Thursday, May 29, 2014

Inlaid Dovetail Box

Boxes make great gifts and are extremely useful, but they can be decorative as well. If you’ve been reading woodworking magazines for any length of time at all you know just about everyone has a dozen articles on dovetailing. It’s a great way to make a box, and it can be a decorative focal point if done well, but there’s really nothing like a little inlay to dress up a […]


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Soup Up a Veneer Saw with Mario Rodriguez

Once at a woodworking show, I witnessed Frank Pollaro making up veneered chess boards. He must have produced more than 30 pieces and each was perfect. The seams were tight and clean; there was no tear-out or split veneer. What impressed me most was that he was getting these results straight from his veneer saw, with no fussing or cleaning up on a shooting board later. After that, I was […]


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Better Start Building – Excellence Awards Deadline Fast Approaching

Just a reminder that the deadline is fast approaching for the 2014 PWM Excellence Awards; all entries must be submitted by 11:59 p.m. on June 20. Winning work will be featured in the November 2014 issue of Popular Woodworking Magazine. We’ve already received a number of entries (you can view them by clicking here)…but do we have yours? If not, click here to enter (and for a full run-down of […]


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Learn to Design Furniture – Build Reproductions

Early on in my woodworking career, I fancied myself a designer. I wanted to create new and exciting stuff and managed to have my work accepted in some pretty good arts & crafts shows. My qualifications? I had read “A Cabinetmaker’s Notebook”, had the tools, access to wood and I was willing to experiment. Thirty years later I still have some of those pieces and a few have sidled their […]


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Wednesday, May 28, 2014

An Easy Way to Draw Any Ellipse

On my most recent project I needed an elliptical arc. Although my arc conforms to the Golden Ratio (1:1.62), the method I use works for an ellipse of any proportion. Determine the overall size of the ellipse you need and cut a piece of pattern material large enough to encompass it. Next, draw vertical and horizontal lines that bisect the pattern stock. This divides the material into quarters; the arc […]


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SuperMax 19-38 Drum Sander

Attention to detail makes this machine a top-quality addition to any shop. by Chuck Bender page 14 The first thing that comes to mind upon seeing the SuperMax 19-38 drum sander is the company’s focus on quality. It’s evident in everything from the castings to the precision-milled drum to the thoughtful placement of the controls and adjustments. Though Warren Weber and Bill Schroeder founded SuperMax Tools in 2005, they’ve had […]


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SuperMax 19-38 Drum Sander

Attention to detail makes this machine a top-quality addition to any shop. by Chuck Bender page 14 The first thing that comes to mind upon seeing the SuperMax 19-38 drum sander is the company’s focus on quality. It’s evident in everything from the castings to the precision-milled drum to the thoughtful placement of the controls and adjustments. Though Warren Weber and Bill Schroeder founded SuperMax Tools in 2005, they’ve had […]


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Improvisation

Modifying a design means more than simply scaling. by George Walker pages 18-19 How do you modify a design without making a hash of it? It’s a common question that dogs even the experienced woodworker. Any good cook knows that simply doubling ingredients is asking for trouble. Somehow those flavors that danced together in a recipe for six go flat when combined for 12. Scaling an adult-sized chair to a […]


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Craftsman Wardrobe

This Stickley No. 624 reproduction provides adaptable and abundant storage. by Robert W. Lang pages 20-27 The lack of closet space is a common problem in older homes. In the early 1900s Gustav Stickley offered this wardrobe as a solution. He used a shorter version in his own home, and in his retirement experimented with finish formulas on the bottoms of the drawers. I’ve taken a few liberties with the […]


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Improve a Coping Saw

Your saw can work better by adding washers of by changing the way the saw. by Christopher Schwarz pages 28-32 When I was a kid, the first saw I bought was a Craftsman coping saw with a chrome frame and red-stained handle. For years I did everything with that saw – crosscuts, rips, curves and even joints. But I made none of those cuts particularly well. Part of the problem […]


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Tuesday, May 27, 2014

Mid-century Coffee Table

Top this sleek design with patterned veneer – it’s much easier than it looks. by Mario Rodriguez pages 33-37 All over the country, mid-century designs, with their sleek surfaces and clean lines, are turning up in high-style interiors. Here’s a simple table that’s perfect for any modern interior setting. It employs loose-tenon joinery and a veneering technique I introduced years ago that uses yellow glue and a common household iron. […]


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Massiv Mouldings

Add a few hand tools to a mostly machined process, and it’s simple to make any profile. by Chuck Bender pages 38-43 When it comes to making mouldings, size should not be a limiting factor. Using tools you probably already own – combined with a little creative thinking – you can make just about any moulding profile you desire, regardless of size. Owning a half-set of hollow and round planes […]


