Dealing with complex projects

102_2864 Except for maybe the quick and dirty projects that we all sometimes just throw together in an afternoon, most every project presents its own unique challenges.  My current project, the hand tool cabinet, has relatively simple joinery, largely rabbets and dadoes, with some hand cut dovetails for the drawers.  The complexity in this case isn’t the joinery, the complexity comes from the number of individual pieces in the cabinet.  Based on the sketch-up drawing, there 49 pieces!  If I took the entire cut list and started planing down boards and cutting individual pieces to size, I would have created a confusing mess. Plus I would have parts laying around for weeks, even months, before I would be ready for them.  There is a good chance the piece has moved due to humidity changes, or the piece may no longer be appropriate due to mid-stream design changes.

2013-05-05 17.54.26Instead, I try to componentize my projects.  With the hand tool cabinet, this was very easily done.  For example, I started out with the main box.  I planed down only the wood I needed for that component.  From there, I either work on one joint (if a complex joint) or one joint type.  For example, the main box is put together using rabbets.  So, I start out concentrating on the main rabbets, not worrying about the dados for the shelf or for the back.  If I start thinking too far down the road of the project, it makes concentrating on the task at hand that much more difficult.  Once I get all my rabbets cut, I move on to the next joint.

For more complex joinery, I concentrate on one joint, typically two pieces of wood, at a time.  This is especially important when fitting more complex joints like dovetails, or even hand cut mortise and tenons.  As I get each joint fit, I expand out to the next one, and proceed until all the joints are fitted and square.  Revisiting joints as necessary.

I had someone comment once that my chisel rack would be to far above their skill level to attempt.  Even though my chisel rack was my first real foray into a more “fine” woodworking using real joinery and no mechanical fasteners.  My response back was to them that was simply not true.  As I had accomplished this project, and I still consider myself a beginner!  While there are definitely techniques out there that are best left to the master craftsman, there are many complex projects that a beginner woodworker can undertake, just by taking it one piece at a time.

 

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Hand Tool Cabinet Update – Door boxes!

2013-05-05 17.54.26    So this past weekend I made quite a bit of progress on the hand tool cabinet, with the completion of the boxes that will make up the doors of the cabinet.  The doors are boxes as they are intended to be additional storage for my growing hand tool collection.  This was actually my second attempt at making the doors.  The first attempt did not end so well, as when I was cutting the grooves in the long boards (the sides) that would house the plywood backing, I had a mishap on the table saw.  I finished cutting the short boards (tops and bottoms) and I must have inadvertently hit the locking lever for the fence.  Not enough to completely loosen it, but enough to move it each time I pushed a board against.  Thankfully no kickback, but the result was each of the long boards had a groove incrementally further into each board.  After thinking through my options, I decided that the boards I had just worked on can be used for other aspects of the cabinet, so they will not go to waste.  Another aspect was the color of the ambrosia maple had a lot of dark areas in them, so it wasn’t a great match to the existing cabinet box, as well as making some dumb mistakes with wood selection.  So lessons learned, I went back to my hardwood supplier, and took more care in what I selected for the doors.  Armed with new wood, I milled the boards.

2013-05-03 22.33.292013-05-03 22.33.37The boxes are a fairly simple construction, with rabbets on each of the side boards, and grooves to hold the 1/2″ baltic birch plywood for the backs.  After getting the pieces sanded, and dry fitted a couple times, I glued them up.  I ended up only using two clamps for each cabinet, as I had an easier time getting the boxes square.  The two clamps held everything tight enough, resulting in tight joints.

2013-05-05 17.51.592013-05-05 17.58.59The next step in the project is to build the false fronts for the doors.  These will be frame and panel fronts.  I am thinking once those are done and on the doors, I am going to apply the finish to the cabinet and doors, and go ahead and hang it.  The reason being, is it is big.  :)   Storing it while it is being worked on has become difficult.  Once that is done, the rest of the components needing made are relatively small.  I do realize that this puts this at risk to never being done.  However, it truly never done, as it will always be modified and added to as I continue to add to my hand tools.

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Tool Review – Grizzly G0555P, Polar Bear Series 14″ Band Saw

2013-04-20 20.25.15To try to bring more variety to my blog, and hopefully to help other newbie woodworkers make purchase decisions.  Most, if not all, of the tools I will be reviewing have been purchased for my normal usage.  However, on the very off chance someone sends me a tool to review, I will always indicate how I came by the tool I will be reviewing.  I think it is only fair to you, the reader, should know where the tool came from.  I will always try to minimize bias as much as possible.  Also, please comment with your good and bad experiences about the tools I review here.  This will make the review that much more useful for others out there.

2013-04-20 20.26.20The first tool I am going to review is my band saw, specifically the Grizzly G0555P.  I purchased this saw early Spring of 2011, so I have had it for around 2 years.  Order and delivery were uneventful.  I ordered lift gate service, however with my lack of understanding that freight works bit differently then package delivery, I took the day off work for the date the tracking website said it would arrive, not realizing the arrival date was not to my home, but rather to the freight depot.  Not able to take another day off, I ended up driving up to the depot and picked the saw up from there.  Other then skipping out on the lift gate services, the freight aspect went smooth.

