Loading Hose

By john, 1 April, 2010, No Comment

On a very cold morning in Kemmerer, WY I showed up for my first day on the job at the local coal mine.   Although the mining job paid three times my hourly wage as a gas station attendant, I nervously entered the machine shop with an acquaintance and a host of grizzled men wearing dirty hard hats and lots of clothing.  At 20, I knew men who worked hard for a living could be tough on young guys.  It takes time to earn respect, and first impressions can last a long time.

Shortly before 6:00, the men gathered around very large equipment parked inside the mechanic shop, forming a rough circle that suggested someone would soon fill the space. Fidgeting nervously, and wearing enough clothing to know how mummies might feel I made my way over a loader with tires that stood a good foot taller than my six foot frame.  Huge trucks sat in the other bays.  I marveled at the immenseness, and wondered if my first assignment included one of these monstrosities.  I could imagine my flattened body, like in the cartoons, floating in the air like a leaf if I got under one of these beasts.

The foreman stepped into the circle and barked out some commands to the group.  I knew instinctively that this guy ruled the roost, and we did what we were told.  We belonged to the United Mine Workers Union, but he belonged to the company.  For the first time in my life, I understood the fear of the boss.  After yepping to him calling my name, he assigned me to go with two other men, who thankfully looked nicer than many of the others in the circle.

Our leader, Jim, appeared forty something, and the other fella looked to be mid-twenties and Asian.  We introduced ourselves, and walked into a dark, bitter-cold Wyoming morning.  Jim jumped into a large flat-bed truck that he started earlier, and I took the shotgun position at the other window.  With a sickly amount of moonlight illuminating a winding dirt road, we bumped along on shocks that seemed too cold to compress, and so we just bounced.

Nervous about my future, I asked, “So, what do we do?”  “We load hose” was the response.  Few thinking people wish to appear stupid, so I mulled those three words around for a few seconds.  What kind of hose gets used in a coal mine, and how would you use it in this bitter cold?  Nothing made sense, so I asked in feigned casualness, “What do you mean, hose?”  “Dynamite, we load dynamite.” they said.

That pale moonlight obscured the loss of color in my face.  Not wanting to die, I checked beforehand to be certain that no one worked underground at this mine.  Only strip mining and open pit existed now, so it seemed like a safe job.  And now I found myself hundreds of miles from my parents with two strangers preparing to handle dynamite.  A few times in my life, I knew that I ought to flee the situation, but a graceful means of doing so kept my feet from moving.  This was one of those times.  My mind raced from excuse to disaster, but not to clear paths of escape.  Like a hearse, my ride took on grimness and reflection as my driver slowly made his way to my final resting place.

We pulled up to a large, padlocked box, about four feet square.  Jim gathered blasting caps and cord for the day, and warned me to be very careful with the caps and cord, because both detonate from shock.   With our explosive triggers in a gunnysack on the back of the truck next to the cab, our fully gassed truck bounced down the road.

I held my breath and waited for the explosion while my tormentors made small talk about the previous weekend.  We made it to the next stop, a semi-trailer parked alongside the road, and I eagerly got out.  Jim swung open the doors to reveal a trailer filled about two-thirds full of explosives.

The mine used two sizes of tube explosives.  One tube measured about 20 inches long by 3 inches in diameter and the other tube measured about 36 inches long by 4 inches in diameter.  The smaller tubes blew patterns in coal and the larger tubes blew patterns in dirt.  In strip mining, a large drill on the back of a truck drills holes 20 feet and much deeper in a pattern that is later loaded with blasting materials.  Patterns are designed for coal or dirt, and the amount of blasting material needed to loosen that material.  Giant equipment then digs up the loosened material and loads it onto even bigger dump trucks.

That morning, we loaded the back of our truck with tubes of dynamite.  Jim’s instructions included unnecessary concerns for caution.  By the time we finished, I needed to sit down, but warily got back into the truck with blasting caps, cord and dynamite all sitting together on back.  The sun now revealed the age of our well-used potential rocket, and I understood better why the ride seemed so bouncy.   The rough road continued for a long mile or so until we arrived at the freshly drilled pattern of dirt.

At the pattern, Jim explained how we placed x number of blasting caps on the cord and put it down into the bottom of the hole, leaving about 18 inches of blasting cord sticking out the top.  Then, using a rope with a little hook, each bag would be let down into the hole by attaching the hook to a ring in the end of each bag.  I watched a few bags get lowered onto the caps and was warned about the necessity of gentleness to avoid delivering a jarring impact on the blasting caps at the bottom.  When the bag reached the bottom, a little slack released the hook and the rope could be brought up.