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Roubo’s Press Vise

This centuries-old device is effective in use and simple to make. by Derek Olson pages 44-46 In my early years as a woodworker I was prejudiced against veneer – but experience has mellowed my opinion; I’ve realized building the period furniture pieces on my bucket list requires skills working with veneer and inlay. My burgeoning interest in traditional techniques made me want to build a veneer press, but I couldn’t […]


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Danish Modern

Enthusiasm and people skills are the keys to Ejler Hjorth-Westh’s success. by Linda Rosengarten pages 47-50 On California’s Mendocino coast, you really never know who you are talking to by looking. Institutional “costume” doesn’t fly around here, so it is not always easy to tell who belongs into which socially recognizable box. So, when you first look at Ejler Hjorth-Westh, with his aw-shucks overalls and his outsized signature beard, you […]


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Painted Bucket Bench

A simple project from home-center wood is transformed with faux graining. by Catharine Kennedy pages 51-54 Faux graining is the art of illusion. Use this technique, and your choices aren’t constrained by what woods are available or what’s shown in the veneering catalogs (or your bank account); you are limited only by your imagination. With the use of simple tools and materials you can transform a modest piece of inexpensive […]


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Don’t be Such a Square

Make a 45° miter square with help from dividers and a straightedge. by Bob Rozaieski pages 58-50 The very first lesson any woodworker learns is that precise work requires square corners. We ensure that stock is square before cutting any joinery. We check to make sure that casework is square during assembly. Almost everything we do is dependent upon things being square. That is, until we need an angle other […]


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Matching Colors

Use the method that allows you to keep trying until you get it right. by Bob Flexner pages 60, 62 One of the most challenging tasks in wood finishing is matching the color of an existing object, color swatch or photo in a magazine. Most people try to accomplish this with just a stain, but it rarely works. Most factory-finished objects, for example, are colored with more than one step […]


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Take Your Work to Home

A lunchtime woodworking break yields more than a nice saw handle. by Ethan Sincox page 64 Last summer, I took Matt Cianci’s “Build a Backsaw” weekend class through my local woodworking guild. There is never enough time in a weekend class to finish the project; this was no exception. I’d roughed out the tote, set the saw plate into the back and sharpened the teeth (with impressive results), but it […]


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Threadboxes: One More Song the Radio Won’t Like

Whenever I write about threadboxes, my personal blog gets swamped with spam from the Pacific Rim. So batten down the firewalls, mateys. I started writing about the Moxon double-screw vise in 2010 (original post here) and have made many of them using a threadbox and tap that you can buy from many reputable woodworking stores. My first threadbox worked fine until it needed sharpening. The blade was so brittle that […]


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Monday, May 26, 2014

Modeling the Core Box Router Bit in SketchUp

A student emailed me and asked: “How do I model the cut a core box router bit makes in SketchUp?” At first glance you might think the answer is the usual – model the shape of the bit and use the “Follow-me” tool. After further consideration it becomes clear that the answer is much more complicated. When router bits are used to make cuts inside a board – as opposed […]


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Saturday, May 24, 2014

Chairmakers’ Roundtable at Woodworking in America

Because of the wealth of many excellent chairmakers who are teaching at Woodworking in America 2014 (Sept. 12-14, Winston-Salem. N.C.), among our session offerings is the Chairmakers’ Roundtable, on Saturday afternoon. Initially, the panel discussion was slated to include Peter Galbert, Drew Langser, Don Williams and Phil Lowe. Chuck Bender, who is also an excellent maker of things upon which to set your posterior, was scheduled to teach another session […]


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Thursday, May 22, 2014

A Twice-turned Bowl from Green Wood

Next week on Woodturning with Tim Yoder, Tim will demonstrate his two-stage process for turning a black walnut bowl from a chunk of green wood. Green wood is a pleasure to turn because the fibers cut easily due to the wood’s high moisture content. But if you try to turn a finished form, the green wood will deform as it dries, leaving you with a bowl that’s likely oblong and […]


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Not Just a Stuffed Dove

What’s really fascinating about this “Woodwright’s Shop” video excerpt is the way Roy Underhill expands the definition of dovetails and dovetailing. Woodworkers can get into a rut thinking only about through dovetails and half-blinds. But what makes a dovetail a dovetail is not just the look of the pins and tails on the corner of a drawer – it’s the internal structure of the joint and how the wood faces […]


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Wednesday, May 21, 2014

The Monogamy has Ended

When I teach people to sharpen edge tools, I am very much an “I’m OK, you’re OK” guy about the kinds of systems out there and whether you should use jigs or not. But there is one thing I’m all fire and waterstones about: Stick with one system until you know it – at least 12 months. I call it “sharpening monogamy.” I also practice “saw monogamy” and the regular […]


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Puzzle Stool Video – a Different Project, a Different Kind of Video

There are many ways to learn woodworking and I think making a project is way better than getting bogged down in theory, tool collecting or setting up the ultimate shop. A good project offers a challenge and more often than not you can work with the tools and shop you have. One of my all-time favorite projects is the three-legged stool seen here. You don’t need a ton of tools […]


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Tuesday, May 20, 2014

It Floats. It’s Full of Stars….

