, I cut to my layout lines. Then I completed the shaping with my folding carving knife.

And that is how you turn a clear piece of pine into a piece of knotty pine.

knotty pine

Stacked Veneer Experiment with a Shocking Lesson

You’re probably aware that I like to incorporate a twist in my designs.

For some time, I’ve had this idea to laminate a stack of veneer in a twisted manner, so each subsequent piece of veneer is rotated just a degree or two. I suspected that, due to the difference in appearance between long grain and end grain, I would see a gradual lightness/darkness shift along the surface.

To test my theory and see what it would really look like, I cut cherry veneer into 2-3/4 inch squares with my bandsaw, because is was the quickest and easiest way I knew. I chose cherry because of the marked difference in darkness between its long grain and end grain, for better contrast.

I also grabbed two Quick Grip XL clamps, a bottle of Titebond Extend wood glue and prepared some small pieces of melamine as cauls to permit even distribution of clamping force and help ensure the faces stay flat.

Working efficiently and methodically, I spread glue on one face of a piece of veneer and placed another piece of veneer on it, rotated one veneer thickness counter-clockwise. I repeated the process for about a dozen pieces, then put the assembly between cauls and clamped them tightly. I glued together another dozen, then glued it to the previous dozen and put everything back in the clamps, continuing until I had two stacks each about 1″ high. The whole process took about an hour.

After a full day of drying, I unclamped the twisted veneer stacks and trimmed the uneven edges. The yield wasn’t particularly high, so I didn’t have many options for a finished product. I did have some pen kits on hand, so I decided to make a pen with the veneer. I cut one stack into 5/8″ squares, then glued them together, again rotated the thickness of one veneer.

I built a mini router jig to true up the pen blanks then drilled out the centres and mounted them on the lathe.

Once that dried, I made the pen. As I neared completion, I noticed some darker rings in the wood. They puzzled me, and I wondered if I had somehow put some veneer pieces in indirectly. Anyhow, I finished the pen and this is the result.

The twisted design I had attempted to produce was evident, and even more pronounced when I applied a thin coat of oil-based polyurethane to accentuate the long grain/end grain difference. But those rings!

After carrying the pen around for a few days, it struck me that the dark lines were caused when I put a dozen pieces of veneer in clamps to work on another stack, then glued them together! Somehow, this resulted in a darker veneer. How? Did the PVA glue absorb more into these pieces?

To avoid those dark laminations, I may have to glue all the veneers together in one shot before the glue starts to set. A glue with a longer open time would definitely be an asset. Or maybe a different glue, such as a plastic resin or epoxy would work. Or maybe if I just soaked the veneer in water first, the PVA glue would dry more slowly and encourage equal penetration.

If somebody can offer an insight as to why this happens, or if you have your own theory on how to prevent it, I’d love to hear it.

Butternut & Ash Side Table

I recently completed this small side table and it has already become a much-appreciated addition to the home. With a table top about 10″ x 18″, it has proven itself to be compact yet stable, and suitably sized to hold a book, or a dinner plate and drinking glass.

 

ash-butternut-side-table-low

Followers of my blog may recognize the top as a slice from the same piece of ash that was used in the doors of Insanity 2.

ash-butternut-side-table-high

The form took a while to realize, and I had fun mixing straight lines and convex shapes.

The butternut base is joined with bridle and lap joints, and the teardrop ash top is joined with a pair of floating tenons and a little glue.

Stool with Sculpted Seat

This project actually started over eight years ago, but in a very different form.

While down in California working a trade show for Lee Valley, the crew and I made a detour to Sam Maloof’s house in Alta Loma. We got a very inspirational tour of the very unique house which he had built for himself and left me very inspired to make a sculpted chair.

I bought a copy of Sam Maloof, Woodworker which Sam signed for me. Unfortunately, I didn’t have the opportunity to meet him.

Sam Maloof Autograph

Back home, I started by making a maple seat. I beveled the edges of four boards and glued them together to create a blank curved to the approximate shape of the seat, then sculpted it with my Arbortech carbide wheel on a grinder, and sanders. That’s as far as the chair progressed until I rediscovered it when I was cleaning out my old workshop earlier this year.

To turn the chair seat into a stool seat, I needed to shape it further. The chair required square edges to join into the frame members, but the stool seat was designed to be supported differently.

Curved workpieces have always been challenging to hold securely while working them, but that task was greatly simplified by using the Festool VacSys Vacuum Clamp at my workplace, Ultimate Tools.

Stool Seat on Vacuum Clamp

To make the seat look less bulky, I wanted to thin out the seat towards the edges. I started with a jigsaw, tilted at a 45 degree angle, followed by sanders.

