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Building Backyard Furniture

As usual, summer has snuck up on me. I keep finding myself in the backyard, fiddling with two old bird feeders, looking out past the hedges to the where the river starts, or just sitting on the steps enjoying the warm breeze with the dog. Even my wife, who has not been overly pleased with the weeds and some of the sandier parts of the yard, has found herself outside. Unfortunately, our outdoor furniture, a good 10 years past its prime, has finally given way to complete despair. I was pulling of the arm rest of the wicker loveseat when my daughter asking when we’d be buying something new.

While not opposed to finding out what the nearest furniture store had in stock, I realized that this was a golden moment for a project—one which would give me an excuse to work outside as well as something more comfortable that the concrete stairs or the wicker. While I surveyed the tool situation in the garage, my wife and daughter searched for images of what they might like. I ultimately decided that this would give me a great reason the buy the 5-piece drill bit set I’d had had my eye on. The ladies requested Adirondack style and was able to I find an excellent how-to by Family Handyman.

adirondack love seat

To build the Adirodack furniture for your own backyard, here is Family Handyman’s “How to Make an Adirondack Chair and Love Seat.”

 

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Use Forstner Bits, Combinations Blades and Other Tools to Organize Your Shop

As a woodworker, we often amass large amounts of tools – both big and small. While I have seen some very well organized shops, I admit that I am not the most organized person. I try to keep my router bits, saw blades and hand tools in their set places, but there have been numerous times that I had to spend more time that I’d like to admit searching for specific router bits and other tools when I needed them.

For those of you out there would also appreciate some organizational tips for your woodworking shop, and those of you who are by nature organized and appreciate finding tips to help your workshop stay neat, I recently came across a great article which explains how to make tool holders. Not only can most of these tool holders be made using tools you already have, such as router bits, forstner bits and combination blades, but they are easy to make and can be created to fit any cabinet. Plus, there is no better way to get motivated to organize my workshop than a new project.

Brad Point Boring Bit

See the full Simple-to-Make Tool Holders for a Cabinet article, and learn how to make chisel holders, spokeshave holders, file and scraper holders and more.

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Looking Back in Time for Inspiration

As a furniture maker, it is always an interest of mine to gain inspiration wherever I can. Sometimes it is looking up at the skyscrapers in the city and using architectural designs for ideas, other times it comes from looking at a suspension bridge. But, my favorite source of inspiration is to look back in time.

My favorite activity, aside from creating pieces of furniture for family and friends, is to take a Sunday drive into the country and walk into antique shops.

The furniture found in these shops has most likely had many owners, been moved from here to there, and been hit in the foot by a vacuum or two.

There is no surprise that these pieces have lasted this long, whether they were created 250 years ago or just 60 years ago. Furniture is art which is used, and if it is not built properly it will only last for a short time.

When designing furniture, I make sure to use the experience I attain in the antique shops. I make sure to look closely at the joinery and construction of the pieces and implement many of the principles found there into my new pieces.

What I do see more than 90% of the time are dovetails. Pull out any drawer from a piece of furniture which has been on this earth for some time, and you will see solid construction and joinery. One cannot find a stronger joint than dovetails.

 

Dovetail Router Bits

 

Back in the day when many of these pieces were constructed, dovetail joints were created by hand. Two signs of handmade dovetails are small inconsistencies (which are not found when machining) and an etched line which was drawn into the side in order to mark the depth of cut. This mark was typically not sanded out.

As I take these construction methods back to my shop and design my pieces, I tend to like to work smarter and faster than doing all my work by hand. Therefore, my dovetail jigs are one of my most prized tools. My investment in a high end router and bits has made my job of creating high quality pieces much easier. I hope to one day have my pieces of furniture in antique shops 250 years in the future…and don’t tell anyone, but sometimes I etch that line into the edge in order to give it a bit of a handmade look.

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How Does One Know What to Buy When Opening Up a Shop?

So the dream has come true. Since you have been 15, you always dreamed of opening your own woodworking shop in your home. Now, you can move the 2 cars out of the garage to set up a shop to create those beautiful pieces you have been planning in your head for years.

