Dining Set Tutorial #1 - Design Process and Back Chair Legs.

A dining set is quite an undertaking for any woodworker, but I seem to enjoy the challenge. There's a few folks who requested that I blog my process so this my attempt to oblige. Now, this won't be completely comprehensive, but it will show each step and point out things I think important. That said, I try new methods and learn new things with everything I build, you'll get to see some of that too.

Design...

Here we go. After getting a good idea from my aunt and uncle (whom I call "clients" for the rest of the blog, to keep it all professional-like) of what they'd like as far as wood species and design, I set out to designing the rear chair legs. My clients fancied the chair legs in this picture:

Photo from Branchhill.com

Brass City Records and Toolworks- The Leader of the Band Has Died

I was on the road to the Handworks show in Amana, Iowa when I received word that Walt Quadrato had lost his battle with cancer. Walt was the owner of Brass City Records and Brass City Toolworks in Waterbury, Connecticut. I can't say I knew that man well, but I considered him a friend. It's interesting the grief, the sting of loss you can feel for someone you've never met in person.

Walt was one of those people who left a lasting impact on nearly everyone he came in contact with. His love for music and vintage tools was contagious. His kindness and integrity was second to none. For local musicians, vinyl record and vintage tool lovers alike, Walt wasn't just a man, he was an institution. Walt must have had the digs on every flea market within a couple hundred miles. He would dig up the bargains, all the hard to find items, and pass them onto us. Of course, he made money doing this, but his markup was always reasonable. He priced tools so that the average guy could afford them and we woodworkers were especially grateful.

Handworks 2015 and Mr. Studley

I had a great weekend attending the Handworks event at the Amana Colonies. Being a furniture maker in Iowa, a show like this is simply too good to pass up. 

This picture prior to opening speaks to the success of the event before it even started. Obviously there are a lot of woodworkers in the midwest, and we were all excited about this event.

To begin each day it was pretty crowded in the big barn. My wife said it was filled with "man stink." (snicker) I found it wise to come back later in the day if you really wanted to visit with some of the toolmakers. 

Tour of a Rural Iowa Sawmill

Recently while making a trip to one of my favorite little mom 'n pop sawmills, I decided I'd snap some pics to share with you all. Something tells me not every woodworker gets to see something like this.

The sawyer's name is Paul and we've become friends. He's in his mid 70's now. How he keeps this place in operation by himself is beyond me. Paul always enjoys when I bring him pictures of the furniture, benches, and whatever else I make with his lumber. I could see how that would be rewarding for a him.

Of course his prices are pretty good since we're cutting out the middle man. That said, some woodworkers don't like this type of lumber source because they only want select grades. There's a lot more common grade wood in a log than people realize. I have no problem working around/with defects, especially when the lumber it's priced correctly.

Here goes. Entering a "hardwood farm" that has been in the same family for over a century.

The Making of Heather's Tea Shelf

This week I finished a teacup display shelf for my wife. The shelf was heavily inspired by an Arts and Crafts shelf I saw in Fine Woodworking a few years back. Basically, I took that design and made several changes to suit my wife's taste's and needs (specific tea set dimensions).

Her shelf is much larger than the one in the magazine, about 48"x 30". And it's made of curly maple instead of oak. The show faces are actually some "musical (instrument) grade" maple I was able to acquire. Here's some shots of the build...

The columns were mitered and edge glued with the nicest pieces of stock I could muster.

Mortise and Tenon Joints (Mortising Machine and Dado Blade Method)- A Tutorial

Ok, here’s how I make mortise and tenon joints with a dado blade and mortising machine. My zeal for hand tools aside, I can’t get away from this method. It’s just so darn efficient and consistent in results.

Most of us have a tablesaw. Benchtop mortising machines are pretty good for what they do. Better yet, they're affordable compared to most woodworking machines. It's not uncommon to see them on the used market either, Good thing, I can’t imagine making a set chairs or anything with a plethora of M&T joints without one.

An Inheritance

Most folks can appreciate when wonderful tools are passed down from previous generations. I hadn't really counted on an inheritance myself. I never met my paternal grandfather, nor did I care to. My father passed while my mother was pregnant with me. Shamefully, when my mother went to collect my father's tools from the foundry where he worked, his co-workers had already looted his toolbox. Nice. So, I took silly pride proclaiming that everything in my shop I had worked for, and paid for myself. You'd think I would would have learned by now,  every time I puff out my chest I'm setting myself up to be humbled.

My wife and I moved to the midwest about a decade ago. I soon learned I had a great aunt and uncle whom I'd never met. This would be my paternal grandfather's youngest brother. To our delight, Wayne and Ethel are wonderful, salt of the earth folks. And wouldn't you know it, Wayne is a woodworker too. He mostly makes wooden toys that he donates to churches, fundraisers and the like. Not just any wood toys either. Wayne made complete functioning train sets, airplanes, and so on.

Unfortunately, I got to know Wayne just as his woodworking days were winding down. He was in his 80's, his eyesight was getting worse, and he no longer trusted himself with power tools. Poor fella had to start living his woodworking dreams vicariously through me. He didn't seem to mind. He's very proud of my shop and the the furniture that has come out of it. And I have to say, I have a renewed pride in my heritage after spending time with him.

Fast forward to this year. Wayne and Ethel are selling their homestead and moving into an assisted living apartment. I was honored when their daughter offered some woodworking tools that had been in the family for generations. I know some of my woodworking friends enjoy this sort of thing too, so I thought I'd share.