When I got my first chance to lower a large tube of dynamite, I imitated the strategic process described that I witnessed.  Moving the bag to the edge of the hole, I put tension on the hook and lifted one end of the bag to slide the other end into the hole.  About half way into the hole, the hook came loose.  We all froze as my bag of explosives slid down the hole at gravity speed toward another bag and several blasting caps.  Thud, just a thud.  After a little nervous laughter and exchange of glances, we shook it off and I hooked up another bag.  I never lost another one, and we finished loading all the holes to a certain level and filled the rest with dirt.  Afterwards, we took more blasting cord and tied all the 18 inch pieces together and ran a long cord way over on the other side of the man-made valley.

After alerting the foreman and all surrounding workers, Jim set off the explosion with one of those official gadgets hooked to a battery, and lifted dirt 30 feet into the air.  I must say that at the end of the first day, I enjoyed myself.  The sun shown, I made some friends and only a healthy fear remained every day afterwards.  After nine days, the union went on strike for three months.  I returned to the mine months later, but never again with the blasting crew.

Over the years, I have used a lot of power tools and machinery, but nothing that powerful again.  Many tools come with warnings about risk to limb, but not many with warnings about life.

Even today, I approach a new power tool with caution and some trepidation.  Learning to use power properly cannot be underestimated.  I still have all my slightly battered fingers, and I want to keep it that way.

Wear your eye protection and read the instructions.  I could tell you stories, and maybe I will.  But let’s not become one of those stories that make people shudder.

Enjoy the power!

Making shavings

By john, 25 March, 2010, No Comment
Plane Full of Shavings

Plane Full of Shavings

The shelf underneath the drawers for my desk needed flattening.  With some experience now in getting a plane sharp and flat, planing is more fun.  So much fun in fact, that I found it hard not to get carried away.

Right away, I loaded up the throat of the plane with a pile of while oak shavings.  I knew then that this could get away from me quickly.  It sounds funny to say that, but it really is a satisfying feeling.

Bedrock and Shavings

Bedrock and Shavings

Flattening remained the goal though, and I stuck to the task.  These pieces were glued together several weeks ago, and the entire piece began to cup a little.  Now that I want to fit it to size, it needed to be worked.

The plane in the foreground was not the only plane that I used, but it is my favorite.  The plane is an older Bedrock.  The ear on the tote was knocked off when I bought it, so it has a purple heart replacement.  Now that the planes have done their work, I am ready to cut to size and then apply stain and finish to this shelf.

Gluing Desk Legs

By john, 22 March, 2010, No Comment
Clamping Leg Sets

Clamping Leg Sets

Assembly, or glue typically comes after sanding everything.  The many small pieces in this desk complicates the glue up, and I feared glue squishing out everywhere and ruinging my hard work.  So, after sanding and staining I spent time applying a finish to all of the small parts that would be in the drawer stack.  For the record, I used Deft lacquer for the finish coat.

Glued Legs

Glued Legs

When the finish dried, I began gluing up two legs, the apron and the rail.  Funny thing, getting to this point after so many months of working on the little parts, I felt a wave of nervousness creep over me.  However, I felt that gluing up these groups of pieces gave me the best chance for success and square alignment.

Gluing the two legs sets together required gluing 6 rails between the two sets.  I decided to call on the aid of my wife to help hold all of the pieces and to wipe up little glue drips that would show up as the pieces came together and I needed and extra hand with all of the clamps.

Glued Dawer Stack

Glued Drawer Stack

Overall, the glue up went well.  This picture shows the current state.  The color looks good to me, and I am eager to move on.  I put finish on the remaining leg and rail set tonight.

A drawer fits on each side, but I will leave most of that work for a while.

#2 Yellow Wood Pencil

By john, 17 March, 2010, 1 Comment

Identifying the most fundamental, basic and essential tool in the shop would be difficult.  But, I think that the yellow #2 wood pencil might get my vote.  From my earliest years, the yellow pencil symbolized achievement and creation.  The moment that you learn how to grasp with authority that slim instrument, and to master the ability to draw recognizable shapes and letters, you know as a child that you have crossed a bold line from little kid to adult skills.

Even today, my best thinking flows through the end of a yellow #2 wood pencil.  Although my days are filled with email and software development related tasks, no process better focuses the mind than moving away from the computer and jotting down notes on paper using the yellow pencil.  Psychological perhaps, but few things about the pencil distract you from your focus.  The computer waits upon your every command or whim with a myriad things to distract the point of your attention, and to erase fluid thought.

