Posts by John

Purple Mallet From Scraps

By , 20 February, 2010, No Comment

For quite some time I have been aware of the fact that I did not have a wooden mallet that I could use to pound on the chisels as I cleaned out the mortises.  Months ago, I had glued up some scraps of purpleheart wood and cut it into the shape I needed for the mallet head.

Mallot

Mallot in Construction

So, I took some other scraps of purple heart wood that I had that were shy of a half inch thick and glued them together.  the next morning, I drilled a hole in the mallet head and started shaping the handle so that the top of the handle would fit the hole.  One of these days I will buy a lathe, but not yet.

This actually turned out very nice, and I was quite pleased with the result.  I decided to roughly shape the rest of the handle so that it was comfortable and then use it for a while.  I figured that after I used it

Finished Mallot

Finished Mallot

some, I would know if the handle needed further adjustment.

I have used it now for several weeks, and the adjustments that I expected to make have not come.  In truth, I don’t do a lot of pounding, but the fit has been good thus far.  What I especially like is that the shape and angle seems very good and I never look at it before swinging.  It always hits well and is solid.

Building a Desk – Part 3

By , 20 February, 2010, No Comment

Each side of the desk has three legs — with a small 12 inch gap between two of the legs where a drawer will fit.  I decided that using mortise and tenons on those pieces between the legs was the best way to get some strength and to keep them in place.  So,

Legs With Mortises

Legs With Mortises

I put the legs onto the drill press and using a 3/8 inch drill bit, I chopped out the general area for each mortise.  It has been a long, long time since I did any mortise and tenon work, so this turned out to be a true skill building process.

I also want to offset the mortises where there is a mortise and tenon on each side of the middle leg and the corner legs.  That way, I still have some strength.

After doing a bit of reading, I decided that the top spacer above the drawers would be a lot stronger if I used a dovetail instead of a flat tenon.   I found this worked pretty well.  You start by laying out the

Dovetail

Making the Dovetail

shape with a pencil, cut it out with a small saw (I am using a Japanese pull saw now), and clean it up with a chisel.

Then you lay the dovetail over the area that needs to be cut out to receive the dovetail and clean it out with chisel.  I also used a tiny router type bit in a Dremel tool and freehanded just to take out some of the large waste and to get me close to my lines.  The finished joints turned out pretty good, but don’t look real, real close just yet.  The backside has a bit of a gap!

Fitted Dovetail

Dovetail Fitted Into the Leg

I moved on to clean out the mortises to receive the spacer below the drawer.  This is extra tricky since this one is on an angle.  I am carrying the cloud lift from the Greene and Greene style all the way across the front of the desk.  That means that the bottom support for the drawer is going to be on an angle.  The represented a challenge for rusty skills when I needed to layout and mortise the piece on an angle and at two different levels across the front between the legs.

Drawer Supports Fitted to Legs

Drawer Supports Fitted to Legs

This turned out pretty well, and I am ready to do the other side which is a mirror image of this side.

Building a Desk – Part 2

By , 20 February, 2010, No Comment

This picture shows the well used plane that I purchased when Judy’s parents left the farm and retired.

Curt Regehr Plane

I am using this number 7 plane to joint the boards that form the top.  Normally, you would use a power joiner, but I don’t have one at the moment.  So, the old fashioned way of doing that was to get a longer plane, like Dad’s and to use it to produce straight boards.  The other part of the trick, is to plane to boards side by side so that they glue up without gaps between them.  That is happening in this picture, and it why that plane sits there so steady, but you cannot see the second board.

Here is the top mostly glued together.  The overall dimensions will be 60 inches by 32 inches.  I am not sure yet that I am happy with it, because it is exactly 3/4 inch thick and I really wanted something thicker.  3/4 will bow and warp if I don’t do it right.  So,

Glued desk top

The top mostly glued up

I might change and cut these boards up for smaller panels that I will need later.  The board laying across the top is to be ripped and added to the ends in what is called a breadboard.  That helps keep the longer pieces from warping and splitting.

Here are the legs all cut out and the piece of wood that I am using for the front.

Front and Legs

Legs and front piece

There will be a low profile 12 inch wide drawer on the left which you can see being proportioned in the next photo.

Since I am doing my own plan, I took the pieces and laid them out so that I could get an idea of how the proportion was going to look.  The desk will have a drawer on the one side, and I will sit under the rest of the desk length.

I decided that the general size for the drawer would be 12 inches wide and maintain a low profile.

Spacing the legs and finalizing the proportions

I have cut out and shaped the front piece under which the person sits in the next photo.  The Greene and Green style requires a lot of hand work, and I found it helped to use small planes and a lot of work with files.  You can see the jig saw in the background, and a bunch of files.  Since the piece has an arch, there was a limit to what I could do with a plane smoothing plane.

Front with shape

Cloud Lift Cut Into Front

I like the ‘cloud lift’ that was used in the most popular of the Greene and Greene pieces and architecture.  It works very well for me on this desk since I have a long leg and it is sometimes difficult to sit under some desks and still have the chair up to the full height.  The arch that represents the cloud lift is ideal to give me a little extra room for my legs.

I found that this very small plane was very helpful on this arch work.  Originally Stanley sold these as toys for tool sets for boys.  I discovered that it helped me get into small spots and take off wood quickly so that I did not have to use my files quite as much.

Small plane in action

Small Stanley Plane Used in Tight Area

I mostly work an hour or two a day on this project and several hours on the weekends.  My daughter Jodi and spouse Tyler want to build a crib too, so there will be some competition for space and time once we start on that project.