Bevelling with Jigsaw

I designed a simple base and selected a suitably-sized board of Gary oak that I had bought years ago. I milled it into square sections and cut them to length to make three legs and two stretchers. I cut the angled dadoes by hand, and cut the mating open mortises with my table saw.

Stool Bridle Joinery

With carving gouges, I shaped round tenons on the tops of the three legs. I paused to admire the polished surface on the tenon shoulder left by my sharp tools. Then I assembled the base to locate where mating holes needed to be drilled in the underside of the seat.

Tenon

It have always found it satisfying to push together a well-fit joint. Or four. Or seven. It was a little nerve-wracking pounding the leg tenons into the holes in the seat, wondering if anything would crack. Nothing did.

Bridle Joints

I used the VacSys to hold the stool for a final sanding before applying a couple of coats of oil-based polyurethane.

Stool and Vacuum

And here’s the finished result.

Sculpted Seat Stool Front Right Sulpted Stool Stool Back Left

Cribbage Board 18, and a Pricing Structure

I recently completed this cribbage board in apple for a customer who also has one of my tables.

Like many others, this one was a gift. Interestingly enough, some customers have told me that they don’t play crib, but just like the look of them.

Cribbage Board 18 Right

Cribbage Board 18 Top

Pricing Structure

Up until now, I have only been making boards with three tracks since they offer the most flexibility (they can accommodate one, two, three or four players).

I am now offering cribbage boards with one, two or three tracks.

Prices for live edge cribbage boards are as follows, and all cribbage boards include the required number of metal scoring pegs.

  • $90 – 1 track without scoreboard
  • $95 – 1 track with scoreboard
  • $120 – 2 tracks without scoreboard
  • $130 – 2 tracks with scoreboard
  • $155 – 3 tracks without scoreboard
  • $170 – 3 tracks with scoreboard

Contact me if you would like to order a custom-made cribbage board.

Shipping within North America is usually around $25. Prices are current as of this posting and are subject to change.

Shop Stools/Bar Stools

The kitchen island in my new house was calling for a pair of bar stools. My shop stool that I completed in the Shop Stool Build-Off found its way there during the move, and with the chaos reigning in my shop, I was happy to let it live there.

Shop Stool

My shop stool

A second stool was in order, and it looked like it would be a while still before the shop is in any sort of shape to work.

Fortunately, I recalled that, a little while after the Shop Stool Build-Off, I had tried again to make the crossed-leg stool which I had originally attempted but due to a miscalculation, wasn’t able to pull off in time.

Shop Stool Build-Off Design

Attempt #2 was already together, but needed some attention. The joints didn’t fit quite as well as I wanted and hadn’t been glued. The seat needed to be cut to shape, and the legs needed some finishing touches.

My goal was to make it into a usable stool – I had more important things to do and didn’t want to spend the time required to bring this stool up to the level of “fine furniture”.

First, I glued the legs into the seat. To avoid having to drive them apart and back together (they were a tight friction fit), I applied Veritas’ Chair Doctor Glue to the joint’s seams and let the watery glue seep into the joint. When the glue was dry, I cut the seat round with my jigsaw.

Shop Stools High

Although the stool was usable at this point, I couldn’t resist taking it further. I tilted my jigsaw (the whole saw, not just the base plate) and trimmed the edge of the seat to line up with the angled legs, gradually bringing the jigsaw back to plumb so the edge returned to square. I did this in both directions – clockwise and counter clock-wise at each leg, so the seat’s edge effectively twists and untwists as it goes around. I faired the edge of the stool with my random orbit sander, starting with 24-grit, and progressed up to 120-grit.

Shop Stools Low

Finally, I scooped out the seat with a carving gouge, sanded the surface smooth and even, and softened the edges.

Shop Stools Mid

So much for a “basic” stool – I just couldn’t resist adding a few extra touches. Know what I mean?

21st Century Writing Desk, Complete

A textured top might at first seem the wrong choice for a writing desk, but with computers leading the writing world nowadays we think it’s a great idea.

– Canadian Woodworking & Home Improvement Magazine

I completed the base for the 21st Century Writing Desk, to go with the top that I carved in November.

21st Century Writing Desk Top

The base had to be visually lightweight to avoid overwhelming the thin top. I achieved this by leaving space below the top and tapering the legs.

To allow ample space for knees, I opted to omit the front apron. I made up for the missing apron by using an H-shaped stretcher assembly positioned low on the legs.

21st Century Writing Desk

Turned around, the desk can be used as a side table as well. The long stretcher provides some more visual strength.

