Tuesday, 14 October 2014

Best of the Woodworking Web - Brass Tacks

Sorry we've been a bit quiet on the blog front recently, but we've been busy helping the team in South Africa with a couple of fantastic woodworking shows (more to come on those soon!).

Today we're bringing you a great video featuring the team at Brass Tacks, a furniture design company who use reclaimed bits of wood and craft them into beautiful pieces of furniture. Kevin and his team enjoy using only their hands and a select number of tools to carry out these incredible transformations:

"Picking out the lumber is my favourite thing that I do, just because it's the beginning of something that's going to end up really beautiful. We really put care and love into it, and it turns into something that was completely the opposite of what it started out as, and that's just what we get so excited about - the transformation."


Credit: Brass Tacks - Kansas City from Summer House Films on Vimeo.

If you've come across any interesting videos like the above, we'd love to see them! Just leave us a comment below.

Wednesday, 24 September 2014

Router-based Techniques: Dowel Making with Half-round Bits from Woodworker's Journal

Freud lead image

Here is a great article from Woodworker's Journal - a challenge for your router table and a great way to add a touch of class and innovative design to your projects. Let us know what you think!

Why make dowels? It's a fair question, until you encounter a project where the home centre options for dowels won't do. As you probably know, wood species of common dowels is pretty limited: red oak, poplar, maple and possibly cherry or walnut. What happens when you want to accent some stylish joints with dowel pins and you wish you had a dowel made of cocobolo, Osage orange or purpleheart? Good luck finding them! Or, say you're building an outdoor chair made of cypress or redwood. You want to cover the screw heads with wood plugs, but should you use a red oak dowel to do it? Not if you want the plugs to last as long as the chair will. Most common dowel species aren't suitable for exterior use. But, there's a solution: all you need to make dowels in any species you like is a half-round router bit. As the name implies, it makes a semicircular cut. Half-round bits come in many radii, starting with 1/8-in. and going up to 1-in. or more. For most woodworking projects, a 1/8-, 3/16- and 1/4-in. half-round bit would be all you'd need for the majority of dowels you're likely to use for woodworking. They'll make 1/4-, 3/8- and 1/2-in.-diameter dowels, one after the next, whenever the need arises. Here's how:

Step 1: The key to successful dowel making is to begin with carefully prepared stock. Select material with straight grain and no visible defects, and choose a piece that's a couple of feet long and 6 or more inches wide for safe, easy machining. You'll want to start with at least twice as much dowel stock as you actually need to convert into dowels; there will be some fine-tuning and test pieces involved to refine your router table setup.

photo 1

Step 2: Flatten one face of your workpiece at the jointer, then head to the planer to reduce its thickness to match the dowel diameter you want to make. For our example in these photos, we'll make some 1/2-in.-diameter dowels from padauk with a 1/4-in. radius half-round bit. As you're planing down the material, use a dial callipers to check your progress. Get as close as possible to the final targeted stock thickness (see Photo 1).

photo 2

Step 3: Take your board to the table saw, stand it on edge beside the blade and shift the rip fence over until the fence just kisses the opposite face of the workpiece (see Photo 2). Lock the fence. With the fence at this position, you can rip square dowel blanks whose widths will match the board thickness. After you cut the first blank, check its proportions with a callipers again to ensure the dimensions match. Then cut your workpiece into as many dowel "sticks" as the board will allow. Use a featherboard, positioned just ahead of the blade on the infeed side of the saw, to support each rip cut. Guide the cuts between the rip fence and the blade with a narrow push stick.

photo 3

Step 4: With your handful of dowel sticks ready, it's time to install the half-round bit and zero in the correct settings. This is an important process because, in order for your dowels to have circular profiles, the bit needs to be set precisely. Chuck it in the router table, and raise the cutter until the bottom edge of its "C" shaped cutting profile is flush with the table top. Set a small square or rule against the bit and inspect your bit height, sighting across the table with your eyes even with the table for a straight-on view (see Photo 3).

photo 4
photo 5

Step 5: Now, open your router table's fence facings and slide the fence up and around the bit. Turn the router bit until its cutters are perpendicular to the fence facings when viewed straight down from above. Then, adjust the fence back or forth until the deepest part of the bit's convex cutters is flush with the fence's face. Use a thin steel rule to check this alignment, and see Photos 4 and 5 for clarity. (Note: For dowels 3/4-in. in diameter or less, you can set the bit to make the full radius cut in a single pass. However, for larger diameter dowels, set the bit height as described in Step 4, but begin the routing process with the fence exposing only about half the bit's cutting profile. Make one or two more passes, moving the fence back some each time, until you expose the whole cutting profile. This will reduce wear and tear on the router and bit as well as produce cleaner, burn-free cuts on the dowel stock.)

Step 6: Install a featherboard just ahead of the bit on the infeed (right) side of the router table, and clamp a second featherboard to the router fence. Position it on the outfeed side of the bit. This way, the dowel stock will be pressed firmly down against the table and in against the fence.

photo 6

Step 7: Start the router and feed the stock into the bit at a moderate pace. Use a push stick to advance the blank up to the first featherboard (see Photo 6). Once it reaches this point, step around to the outfeed side of the router table, and pull the dowel the rest of the way through. The featherboards will keep the dowel immobilized while you change positions.

photo 7

Step 8: Next, flip the dowel blank end-for-end so the remaining square edge is against the router table fence. Keep the original "up/down" orientation the same. Push the workpiece through the bit again to complete the dowel shape (see Photo 7).