I have lost track of how many vises I’ve built or installed on workbenches. So my early-morning giddiness about the Benchcrafted Crisscross is worth note. This week I’m putting a leg vise on my Holtzapffel workbench that will have both the new Benchcrafted Classic vise screw and the Crisscross Retro (instead of a parallel guide). I’ve used vises with the Crisscross installed, but this is the first Crisscross I’ve installed […]


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Monday, May 19, 2014

Four-hour Pot Rack

The headline is a bit misleading – this really took me only about two hours to build, start to finish, including a break to empty the dust collector. But I’m counting the one-and-a-half hours in between when I dropped off the metal bits to be cut to length and when they were ready to be picked up, plus the 20 minutes I had to wait for my neighbor to finish […]


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SketchUp Help – 10 FAQs

I have been teaching SketchUp for over seven years, both live and online. Students new to SketchUp struggle with a set of problems that are very similar in nature and can be characterized by one of the following questions. Over the years I have developed some tools to help students through these problems. In some cases the tools are a free plugin to help avoid the problem altogether. Sometimes the […]


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Friday, May 16, 2014

5 Mistakes Beginners Make with Block Planes

When I teach beginners, one of the most common phrases I hear is, “I cannot get this (insert tool name) to work. What’s wrong?” They hand the tool to me and the fun begins. Though block planes are dirt-simple handplanes, there are some important points about them that are rarely discussed in the literature. Here are the five most common problems I see with students’ block planes. 1. Too tight. […]


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Thursday, May 15, 2014

Do You Know Wood?

When I started my job as director of marketing at a lumber company, I received an e-mail from Christopher Schwarz telling me that I would be in a unique position to help educate scores of woodworkers about wood, something they ironically know little about. I laughed it off at the time and felt he mostly was referring to how small a part we woodworkers play in the business of lumber. […]


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Wednesday, May 14, 2014

Renewal Scam Alert

As good as I think our magazine is, it’s not worth $59.95 a year*. A scam company is attempting to perpetrate fraud by mailing the spurious renewal offer pictured above. Do not respond. (And please know that we are taking steps with the U.S. Postal Service and consumer agencies to address the problem and take appropriate legal action.) Our subscription fulfillment service is Palm Coast Data (also rendered as PCD […]


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5 Books I Can Highly Recommend

In the 1990s, I had the good fortune to head the editorial team at Rodale Woodworking Books. It was an amazing time when, thanks to the talent of the editors and authors with whom I worked, we produced a number of best-sellers. The hits included Shop Tips, Woodworking: The Right Technique, Router Magic, Woodworker’s Problem Solver and the Woodworker’s Visual Handbook. Each of those books sold more than 100,000 copies […]


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Making a Vise Chop for a Benchcrafted Classic

I started making the wooden vise chop for a new leg vise for my Holtzapffel workbench (featured in “The Workbench Design Book”) using some crazy new hardware from Benchcrafted: the Classic vise screw and the Crisscross. The only downside to the Crisscross part of the assembly is that you need a vise chop that is quite thick – 3” is a good thickness. I don’t have any maple in my […]


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Another Engine

I have lost track of the number of wooden try squares I’ve built in the last five years. At this time last year I had the parts for about 20 mahogany squares in my shop. Now I’m down to one (the rattiest one I couldn’t sell) and some special parts for squares that I don’t want really want to build. That’s not entirely true; I really want to build them, […]


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SketchUp for Woodworkers – Here’s Why

This topic has appeared once or twice on woodworking blogs. So why list the benefits of SketchUp for woodworkers again? Here’s why: There are still too many woodworkers out there who have never heard of SketchUp and we need to get the word out. Woodworkers have short memories when it comes to tools that don’t reside in a cabinet on the shop wall. Lastly, while this topic has been discussed […]


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Monday, May 12, 2014

Tightening the ‘Stay-Set’ Chipbreaker

Last week I took my new Clifton No. 5 to teach a full-size toolchest class at The Woodworkers Club in Rockville, Md. Several of the students used it on their toolchests, which they made using cherry, pine or poplar. The plane did quite well – the iron stayed sharp through planing up an entire case. As I mentioned in my entry on this plane last week, my only quibble was […]


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Dovetail Marking Gauge Roundup

Whenever one of my dovetail marking gauges shows up in the magazine, in a blog post or a tweet, I get questions about it – so I’ve written about it before. And today, I got another question about the one (shown above) that I use in a YouTube video on using dividers to lay out DTs. It’s the Precision Dovetail Template from Woodjoy tools, with a 1:6 slope on one […]


