recent projects-in-the-works

A long stretch here without a blog post. That means I wasn’t shooting many photos in the shop. well, not woodworking photos anyway. The shop has been a bird blind lately, more about that later. But I have done some woodworking, mostly stock prep. Sorting the hickory, I’ve been splitting and shaving it into chair parts.

some of the hickory

The photo above shows just some of it. In that heap are parts for shaved windsor chairs (Curtis Buchanan’s “democratic chair”), some ladderback chair rungs, tapered legs for brettstuhls, some shaved stuff to make basket handles and rims, and some oak for a joined stool. There was more work that didn’t make it into this photo, some back posts bent on forms for ladderbacks and two pitchforks from Drew Langsner’s Country Woodcraft: Then & Now. https://lostartpress.com/products/country-woodcraft-then-now

a few baskets woven

During the recent heat wave (we had it easier here than most, but it was still pretty warm) I wove a few baskets from some ash splints I had stored. Easy work and you slosh around in a bucket of water. Next I’ll finish off the tops of them, then make handles & rims from the hickory.

kids’ chair & full sized version

These two chairs were kicking around, so I wove hickory bark seats on them from some of the last bunches of old bark I had around. The kids’ chair had a boring error that needed plugging, so I experimented with coloring it to hide my sins. The chair behind it is hickory with oak slats. It has been in the loft for a year or more, and I finally decided it was either getting burned or getting a seat. It too had a boring error, no real harm other than to my pride.

hickory bark seat

Also down from the loft is this box.

carved oak box

The box was maybe #12 of 11 boxes I made last fall (or 11 of 10, I can’t remember). I got the body made & then stuck it up in the loft. There it sat til I was cleaning up there last week. Found a wide piece of pine and glued up 2 quartersawn boards for the lid. So this is sort of the first box for 2021 – except I made the box in 2020. It’s a big one, I’ll get the measurements when I do proper photos in the next few days.

OK – the birds. Out one window has been the house wren (Troglodytes aedon) nest in one of the gourds Maureen grew last year. They kept me pretty occupied with their comings & goings. Here’s an adult with a chick in the gourd, mouth opened wide.

begging for more

out the same window, but closer to the shop, a robin (Turdus migratorius) was building its nest for a 2nd brood of the season.

working on the nest

I also kept an eye out on the other side of the shop for the great blue heron (Ardea herodias) who was hunting in our yard for chipmunks and other critters.

looking out from the hurdle

This strike was a mole or vole down in the shavings pile by the garden.

gotcha

It’s gone on like this for a month, day in & day out. The wrens have fledged but I hear the male singing again. Time for a new mate for him and a last brood of the season. The robins hatched just one chick this time, and it’s growing daily. The heron keeps coming back. There’s no shortage of chipmunks.

works in progress

some recent chairs

I haven’t taken many photos lately, which is why there’s been no posts. I have been working, though. As I wait for the oak I planed up to dry some before I begin framing the cupboard, I’ve been making chairs. And I have a few more to do – I am shopping for a new oak log to finish prepping the cupboard stock, but started another brettstuhl, a joined stool and some more ladderback chairs. Below are the next three- each waiting for the next step.

next 3

The joined stool parts are at the end of the bench. Joinery is all cut, but I’m letting them dry a little more before I do the turned decoration. Maybe a week.

Then the brettstuhl – that one’s next. Right now, the oak battens are drying in the kiln, and later today I’ll begin shaping them & fitting them to the seat board. So that one will be done in the next three or four days. (longer if I find an oak log Friday…)

The ladderback chair in the front of this pile – its rungs need to go in the kiln now. There, they’ll dry a few more days and I can then bore & assemble that chair.

Someone asked about how I store bits & pieces for many projects at once. In my small (12′ x 16′) shop, it’s tricky. The chair parts are easiest – they get split & shaved, then tucked up in the ceiling/floor joists above my head.

chair parts drying

The stuff for the joined cupboard I’m doing is difficult, in part because the parts are big, but mainly because there’s so many – maybe 60 pieces in the frame. Here’s part of them, stickered & sitting on the loft floor.

stacked & stickered

The absolute worst storage, if you can call it that, is this one – a heap standing in the corner.

storage or out of control wood pile?

I think I’ll tackle this heap first today. The bent chair posts can go into some racks between the rafters. Then I’ll sort out the cupboard parts here, and stack them somewhere. some of this is bound to become firewood – so that can go outside. And on & on.