You have a good job which pays well and the kids are old enough that your spouse does not need you in the house helping as much. It’s time to take some time for yourself and set up a place where you can hibernate on Saturdays and Sundays.

Opening up a shop is not an easy task. If you are like most, you are have a limited budget and do not know exactly what you need. As you shop around the local or online hardware stores you will see that the salespeople may try to sell you everything under the sun. They hear you are buying tools for a shop, and the list of “requirements” grows larger and larger. But do you really need everything?

woodworking tools

A good rule of thumb before going shopping is to ask yourself what exactly you will use the shop for, and I do not mean for the answer to be woodworking, which is clear. What I am asking is what you are looking to create, what style, what types of wood.

To begin, plan-out your first three projects. Evaluate which tools you will need to make these three pieces. If you see that each one of these pieces requires something much different, perhaps you should change two of them to better fit the one and keep within the same style.

Planning your projects in advance will allow you to go to the store and buy exactly what you need and not end up purchases additional tools that just seemed like a good idea at the time. As you continue creating new pieces which require certain tools, you will have more opportunities to expand your tool collection.

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One of My Favorite Tools on Toolstoday.com

Now, I may be a bit biased towards Toolstoday.com, but let’s be clear that they do provide us all with a great service. Not only do they sell great products which are guaranteed and tested, but for someone without the full knowledge of exactly what they need, their customer service is very helpful.

As a customer, I was looking to replace and upgrade circular saw blades. I tend to like buying products which are the best quality that I can afford because I have learned many times over that you get what you pay for. In the end, when you buy cheap products you often end up spending more.

Although I would consider myself well versed in the world of woodworking, it has been some time since I was shopping for circular saw blades. I certainly knew I needed blades for ripping and cross cutting as well as a combination.

I went online to the website and searched for blades. I could not believe it. It must have been a while since I searched for blades because there now seemed to be a million different choices. My head was spinning. What was the difference between the brands, the steel vs. carbide, and the specialty blades, etc.?

To my surprise, I found a great tool on the Toolstoday website, and it was not a woodworking tool. It was a search tool called a Saw Blade Finder. I was able to select the category, or type of blade I was looking for, the diameter, the number of teeth, the brand and more. Instead of getting on the phone with customer service, I was able to get this help independently. I was able to choose from a much lower number of blades, which was something I was much more comfortable with. At the end of the day, I was able to call up only those blades which I would need and selected them based on just a few factors, price being number one.

Saw Blade Finder

So, when someone asks me about going shopping for blades, where to go and what to ask, I will definitely recommend the Saw Blade Finder. It saves time searching, eliminates the need to drive to the store, and the saw blades get delivered directly to your house. Although I am a big advocate for local brick and mortar businesses, I cannot pass up this great time saving tool.

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No Substitute for a Hammer Drill

One of the most common mistakes I see, and have admittedly done in the past, is trying to get away with using a wood bit to drill through concrete. I know, it is not the smartest thing to do, but we justify it by saying, well…it’s an old bit anyway, I just need to drill just one hole, or even, I have no choice since I don’t have the proper tools to drill through concrete.

Whatever the reason, it is clear that we all know/knew what we were doing was far from ideal. Not only can it be dangerous since the steel bit can break and become a flying object, but the end result can put real damage on the drill, not to mention not even achieving the goal of drilling a hole.

masonry drill bit

Using tools should be an extension of you. Feeling the power of the tool and knowing that it is working well provides you with the confidence that the tool is doing the job. If you misuse and overwork the drill, its motor can begin to overheat and give up on you. A tool which is used for the purpose of another task is not likely to stand up well in the long run. Therefore, it is important to use the correct tools for the correct tasks.

The hammer drill does not make its appearance too often for most home improvement tasks or projects. At times, it can be over a year before I see it again. I can only image that most people do not have a hammer drill in their shop, let alone masonry bits.