My oldest daughter, Jenny, collected pencils for a season.  Prized pencils come in bright colors with bold writing along the sides that remind you of someone’s value to the community.  Pencils covered with fluid shapes and colors grab the covetous nature within, but reject your intentions of use.  Purposing to sharpen such a creation produces inaudible screams of ruination within the mind, and so those works of art lay in boxes alongside other trophies of shopping expeditions, existing only to be shifted aside as the finger and eye probe for something useful, like a plain, solid color pencil.

Once acquired, a pencil belongs to one person.  An unspoken rule existed as a child that everyone knew in the core of his or her person.  You don’t take or use another person’s pencil.  Heck, the bite mark ornamentation of another’s pencil deterred any thought of touching it.  But, when you get right down to the core, maybe taking another’s pencil is sin.

Before marriage to Judy, I had a short-term painting job on a remodel.  Not possessing a vehicle, I got to the house by running the two miles each way.  I left my timesheet and my pencil on a closet shelf since I did not want to carry it back and forth every day.  One day a guy showed up to fix some other things at the house.  Amazingly, he found and stole my pencil!  Outraged, I pawed through his open toolbox in secret until I found one of his crappy pencils and with a dark cloud following me, I squirreled it away where he would not find it.  But, all night it bothered me that I had violated a cardinal rule.  You don’t take another’s pencil.

The next morning on my run to work, I stopped dead in my tracks when I spied two brand new sharpened yellow pencils lying on the sidewalk before me.  Surely, God has a sense of humor and gentle in His reproof.  I violated an innate rule for a measly two cent, half used pencil.  But He provided me with two new ones.  The message was clear — one for me, and one for the other thief.

Well, I ran around the office the other day looking for a plain old #2 yellow pencil, and only an abandoned one turned up.  Later, I went to the grocery store and purchased a 10-pack of brand new yellow Dixon pencils.  They were on sale, and I felt relieved to know that stores still sell them.  Two stayed in the office and the rest came home to the shop with me.

Of course there is a website about pencils.  Watch out though, they sell those fancy kind, including some that smell good.  But consider carefully before buying those crazy round pencils.  They will sit behind your ear as well as the hexagonal pencil, but round pencils require constant attention when you lay them down.  People with real jobs don’t have time to chase round pencils all day long as they yearn to fall off your table.  Get one that stays put, waiting and ready for you to pick it up again and get to work.

What about you?  Do you think best with a pencil?  Do you care if pencils exist or not?  I am at peace today, because I have 10 new #2 yellow wood pencils, and I know that I will be able to think and create for 10 pencils longer.

Sand and Stain

By john, 14 March, 2010, 1 Comment

The time line for this project spans quite a few months.  I took some extra hours this weekend to work on the desk.  Some of the steps in the process require more focused time than other steps, and this weekend, getting the main stack sanded, dry-fitted and stained took a commitment.

Sanded Desk Parts

Sanded Desk Parts

Before committing to sanding the legs, making a decision about the shape of the bottom of the legs needed to be done.  I made a jig for using a pattern router bit, and shaped the bottom of an extra leg that I kept for just such a time.  The original inspiration for this desk used a style that was used on a chair in the Blacker house.  I liked the look in the photos, but after working on my extra leg, I decided that a thicker, straighter bottom would give me the look that I wanted.  This photo shows the sanded parts stacked up, and the square legs.

Dry Fitting the Sanded Parts

Dry Fitting the Sanded Parts

After sanding, I assembled the parts without glue to be sure that the dry fit was still looking good.  After working with just pieces for so long, getting them back together is very satisfying.  I placed a piece of plywood behind the drawer stack to obscure the background clutter.

Before Christmas, I learned a technique that worked well for me when I made some gifts for the family.  Before gluing the pieces together, I had applied finish to the parts so that the impact of glue on the bare wood would not cause me any pain.  It worked so well, that I determined to use the same process again this time.   Judy and I visited a supply store in Omaha where we picked a color in a gel stain that we both liked.

Having not used a gel stain before, I went to the Internet to find some tips.  One that I ran across gave me pause.  This tip was familiar to me, but I had never implemented it.  By diluting 3 parts denatured alcohol with 2 parts shellac, the tip promised a nice even stain coverage.  Messing up at this point with some counter-intuitive tip did not excite me, but neither did a bad stain job.  I decided to try it, and it worked marvelously.  A nice extra was that virtually no grain raising occurred, and I lightly sanded the shellac sealer to make it very smooth.

Stained Desk Parts

Stained Desk Parts

Applying the stain turned out to be a very easy and satisfying process.  The legs look beautiful with the rays of quarter sawn oak showing on the sides, and the general tone looks warm and rich.

After these dry for about 24 hours, I start applying finish coats.  Then when I put on the glue, there won’t be any blemishes should I get any squeeze out and cleanup will be easy.