2013-04-20 20.26.30The saw and all of it components came well packed in one large box.  Unpacking was straight forward, and each component was well protected.  It did take two of us to lift the main saw out of the box.  Assembly was not difficult, and took me a few hours.  Most of the assembly was easily done by myself, but I did need some help lifting the main saw body on to the stand.  The instructions for assembly were outstanding, and made assembly go smoothly.  Tuning of the saw went well also.  The instructions were very clear on this process as well.  I will say, I did not use the blade that came with the saw.  From what I have read, the stock blade was okay at best, and others had recommended going with a better blade.  So I put a 1/4″ Timber Wolf blade on it, which has been the primary blade I have used on the saw.   First time I powered up the saw I was amazed at how quiet and stable the saw was.  It passed the nickel test with flying colors.

2013-04-20 20.28.35Overall, the fit and finish of the saw is excellent.  The only real negatives I have about the saw is on the guide bearings, and the fence.  Neither of them are truly bad.  The complaint I have with the guide bearings is that they are noisy.  They otherwise work fine, and do well with keeping the blade straight.  The fence is okay for most straight cut operations.  The lock handle is the main issue, as it sometimes doesn’t lock down as tight as it should.  I now always give it an extra push down to make sure it stays in place.  The fence adjustments for drift are not great.

2013-04-20 20.29.00The saw has a single dust collection port in the back for a 4″ hose.  This does an adequate job clearing the dust from the machine.  Except for a little bit of dust left on the table after making a bunch of cuts, there is typically very little sawdust left in the saw itself.

The actual use of the saw has been outstanding!  Once everything was adjusted on a brand new blade, drift was virtually non-existent.  I have even cut thick bowl blanks on it, and the saw cut right through them with no issue.  In the two years I have been using it, has done everything I have expected of it, and never gave me an issue.    All in all, if I had to do it over, I would have no complaints buying this saw again.

Full product specs here

As a note, I do not yet have the rise block or mobile stand for the saw.  These will likely be future additions as I encounter the need for them.

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Box Challenge – Finished!

2013-04-19 23.20.46 Despite the fact I long missed the deadline of the original challenge, I continued to push forward on getting the box complete.  Now that the weather is warm(er) I am getting out in the shop more.  While my main focus in the shop is the hand tool cabinet, and Erick turning pens, I didn’t forget about the box.

2013-03-10 20.54.31In my last post I mentioned that the box was almost completed, that I had an idea to cover the hole left from the wood worm screw from when i used the lathe to make a domed top.  What I came up with is a sort of medallion made from a small piece of walnut with my initial “M” on it.  I don’t really have any carving tools.  I ended up using my trim router with a V groove bit and free handing the M over layout lines I drew on the work piece.  I then simply used my bench chisels to straighten out the lines of the M.  I then attached to the bottom of the top, resulting in no more ugly hole!

2013-04-19 23.21.12About a month ago I put a couple coats of boiled linseed oil on the box, and I let it set.  Since we were getting days consistently over 50 the boiled linseed oil slowly cured.  From that point I started wiping on shellac.  I believe I put on 5 or 6 coats of shellacs, till I got the look I was going for.

Now that the finish is on and done, I am really glad I paid close attention to the grain of the wood.  Where the grain continuing around the entire perimeter of the box wasn’t real noticeable, with the finish, it really pops out.  The effect really cool.

2013-04-19 23.21.30As with any good challenge, I learned a lot on this, and strengthened many skills.  While my dovetails still have room for improvement, I feel I now have the confidence to use them in more projects.  Also worked on my hand plane skills when I raised the panel on the bottom .

Looking forward to the next challenge project.  Maybe I will even finish that one on time!  Thank you to Roger for hosting the challenge, and thank you to

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More thoughts on the power vs. hand tool debate

2013-04-19 22.45.53_enhancedThe heated debate from a few weeks ago seems to have settled down, but the discussion continues, I think for the good.  I have been reading through the various blog posts and tweets on this subject, and have found it thought provoking.

One of the blogs I read described how there is a tendency to use power tools to mass produce projects, thus reducing their uniqueness and the artistic value is lost.  (Noting that dollar value is lost as well)  It isn’t that big of a stretch to realize that we as woodworkers can and do get trapped in that same mindset when working our own projects, thus losing the “woodcraft” or artistic value within our projects.  To be honest, I don’t think I can disagree with this.  Why?  Sometimes we as woodworkers focus on getting to the next step of the project as quick as possible rather then putting our heart and soul into the project as a whole.  I think part of what makes a project woodcraft is allowing the flow of the project to come together organically rather than systematically.

The big question is, does this change my view point in my last post on this subject?  I did have to think about this for awhile, but I do still feel the same way.  I believe that this organic flow can be achieved using power tools, hand tools, or a combination of both.

Where I also did some thinking is what it takes to achieve woodcraft.  Don’t get me wrong, organic flow of the project is a significant part of it, but its not everything.   Its also taking the medium we are presented with, understanding its properties, imperfections and other qualities that makes it unique, then using the mind’s eye to work it into an art piece.

Admittedly, I do believe using hand tools does make it easier to bring us closer to the work piece leading to a better understanding the wood’s properties.  For me, when I started using hand tools, I did start looking at my projects in a different light, and in fact I feel that using hand tools has made me a better woodworker in general.

So how is all this possible using power tools.  The obvious answer is start out with power tools for doing the tough work, the finish up using hand tools.  That is one way, but I don’t think that is the only way.  I think as long as a woodworker stays out of the batching out mass produced parts mindset it is very feasible to complete an artistic project.  Ultimately, I think it goes back to allowing the project to flow organically as well as using the minds eye to determine what tool is used.

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