Although not needed for everyday tasks, when they are needed, hammer drills do a job that no other tool can do properly. Its hammer function, customized bits for drilling concrete, and its power allow for easy drilling and long life for both the drill and the bits. It is a worthwhile purchase if you keep in mind that the alternatives are either hiring a contractor to perform this simple task or risk the life of your standard drill and bits.

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Shortcuts and Shaper Cutters

There is a saying that the shoe maker’s wife goes shoeless. If you haven’t heard that before, you are a better husband than I. My wife seems to remind me every once in a while. It seems that work is work and home is where you don’t work, or at least try not to.

As a home owner, we find little things need to be maintained and fixed every now and then. Perhaps a light bulb needs to be changed, a smoke alarm battery is dying or a ceiling fan needs to be installed – these are the small jobs, and I don’t mind doing them.

Yet, when it comes to the bigger jobs, such as redoing our kitchen cabinets, I tend to push them off. Not only is this a big job and quite a large investment of time and money, but the fact that I have to cut into work time and use my weekends to redo the kitchen is daunting.

In the end, like anyone doing work in their home, you try to see what NEEDS to be done, not what is wanted. With that being said, I decided that there was no real reason to dispose our cabinets and create new ones. Instead, I was just going to reface them.

The older cabinets were completely outdated and had needed a new finish for some time. My wife wanted to get rid of them and give our kitchen a more modern look. As a woodworker, although I wanted to keep it simple, I also wanted to create something I could be proud of – something with technique, depth, beauty and strength. We decided to make mission style doors from maple. It became a much less daunting task knowing that this is a simple design to make and my wife was happy with it.

After taking all of the measurements, it was just a matter of producing the stiles and rails, which I did using my planer and table saw. Then, I needed to cut the rabbits for the insides of the rails and stiles to house the floating panel. I took advantage of using my shaper with specialized shaper cutters to cut these rabbits. One cutter cuts the rabbit and a slight profile on the inside of the rails and stiles, and the other cuts a complimentary profile. I then mill the edges of the rails for a perfect fit when gluing up the frame.

Although I am not a big fan of undertaking large projects in my own home and tend to avoid them whenever possible, in this case, I was able to find a middle ground where I refaced the cabinets instead of redoing the entire kitchen. At the same time, I was able to work quickly and precisely with a stile and rail shaper cutter set that saved a lot of time. This project was completed part time in just a couple of weeks, and everyone was happy.

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I Am A Woodworker, Not A Mechanic…

We all went into woodworking because we love the craft. We feel refreshed by the sound of a hand plane sliding over the edge of stock whilst tossing the shavings from our hands to our feet, or we love the feel of sunlight blasting through the open window of our shops accompanied by the wind of the cool air breeze. To me, woodworking is a form of meditation. It’s a space where I can create and be on my own.

This is quite a romantic picture I have created for all of our woodworking dreams, but one thing is for sure, these moments are disrupted by the need to maintain and hone our tools. Properly maintaining our tools, including knives, blades and machines, ensures they work much smoother, more efficiently and safer.

The challenge is that we all went into woodworking to work with wood, not to become knife sharpeners, mechanics, etc. Yet, we all know that unless you have a go to guy in your shop, the job of tool maintenance is in your hands.

There are many things we can do to maintain our shop’s tools for precision work without toiling with them for hours on end. For instance, we are all familiar with sharpening chisels and the difference between using a flat oil stone and a turning stone wheel. The difference is not only time but precision. When sharpening a chisel on a stone, we must be exact in the angle we are hold the chisel to the stone while we move the chisel forward and backwards. In contrast, when we use a turning stone wheel we simply hold the chisel in place while the stone moves.

Another example, and the least favorite for many of us, is the sharpening and reinstallation of jointer and planer knives. The most basic technique for reinstalling planer and jointer knives is to put them in, lightly tighten the screws which secure the knives into the header, lay a flat edge over top the table, make sure that the knives are set at the right depth and tighten. This procedure must then be repeated for an additional two or three blades. The problem I have with this is that for some reason it is not accurate enough for me; I always seem to get the blades off by even a millimeter.