Make a Joint Stool from a Tree

2012. That’s when the Joint Stool book appeared with Lost Art Press. I forget, but I think it was one of their first “outside” books, i.e. authors other than Chris/or reprints. It is a book that is near & dear to me, representing 20-plus years of my collaboration with Jennie Alexander – I learned so much in that period it’s always fun to look back on the whole ride. 

Chris wrote to me recently, saying it’s time for the 2nd printing, and would I write something about JA for it. So I added a new short intro – that’s all that’s changed for content. Chris made some changes in paper choice, and we switched it to a board cover. The aim was to lower the price of it from here on out. 

But there’s still some hardcover copies left, and they have put them on sale to move them ahead of the new printing coming in. So if you want the original hardcover – now’s the time to get it for $27 – I think it was $43, so not insignificant. Have at it.  https://lostartpress.com/collections/books/products/make-a-joint-stool-from-a-tree 

In my back & forth with Chris, I mentioned that I had wanted to add a shaved baluster instead of a turned one. But never had the time. So I said maybe we could do it as a blog post – then I searched & realized we had already done it! I knew it was a good idea.

 https://blog.lostartpress.com/2012/07/02/joint-stools-without-a-lathe/

the next wainscot chair

I’ve been working on some blog-housekeeping lately, with more to come. I re-did some of the drop-down menus at the top of the blog. A couple new pages just show examples of things like carved boxes, wainscot chairs, chests, etc. On the side menu there’s a link to the page at Lie-Nielsen for the videos they produced of my work.  I think there’s 8 of them now, including the new one about making a shaving horse. I have some of the shaving horse one for sale still, or you can get them from LN.

Meanwhile, I’ve just started another version of the chair above. The wainscot chair isn’t in the book Joiner’s Work, but I did shoot a DVD with Lie-Nielsen about building one. Making the rear posts is as “un-green-woodworking” as you can get. The wood is fresh, wet, all that. BUT – it’s non-supportable in an ecological sense. The back posts are hewn and planed out of a large piece of oak. Most of which ends up as chips. Here’s a side view, showing what I’m after.

Here’s how I shaped them this week. The bolt I shape them from is about 4′ long, and initially maybe 6″x 6″. There’s one on the sawbuck in the right of this photo. I’m using a hatchet to remove the bark first.

This is a case where I work the tangential, or growth ring plane first. Now using a joiner’s hatchet to get a relatively clean surface to lay out the shape on.

I lay the chair stick on there, and shift it this way & that to get the orientation the best I can. There’s compromises happening with grain direction. I’d like the upper part to follow the fibers, but then I’d need an even bigger bolt to start with. So shift it some more.

Using a froe to knock some excess stock out of the way.

In the shop now, having planed the surface some, re-do the layout of the shape. But there’s one problem down at the foot. The riven shape falls away, so I had to shift the stick over some more.

The detail showing how the stock is tapered under that surface.

There’s a lot of back & forth between the planes, the hatchet and layout with the chair stick.

 

A chalk line to mark out the width of the stile – then hewing it to nearly that line.

I almost gave up this indoor chopping block. It’s in a tight space & I don’t often use it. But I’ve had this particular one since 2001 so I figure I’ve kept it this long…

checking the front face above the seat, I want it flat along its length. There’s going to be joinery in two planes there, and carving too.

The front face both above & below the seat level are mostly defined now, and I’ve laid out the back line to this post.

The easiest way to hew that rear section is to cut reliefs in the wood along the layout lines. These saw cuts go down to a depth, then I hew to them.

I’ve switched to a smaller hatchet, this one by Julia Kalthoff https://www.instagram.com/kalthoffaxes/?hl=en. I’m using it to knock out the blocks between the saw kerfs. Several saw kerfs takes most of risk out of this step. You can do it with one, right at the junction between up & down. But more kerfs helps.

I set it on the bench now on its face to work the back surface.

A holdfast grips it down to the bench, and I shimmed under the foot at the other end. Then went at it with the scrub plane. Flipped it end for end to do the same to the top end.

The first one took forever, because I was photographing it. The second one went more quickly. About halfway through the 2nd one, I switched from using the chair stick as reference to using the first post. More important that they match each other than getting them to agree to the stick. I timed the 2nd one and it was 1 hour & 5 minutes from the split-out section to the finished post. All the steps above included. Now these (and the other parts for this chair) will sit for a month to six weeks to begin drying at the surface. Then I’ll work them along, planning to work on this chair at Fine Woodworking Live in April. http://www.finewoodworkinglive.com/ 

 

 

 

 

 

 

 

 

some random photos & a couple of projects

a few photos from this week. Just a month past the solstice and I see a big difference in the light in the shop. Some stuff caught my eye just because of the light. Carvings for one, but what else is new? There’s always carvings around here to catch the light.