Out-of-round Dowels and Their Causes

photo 8

Hopefully, your first router table setup has produced a perfectly round dowel. But, as we forewarned, you may need to do some fine-tuning to correct less-than-perfect attempts. Take a look at Photo 8. The left-most dowel is round. The four other darkened examples need some tweaking. Here are their causes:
Second from left: This dowel turned out oval-shaped, horizontally, during routing. Chances are, the stock is a tad too wide, but the bit is set correctly. Use a slightly narrower workpiece, and rout again.
Center: The flat sides of this dowel indicate that the deepest part of the bit's convex cutter is not flush with the router table fence, so part of the cutting profile isn't being exposed. Re-check the bit/fence setting carefully.
Second from right: If the dowel emerges from routing with a single flat top or bottom, either the stock is too thin or the bit is set too high or too low in the table. Adjust the bit height, and try another dowel. If the problem persists, prepare some slightly thicker stock.
Right: Here, the dowel is oval, top to bottom, after routing. Either the stock is too narrow, or the bit's profile is slightly proud of the router table fence: it's cutting away too much material with each pass. Double-check your stock dimensions and the bit's fence projection again.


Friday, 19 September 2014

Best of the Woodworking Web - Walking in a Wooden Wonderland

Henrique Oliveira is a São Paulo-based artist who uses recycled materials and returns them to their true natural form. This latest piece, titled Transarquitetonica, is a giant network of root-like tunnels which can be explored from the inside. Oliveira's largest piece to date, he sees it as not just an installation but an experience for the senses.



We love this creative use of discarded construction site materials and the way Oliveira's work returns the wood back to the beginning of its journey.

You can see more of Oliveira's work on his website: www.henriqueoliveira.com

Tuesday, 2 September 2014

International Woodworking Fair - Atlanta


Every two years the city of Atlanta plays host to the International Woodworking Fair, and the range of products and services on display this year was astonishing. From specialist manufacturers of the smallest carving tools, to demonstrations of factory-scale high speed processing of sheet materials, there was something for all to see. 
A particular crowd-pleaser was the growing number of displays with high specification CNC routers, which were able to reproduce designs with intricate detailing at simply the touch of a button.
Triton Tools exhibited with an impressive booth displaying the full range of equipment available, as well as a couple of special show previews. Whilst the award-winning Triton routers and a limited range of Triton Precision Power Tools have been available in the US for some years, the complete expanded range already distributed in other parts of the world will arrive in the USA for the first time from November 2014.

Due for release in 2015, the new Triton Workcentre WX7 attracted a lot of attention at its first showing in the US. Hands-on enthusiasts and experienced journalists alike were keen to learn more. Here is an interview with Woodworkers Journal that offers a bit more information.

Thursday, 28 August 2014

Best of the Woodworking Web - A Day in the Life

Day in the Life: Furniture Designer/Maker from ConnectEd Studios on Vimeo.

A day in the life of Jared Rusten, a woodworker who creates modern furniture in San Francisco. We love the California coffee table and his modern take on the rocking chair!

Monday, 18 August 2014

Woodworking Book Review: Making Furniture Projects & Plans by Mark Ripley

This is a book that achieves a rare double; it has great appeal for the novice woodworker and the experienced cabinet maker alike. For the beginner it offers a glimpse into the world of the possible, aspirational plans and exotic joints with explanations that make it all seem very reachable given time and practice.  For those with well-developed skills it’s an exploration of form, function and design with some great insights into harnessing the natural properties of timber to make beautiful and functional furniture.

The book is set out in two parts; the first section has an overview of the principles of furniture design balancing the four essential elements of structure, function, aesthetics and economy.  It also looks at the process of batch production with a case study of a set of chairs the author created.

The second part of the book is where it can become your coffee time browse to muse over the 24 projects. They are really well written, rather than a list of simple instructions there is an easy to read narrative that talks you through the process in a conversational style. There are some excellent photographs of the details of each project and a full set of dimensions for you to work from.  What it is not, is a strict set of rules to reproduce what you see on the page.  You are invited to understand the process and to put your own interpretation on each of the pieces.

There is no doubt the quality and design of the furniture in this book will appeal to many, and those with real ambition, a quality workshop and plenty of time should be able to reproduce Mark’s plans to great effect. For everyone else this is a grand book that will give us all plenty to aspire to and an excuse to buy a few more tools in preparation for that “One Day” moment.

Making Furniture Projects and Plans is available from GMCbooks.com and other retailers on line.

ISBN-978-1-86108-560-3

Tuesday, 12 August 2014

Custom Woodworking at its best

This post highlights the work of Erik Gustafson, a custom woodworker from Chicago. His work combines the best of craft skills with the latest technology and design.


Erik Gustafson Custom Woodworking from Chris Vanderwall on Vimeo.

If you have another great example you would like to share, let us know in the comments below!