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Senco Event Wrap-up

Last week’s Senco event here in the workshop at Popular Woodworking Magazine was a blast! If you missed it then you missed seeing, learning about and trying the best new tools Senco has to offer this year. The Senco crew came out in force to introduce readers to their products. We had not just one but three product managers present. These guys know their products like no one else. They […]


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How to Stop Your Rabbets from Sloping

Cutting a square rabbet with a rabbeting plane is a challenge for beginners; usually they cut a rabbet that slopes in toward the shoulder or away from the shoulder. When I teach people how to use a moving fillister plane, here are some tips I offer them to assist their efforts. 1. Don’t hold the knob. If the plane has a front knob, I recommend you remove it. At the […]


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Friday, May 9, 2014

Furniture Details: Why Philadelphia is Just Better

Short of that stint living in Anchorage (yep, Alaska) from birth until about two years old, and the last seven months or so living in the Cincinnati area, I’ve lived the vast majority of my life outside of Philadelphia, Pennsylvania. You might be thinking that is the singular reason for the title of my post but you’d be wrong. While I truly enjoyed being completely immersed in the history and […]


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Thursday, May 8, 2014

How to Make Wood Pendants on the Lathe

Next week on Popular Woodturning, host Tim Yoder will show you how to turn beautiful figured-maple pendants and then dye them in a 5-step process to create unique jewelry. Tim says his friend and fellow turner Bruce Holden developed the process for creating these pendants. And as you’ll see, it’s a clever one. Tim starts by roughing out the blanks, using a drill press, hole saw and band saw. Then […]


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Dust Collection System FAQ

Is there any advantage/disadvantage to installing a dust collector outside the shop? It may sound as resolute as a long-range weather forecast, but yes, maybe and no. It is really a personal choice. Locating the dust collection machine outside the shop will lower sound levels and free up shop space. For some woodworkers (me included) these are the deciding advantages. But if your winters are cold, first consider how to […]


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Zachary Dillinger a 2014 EAL Top Traditional Craftsman

Woodworker Zachary Dillinger, of Charlotte, Mich., has been named to Early American Life magazine’s 2014 Directory of Traditional American Crafts in the Painted/Formal Furniture category. You’ll find this year’s list in the magazine’s June issue. Zach (whose spice chest shown at left was featured in our August 2013 issue), is only 30 years old, but he’s been making things for two decades. Since 2008, he’s focused almost solely on authentic […]


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Monday, May 5, 2014

DIY Dust Collector – Avoiding Spark Potential

Woodworkers love their toys. Table saws, jointers and planers are serious big-boy (and big-girl) toys. Planes, chisels and saws are cherished, too, and though we all take our craft and hobby seriously, we just seem to love our toys. We collect woodworking toys and play with them as much as we can. Lately, though, a small non-woodworking toy called a plasma globe (pictured above) has caught my fancy – and […]


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Last Call

As the time draws near, a couple of spots have opened for the Senco event here at Popular Woodworking Magazine. They are bringing in their newest pinner, the 21LXP (which won’t even be available to dealers at the time of the event) for you to try, along with lots of other new products. Senco and PWM are giving away door prizes and everyone will get some swag. I forgot to […]


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The Rule of 3 – How to Sharpen

Among the fundamental skills necessary for good woodworking, I’d put knowing how to sharpen your edge tools at the top of the list. Even if you consider yourself a power-tool woodworker, I’ll bet you have at least a chisel (or two) and a block plane in your kit that need sharpening from time to time. There are many different ways to sharpen: waterstones, sandpaper, mechanical solutions, oilstones and more. Now […]


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Saturday, May 3, 2014

Shannon Rogers’ Big French Saw. Dang.

Shannon Rogers of the Hand Tool School brought along his 48”-long Roubo frame saw to the Saturday meeting of the Chesapeake chapter of the Society of American Furniture Makers, explained its details and (most importantly) let us try it out during lunch. It was so effortless to use (as long as you used your legs to propel it) that I wanted to resaw the entire board. Shannon has put a […]


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Thursday, May 1, 2014

Settling Debts: An Update on Clifton Handplanes




Though I’ve been a non-editor at both Popular Woodworking and The Fine Tool Journal for almost three years now, I still have debts to pay. And I take those debts seriously. One of my first reviews for The Fine Tool Journal, which was reprinted in the book “Handplane Essentials,” is a review of Clifton bench planes. I had some of the first-ever Clifton planes, which were both spectacular and troubling. […]

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The Church of ‘Leave me Alone, Please’




During the last 17 years that I have been using a honing guide to sharpen, I’ve been approached (sometimes nearly assaulted) by people who want to teach me to sharpen freehand. My response: “I sharpen freehand all the time.” They don’t believe me, and so they spend an hour or so to show me how they hone their edges. Then they want me to try their technique and say: “That’s […]

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