I put linseed oil on my shaved Windsor chair. I’m patient and I know in time all those various woods will come into agreement. For now the pine seat is a snappy item.

I had just bored some holes for another one of these chairs; and even the brace jumped out in the sunlight.

Alexander gave me this Spofford brace decades ago, and in 1994 the pewter rings in the handle gave way. My friend Pret repaired it for me with waxed linen, and it’s held up all these years.

I was doing more than navel-gazing in the sunshine. I went up in the loft, found this stool and brought it down & put a Shaker tape seat on it. Done. It’ll be for sale/on sale soon.

Assembled these joined stools for a long-suffering customer. Next up is trimming them here & there, and finishing. White oak.

I am making some chairs this winter, and decided to spend some time making a new toolbox for some chair-making tools that have been gathering wood chips and dust. It’s not very large, maybe 28″ long. I forget how tall, 12″ or less. It’s overbuilt, but the tools & jigs that fit in it are heavy. Next up for it is yellow ochre paint & chip carving. Iron handles by Peter Ross.

I’ll store it under my 2nd bench, either on the shelf or the floor. So the handles will work well, dragging it out from under.

till inside for bits, levels and other small stuff. Braces and bit extenders fit in the long tray inside. And various gear for the JA chairs; blocks, holders, etc. I ran out of light, so didn’t fit the hinges today. Hopefully tomorrow. Sycamore till lid.

Planing up some red oak for a wainscot chair I’ll be building at the Fine Woodworking Live event in April. Here’s my equivalent of dust collection.

I wrote one day on Instagram about Big Ray, when I was planing some white oak. All the women go crazy when Big Ray comes to town. (It’s like a combination of The Same Thing by Willie Dixon and Panama Red by Old & In the Way.)

Here’s Little Ray, from the red oak.

I’m really not a wood-collector

I can’t be a wood hoarder (or collector) – I don’t have room. But for someone who claims to not collect wood, I sure spent a lot of time lately gathering it. Much of my wood of choice is green wood. If your eyes get bigger than your stomach for green wood, you end up with stuff that goes bad one way or the other. Some green wood rots, like birch for spoons. Some gets insects if you don’t get the bark off. Like oak. Here’s former spoon wood that never got made:

Winter is the easiest time for a green woodworker; no insects to invade the stashed timber. I have this pile of riven oak bolts standing outside my shop; this time of year there’s no hurry to deal with them. These are between 5 and 6 feet long, a few shorter sections in there too. Most is oak, a few are hickory that just came in this week. 

I have started to split them up and rough plane them one by one. Removing the sapwood and the bark is critical, that’s where the creatures get in. I have some joined furniture coming up – 2 joined stools, a chest of drawers and a wainscot chair. But then I need a place to store the planed oak bits…here’s a small stack up in the edge of the loft. I’ve glued the ends so they don’t check. I often write the date on them too, helps me keep track of what’s what. These are drawer parts and frame stock for a chest of drawers that’s on my list. The chair rungs behind them are a bit too wiggly to be good enough; but too good to burn. For now…

Before most of that oak work, I have two large pieces to build for the Old House in Cutchogue, Long Island out of white pine. A settle that’s essentially 5 feet square and a dresser that’s 6 feet wide and 7 feet tall. Like much early pine furniture, the originals that we studied to base these on were made from wide white pine boards. The settle for instance – the narrow parts are 15” wide. The uprights are from an 18” board.

This week I went to visit a friend of mine to get some of this white pine. We had to sort through a lot of pine boards, because there were too many 24-26” wide boards and we didn’t want to cut those down to 15” stuff. An interesting problem to have – boards that are too wide! I couldn’t leave all those two-footers behind, so a couple came here to be future chest lids. On the left is one of the settle’s uprights – it’s about 18″ wide, the board beside it is maybe 24″ wide. One or two small knots in the settle piece, the other board has none. 

I pulled one down from my loft that I’d been saving for a couple years, and cut it for a chest here in the house that has been wanting a lid for a while. So I can stash one board where that came from. But clearly it’s time to sort and clean out the loft and use it for real storage, not dead storage.

The next day found me helping some friends sawing out white pine boards, and some of them came back here too. These are green, just sawn. So their storage is easy, outside, stickered and forgotten til next year. Some 20” one inch boards, and one 2” thick plank; about 12 feet long. I’m in the midst of covering this small stack with leftover boards from building the shop. 

Then back to the first stop, where now there was a section of green hickory up for grabs. I split some out, about 6’ long. Chair parts, basket rims and handles. This needs pretty immediate attention, hickory has a lousy shelf life, and is best worked green. A detour, but a fun one. 