Building a Desk – Part 1

By , 18 February, 2010, No Comment

Always enamored with quarter-sawn white oak, I picked that wood for my first big project a few months back.  There is a great place over in Dunlap, IA where you can get lumber at nice prices that are planed (roughly) and sawn on one edge.  I bought the oak in late fall, and let the lumber sit for a while in the shop.

By the time I was ready to start, I needed a plan.  My wife and I are big fans of mission furniture, and most of our purchases in the past 6 years all fit that style.  During the search search for the right plan or idea, I discovered Greene and Greene.  I do not remember ever coming across this style previously, but some of the pieces that I read about were very exciting.  I decided that I would have to build something that borrowed from their designs.

After looking around, I found several contemporary furniture makers that work in that style.  I especially liked some of the things done by Darrell Peart,  including a beautiful desk he called the Aurora Table Desk.  He featured it his book which I bought and read.

So, my design falls into place, but now I realize that I my oak is not a traditional wood for Greene and Greene style wood.  I vow to proceed anyway, and I am off to a good start.

As much as possible, I am using hand tools, but all of the sawing parts have been with table saw, miter saw and jig saw so far.  Way too much sawing for hand.  Greene and Greene has a lot of rounded edges too, and I will probably use a router to get that consistent look on all the major pieces.  As I get back into woodworking, I find that I have enjoyed the use of hand tools, and I want to enjoy the process more than banging something together.

Get Me One of These

By , 17 February, 2010, No Comment

As a young boy, the oldest of the children, I often found myself lingering around a project that my father was working during his day off.  In the cold months, his projects were in the warm, company owned shop that was 6 miles away from our house.  In the warmer months, dad typically crawled underneath a vehicle parked in our yard and tore something apart.  I can still feel the warm sunshine, and remember the feel of the grass and weeds that grew in that work area before spring really kicked in.  It is odd that you could feel so close to your father when he was completely preoccupied with something, and you are just hanging around, fiddling with things in his toolbox.

From under the vehicle, dad would shout out to me that he needed a certain size wrench, a screwdriver, a hammer or something else from that toolbox.  After seeing my badly chosen selection come flying back out on to the grass in front of me, and hearing the reissue of the original command, I was incented to learn which tool was what. That learning process also made me slightly less eager to be around when my dad started arguing with hard, greasy metal parts, and I sometimes casually slipped away when the conversation got intense.   I know that meant he crawled out to get his own tools, and that I made a lousy helper that day, but self-preservation wins out from time to time.

During those helper events, my dad would often need a washer, nut or bolt.  Now these were the days when your local Home Depot did not exist, and hardware stores kept regular business hours.  So, a Sunday project would have stopped cold were it not for grandma’s garage across the street.  Grandma’s garage had been a work shop for a husband, three sons and at least one son-in-law.  Only the youngest son and inquisitive grandsons were still around to venture into the garage.

In that garage was a wonderful collection of artifacts from farming, mechanics, welders and construction ventures.  I spent many a happy day in that garage discovering things that had been long abandoned and were never used again by working men.  Old goggles, hammers and who knows what became my own inspiration for adventures.  In the northwest corner sat an old dark colored shipping trunk like you see coming off sea-crossing boats.  To that chest, sitting in an unlit corner, I returned over and over on missions for my father.

From under a car, or a place he had wedged into, my dad would call out a request for something from the chest.  “Go get me one of these”, he would say, or “Get me a hex nut to fit this bolt.” I would dutifully take the item that he held up, grab the flashlight, get the key to the garage and sprint across the road and through the ditch to the garage.  Early on, it seemed a lot easier to find the requested item than it did in later years.  I think we must have harvested most of the typical sizes, and later I would spend a long time combing through 5 inches of nuts, bolt, washers and other items I was unfamiliar with until I found what I needed.  Always the familiar taste of rust accompanied these forays into the trunk.

Expediency was required lest I got chewed when I finally showed up, or worse yet was to have dad show up himself and start pawing for the item.  Oddly enough, it never seemed to take him long to find what he needed.  Yes, those were the days when I just expected that most of what you wanted for a project ought to be found right in your own workshop.

The number of times when mom needed to jump into the car and actually go buy something seemed pretty few.  In later life when I worked at a hardware store, I gained a better appreciation for the poor wife whose husband sends her off to the store, saying “Go get me one of these.”  I saw a lot of flustered wives come in, not having a clue what they were buying, and unable to answer even simple questions.

A treasure I possess is a can of nuts, bolts and washers I took home with me after my dad passed away.  I don’t know if they are from the original trunk in the garage, but I pretend that some of them I have handled for fifty years.  Last year I bought a nice plastic box with dividers in it, and separated bolts from nuts, and sorted longer bolts from shorter bolts.  It seemed like a smart move at the time, but it just isn’t as much fun looking for a something now as it was when I used a flashlight, knelt down in front of the trunk, and used an old welding rod to dig through hundreds of small rusty parts.  I still get that rusty taste in my nose and mouth every time I dig around for something, and I always have a flood of memories.  But, the adventure is gone.

Today, I live in the country, and it is seldom handy for me to jump into the car and drive miles to get what I need.  I certainly don’t want to send my poor wife on those mission trips.  So, even with all of the stores around that cater to the needs of the do-it-yourselfer, I like to have a cache of things around just in case I need it.  Now I have my own collection of stuff squirreled away, and it gives me a sense of security.  If I need ‘one of these’ – I just might have it.