21st Century Writing Desk Back

I wanted to make the legs flow into the stretchers so I created curved transitions at the joints. To do this easily, I developed a process involving two common router bits and a couple simple shims. (Read about this process in the April/May 2016 issue of Canadian Woodworking & Home Improvement.)

21st Century Writing Desk Base

3-Month Review

I am quite happy with the desk after a few months of use. It is plenty stable and the top is big enough for my laptop computer, some wrist support, and not much else. Therefore, it does not attract the clutter with which desks are often plagued. It is also incredibly light, which makes it enjoyable (not an exaggeration) to move around from room to room.

When I work at it, I sit in my 3-Week Chair, Prototype 4 (which I badly want to revisit and further develop).

Bonus

Read the article from the March/April issue of Canadian Woodworking & Home Improvement by clicking the following image.

2016_04-05_21st-century-writing-desk

Custom Box to Protect a Portable Winch

Progress on the 21st Century Writing Desk was put on hold while I built a customized wooden box to protect an expensive piece of equipment for a friend in the tree business. (This kind of friend is good to have if you’re a woodworker!)

He had recently acquired a portable winch which, while seemingly well-made, contained a number of parts that were liable to get bent or broken in the back of a truck. To further compound the issue, the winch wasn’t particularly stable, and it didn’t take much imagination to see it tipping over when turning a corner.

The objective was to make a sturdy, but lightweight box to protect it in transit. Function was first priority, and it didn’t have to look particularly nice or involve fancy joinery.

I started by milling Douglas fir, which he had provided, down to roughly 1/2″ thick and ripped the boards to a uniform width of 4-1/2″. I cut them to length which resulted in an inside dimension of about 16-1/2″.

Using 4 mm Domino floating tenons, I reinforced the butt joints and assembled four boxes measuring 4-1/2″ x 17-1/2″ x 17-1/2″ in a pinwheel fashion where one end of each board was exposed.

Custom Winch Box Open

I didn’t want to rely on the Dominos to hold the box together, so I stacked and glued the layers in a way that interlocked them. The edge-to-edge glue joints were plenty strong, and with the Domino joints interlocking between the layers, there was no way the box was going to come apart.

Simple Interlocking Joinery

To install the top and bottom of the box, I used simple battens attached to the sides of the box above and below the floating panels. I then worked out the shapes and sizes of a few strategically placed blocks that supported the winch and allowed it to be easily lowered in or removed.

Custom Winch Box Top

I trimmed out the box with strap hinges, draw latches, a rope lid stay and rope handles.

Custom Winch Box Closed

Lastly, I added skid feet to help protect the box and allow it to slide more easily into the back of a truck.

This was a simple design with a simple purpose.

I made a custom box for a torque wrench a couple years ago, too.

Don’t be a Wing Nut

Don’t be a wing nut – wear them!

No self-respecting woodworker dresses up with off-the-shelf accessories. Add some flair to your wardrobe with these custom-made cuff links featuring stainless steel wing nuts.

I made the first pair myself a few years ago, and I am always looking for an excuse to use them.

$50 + $10 shipping and handling within North America (contact me for rush or international shipping).

Click here to order.

Cuff Links

21st Century Writing Desk – Designing the Base

So, with the top done, my next step was to design a suitable base for it. I went to my computer and started playing with designs.

I had an idea for a base that consisted of a pair of rectangular frames and cross members. However, none of the variations that looked good to me.

Slim, tapered legs looked much more fitting.

21st Century Writing Desk10 Because the legs were so thin and delicate, stretchers were added to provide additional strength and stability.
21st Century Writing Desk11

A rear stretcher provided further resistance to racking and flexing.

21st Century Writing Desk12

I wasn’t happy with the placement of the rear stretcher in relation to the side stretchers, so I lowered it to the same level. Arranging the stretchers like this presented some challenges with intersecting joinery in the legs, and I wanted to maximize strength while minimizing the size of the components.

21st Century Writing Desk14

Lowering the rear stretcher another 3/4″ gave the joinery more strength, but it wasn’t enough.

21st Century Writing Desk15

Positioning the rear stretcher 1-1/4″ below the side stretchers seemed to provide a good balance of aesthetics and strength (room for joinery).

21st Century Writing Desk13

The last change I made was to reduce the height of the aprons that support the table top, as seen in these last three images.

21st Century Writing Desk18a 21st Century Writing Desk18c 21st Century Writing Desk18b

I’m happy enough with the design to start building, but there are absolutely no guarantees that the finished table will look like the one in the drawings!  Stay tuned…