I disassembled my lathe to make room for all this oversized work; just finishing up the bedstead now, then will begin work on the pine pieces. You can see how tight it is in there. The long rails are just seen by the through tenons in the foot board’s posts. 

Here’s the wedged through tenon. After this photo, the wedges got trimmed a little, the tenon got chamfered on its corners.

After these large pieces, I’ll re-assemble the lathe. By then, it’ll be spring and I’ll start travelling and teaching. Better get to it.

A new red oak log

No matter how busy I am, when the right log comes along, I try to hop on it. Our friend John Scags had a great red oak that I knew would not be there in 4 weeks when I get back from my trip. So even though I’m too busy to think straight, I took the time today to split open this log. I had John crosscut a couple sections; one five feet long, the other 3 1/2 feet. I even got some stuff from the “butt swell” that I had planned on discarding.

This oak split open so nicely; it was a treat. Very slow-growth too. That represents a diminished strength; but for my joined work it’s fine. The stuff is overbuilt anyway. For the JA-style ladderback chairs, it’s probably not the best choice, but will work…

In this first photo, I’m working on the top end of the 10-foot log. This section was trimmed to just under 4 feet. It opened with two wedges, and barely any muscle. There’s some lousy stuff right near the pith, but the straight wood out near the bark is perfect. Flat, straight and easy to split.

These quarters are split, just with some fibers hanging on. I went in with a short axe and snipped them open.

The main section was five clear feet, just above the flared bottom of the log. I bit more trouble inside, but nothing too difficult. Here I am using one of the heart sections busted off the top bits to pry it open after splitting.

I tried to shoot some video with the new camera. It seems mostly to be me fumbling around and dropping stuff. But I do get the wood opened too. It wasn’t as windy as it sounds, the Nikon has a setting I need to go in & adjust to cut out all that noise…

https://youtu.be/KduuYy499Ps

 

How to Read, by an Oak-snob

I’ve been slow to add stuff to the blog here. Time to correct some of that. Today’s chore is splitting up some leftover bits of oak, and some newly dropped-off bits. Here’s how I read these, and how I decide what to split from a few different bolts. the first one is an old one, been split & hanging around a long time, over a year I’d say. It was given to me about 2 months ago. Free wood is sometimes not worth it. this is one of those cases. Note how the radial plane is cupped. This isn’t from drying, it’s the way the tree grew. The medullary rays curve from the center of the tree to the bark. So if I want wide flat stuff from this, I have my work cut out for me. What I do with such a piece of wood depends on several things: what I need at the time, how much effort I want to put into it, and how much other wood I have around. These days, wood is in pretty good supply, time much less so. Thus, I want to get the best piece I can from this as quickly as possible.

The ruler shows how “un-flat” the split is.

The piece was 26″ long, but with the checking at each end, I expect to get about 22″ length out of it. Just right for a joined stool stile (leg). So I opted to split a 2″x 2″ square out from right below the sapwood. First split with the froe gets off the inner twisted bits.

Next I split off the sapwood & bark. Surprise, the sapwood sheared off across the grain. Usually a log that has been around this long has punky rotten sapwood – I expect that. But to shear off like that means there’s something underneath…

And there was – some deformity curving the grain near one end. So didn’t get my 2″ x 2″ x 22″ stile. The resulting piece could be a ladderback chair front post (something I want to build, but have no time for right now. I’ve made parts for 3 of them so far this fall.) or the leg to a workbench out in the yard. I already have maybe 4 of those benches. On to the next split.

This one’s big & fresh. Just came in yesterday. Bark looks good. Very wide bolt, maybe 12″ or more.

But a big knot creating disturbed grain all around it, the full bottom third or more.

I always am working between getting the biggest piece (widest) I can, or getting the best piece of wood I can. Usually I want the best one. Which in this case, is much narrower than what I first expected from a section like this. See the ruler here, the best (straightest, flattest, least-work) piece is from the 10″ mark to 15″. So that’s what I split.

 

Now the distorted stuff is isolated in the right-hand section, destined for firewood.

Then I further split the remaining stuff into four thin boards for carved boxes, or narrow panels for the sides of some chests. Once I don’t think about where they came from, these are excellent clear, straight boards. This is a case of free wood that is worth it.

One of the older bits looked promising: wide, maybe 7″ or more. 24″ long.

But when I sighted down its length, lots of twist from one end to the other. I didn’t shoot it well enough, but you can generally read the twist down at the far end. Its right hand corner is high, as is the left corner nearest us. Means some hewing before planing. Not fatal, but maybe there’s better wood out here.