Lucky for me, there is a way to set the blades with 100% accuracy and not have to deal with a flat edge over a table. The solution is using a magnetic knife setter. This takes the guess work out of the task. And taking the guess work out of maintenance tasks in my shop makes me a happy man who can go back to my hand planes, sunshine and cool breeze.

Woodworking is about the art, craft and expressing one’s self. When woodworking becomes a mechanic’s job, it’s time to take advantage of maintenance shortcuts.

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A Time Machine Would Have Saved Me Time…

As we all work hard and try to find the best and most efficient ways to work, we somehow miss something every once in a while and wish we could turn back the clock.

It all began when I met with a builder who was finishing up a new elementary school. We were speaking because they had plans to put in hundreds of laminated counter tops throughout the school. This was a big job so I took it. To be honest, growing up learning furniture making, this was not the dream job I thought I would be doing. But, like everyone we have our bills to pay, and a couple months of steady work is nothing for a furniture maker to shy away from.

The shop was outfitted to work as a factory with an assembly line. We made room for the stacks of particle board we were using for our base and emptied the racks to make room for the laminate to stand.

We were all ready to go, and the project went really smoothly. We would cut the particle board to size, cut the laminated strips for all the edges, and cut the laminate tops.

We set up a station where we attached two pieces of particle board together for thickness, followed by the station where we began our gluing. The gluing went well, and we had great success.

I am one for details and precision. Yet, to be honest, I was ready to bang out this job and was looking for any shortcuts I could find. Unfortunately, I could not find any.

We continued with applying the edges and then trimming the excess with a trim router. The next step of filing the edges was the most labor intensive and delicate. Although very important to the final product, it was a stage I would have liked to have done without. After hours and hours of filing day in and day out, we were finally finished. We delivered the counter tops, the school was happy, and then it was time to work on the next job.

It just so happens that when speaking to a friend about this experience, he laughed and pointed me in the direction of a trimming bit that also files at the same time. This saves just a few minutes of filing on one counter top, but it would have saved me a few days of work with the amount of counters we made for the school.

I could kick myself and be upset that I did not know such a tool existed, but I suppose that would not help. I have no time machine to go back, but I do know that for the next time I have a way to work much more efficiently.

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The Art of Buying Woodworking Tools

A nightmare scenario: It’s my wife’s birthday and she loves gifts. More than just gifts, she loves when people buy her make-up. I would go through the different types of make-ups, bases and highlights, but I would have no idea what I am talking about. I am not a cosmetician, nor have I ever put on makeup. But one thing is for sure, my wife just loves makeup so I have little choice but to bite the bullet and go for broke.

This is my worst gift buying nightmare. It is a good thing that this is not a reality, but I am using this example to show what it may feel like for a wife to buy woodworking tools/bits for her husband.

Non-woodworkers generally feel a bit overwhelmed searching for an appropriate tool for a gift. As a woodworking expert, even I occasionally feel the challenge of purchasing a new tool. Tools are always changing and being upgraded so there is always something to learn. For the non-woodworker, there is no reason to learn new trends let alone know the old ones.

Knowing how happy your husband would be if you came home with a 3-Piece Ogee Raised Panel Set – 1/2 Inch Shank, wouldn’t you want to know what it is, what it is for and what machine it is used with?

There are many gift ideas for woodworkers on the market, and I often wonder how often they are purchased. As a woodworker, I see great value in getting a packaged deal, but I tend not to buy gifts for myself. So the question remains: how does someone without any real knowledge of tools choose an appropriate woodworking gift? Good question.

The first step is to identify a number of gifts, as seen here on the Tools Today Gift Ideas page.

Second, every woodworker has a buddy who also is a woodworker. Whether they speak every day or just once a year, there is a bond between them, and they talk about the tools that they purchase. This person is your guy. Use this contact as a way to identify exactly what your husband can use.

Please note that as a woodworker I know that we all love to create for the sake of creating, giving to others and seeing them happy. In the end, your gift to your husband might just be that jewelry box you always wanted.

Happy shopping and good luck!

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