Yup. Fresh too. (that means easier to work…) Shorter, but wider.

When I scooch down and sight its radial plane, dead flat! That’s the stuff I’m after…

Gonna have lunch and find some more like this one.

 

Want to learn more about how to read these logs – Plymouth CRAFT has a weekend class coming up that’s just the ticket.  https://www.plymouthcraft.org/riving-hurdlemaking-weekend

Riving, hewing, drawknife work. Me, Rick McKee ( https://www.instagram.com/medullary_rick/  and https://blueoakblog.wordpress.com/  ) and our friend Pret Woodburn will show you all we know about opening oak logs and what to do with them.

 

 

Plymouth CRAFT workshop in October

With Greenwood Fest taking center stage in the Plymouth CRAFT calendar, there is an understandable quiet period in the summer, just after the Fest. But now autumn is here, and we’re back at it. Along with Pret Woodburn and Rick McKee, I’ll be teaching a 2-day class; Riving & Hurdlemaking Weekend in late October; https://www.plymouthcraft.org/riving-hurdlemaking-weekend

An alternative name for this class could be froe, hatchet and drawknife. But even that leaves bits out. Here’s Rick using the riving brake to shave pieces with the drawknife…

This class is an excellent introduction to the ancient method of riving your work-pieces directly from a log, and using simple edge tools to produce your stock for a project. In our case, it’s a garden fence called a “hurdle.” When I first started green woodworking, these were the methods I learned to make ladderback chairs. The 2-day format precludes us making a chair, hence the hurdles.

The workshop takes place outside of Pinecones, part of the Pinewoods Dance Camp where we hold our Greenwood Fest in the spring. The link above tells the details, you can opt to stay at Pinewoods in one of the cabins – it’s a great setting.

We’ll cover the structure of the wood, why we split it this way & that. How to shave it, hew it – the proper shapes of the various tools and equipment like shaving horses, riving brakes, etc. Lots to cover, and a real eye-opener to many who think wood comes from the store or lumberyard.

Here’s a group shot with the nearly-finished hurdles…

 

There’s other classes coming up in the fall and into the winter. Spoon carving, German holiday baking & more. https://www.plymouthcraft.org/

 

rear post for a wainscot chair

The next couple of weeks will feature some chairmaking here. As I said earlier, I’m revisiting the ladderback chairs I began my woodworking career with…I shaved some posts & rungs and chopped slat mortises – but shot no pictures. But today, I had some wainscot chair work to do; and what a world of difference. I had to fashion one hewn rear post for a wainscot chair like this:

wainscot chair, side view

The “cant” or “rake” to the rear post is hewn, not bent like in Alexander’s ladderback. This post starts out as a split billet 3″ x 4″ x 48″. That’s a lot of oak. I hewed it oversized; a few weeks ago I worked one and it was too close to the finished size. When I was done hewing and planing, it came up “scant” – i.e. too small in cross-section to match the first one. Here, you see the template laying on the riven and hewn piece:

Thinking about the JA chairs – this one billet had enough wood to maybe make 3 or 4 posts for a JA ladderback. This is a rare case where I work primarily on the tangential face first. I want the front face of these posts to be the radial surface (it’s going to be carved, & I like carving that face better than this one). So the cant gets laid out on the growth-ring plane.

Once I hewed and planed that face pretty flat, I scribed the template and began to hew the shape. The front is easy enough to hew, because of the way you’re cutting down the grain. In this photo, I have the front faces planed, and I’m cutting the thickness of the post above the seat. I decided to saw, rather than split this, so I can use the piece that’s coming off – it will become either a stretcher or one of the carved figures that is applied to the side of the chair. I made a relief cut at the seat height, and am sawing down to that cut. In the photo, this saw cut is nearly done. Then the stuff below the seat will get hewn away, there’s nothing worth saving there, so hewing is quicker than sawing. Easier too. You can see relief cuts there too, I stood the piece up on its top end and hewed down to the mid-point. 

Cleaning up these rear surfaces is pretty easy. They don’t have to be dead-flat or true. I shim under the end, and shove the post against my bench hook/planing stop. A holdfast keeps it in place. I’m only planing as far as the plane will fit. It gets close to, but not up to, the angled spot where the post leans back. I skew the plane to get close…

Then switch to a spoke shave. it’s one of the few times I use this tool in joiner’s work. That’ll sneak right up to that junction.

I have to let it dry out a couple of weeks, then I can cut the joinery in it & continue on with the chair. I have another to start in the meantime, so there will be more chair work on the blog soon.