Saturday, August 23, 2014

The Sucking, Park VI

In between working on the Funeral Chair and Sal's Clock, I continue plugging along on what I've come to call the Bastard Dust Collector.

The Rockwell Dust Boy.

The design I'm looking to build consists of cannibalizing one of the Dust Boys to connect the motor and impeller directly to the Super Dust Deputy and then add an after market pleated filter. Rather than take apart the new-ish Dust Boy I currently have setup for dust collection, I instead took the motor / impeller unit off the older, Rockwell Dust Boy collector I still had in the attic. This older one seems to be the same spec as the newer one providing a 2 HP 220V motor and 3450 RPM.

Wednesday, August 20, 2014

The Funeral Chair Joinery

On Sunday I managed to finish the joinery on the Tom Fidgen funeral chair.

All milled and joined. Ready for some sanding.

It consisted of routing out a slot in the rear legs to accommodate the slide, drilling for hinges in both sets of legs and the seats, notching the legs for the front stretcher,  and cutting dominos in the legs, stretchers and back.

Saturday, August 16, 2014

How I Reinforced The Seats For My Funeral Chairs

I'm finally beginning to work on my first chairs. Due to the fact that one is a gift and needs to be shipped, I'm making folding chairs.

After searching around for a folding chair design I settled on Tom Fidgen's Funeral Chair as shown in his book, The Unplugged Woodshop.

As you may have guessed, I'm making mine a bit differently than Tom does. I found that my seat design needed some reinforcement. This video shows what I came up with to ensure it could withstand even the most vigorous sitting.


I'll keep posting the chairs as the build continues. In the mean time you can watch Tom build his on his You-Tube channel or catch our interview with him here at the Modern Woodworkers Association site.

Don't forget about the +Modern Woodworkers Association Podcast. We talk woodworking with Guests from around the world of woodworking every other week. Subscribe to the RSS feed or iTunes today.

Tuesday, August 12, 2014

The Sucking, Part V

In Part IV of the sucking I discussed that while I had the dust collector up and running, I was planning to make some future upgrades. Since having three (3) open projects and many more on the to do list is never enough, I decided that the future is now.

This will become the basis for my
improved dust collector.

Before heading off to vacation last week I ordered a Super Dust Deputy and a 20 gallon drum to have it empty into. They're now in the shop, taking up room.

Saturday, August 9, 2014

The (Ply)Wooden Boat, Part VI: The Video

I've spent this past week as I have every first week in August for the last 30+ years, on a week long family reunion with my Dad's siblings and the associated cousins. For the last 20 or so of those years we've been coming to Lake George. Though I didn't get a chance to build anything this week, I did finally get a chance to edit the video of the plywood boat I made while on vacation here in 2012.

The boat on the wild seas of Lake George.

In the video I describe how the boat was made and show its launch and use.

I also have video of it being assembled, which I did not include. I found the assembly video a bit on the long side. If there's interest, I'll gladly publish it. Please let me know though, as I'm guessing there won't be.


You can read the (Ply)Wooden Boat blog posts covering its construction here, if you're interested.

Should you find yourself on vacation near a lake, I'd suggest making the boat as it was a very enjoyable project.

Don't forget about the +Modern Woodworkers Association Podcast. We talk woodworking with Guests from around the world of woodworking every other week. Subscribe to the RSS feed or iTunes today.

Tuesday, August 5, 2014

Sal's Clock

As woodworkers we’re all occasionally tasked with fixing a damaged piece. Such was the case when my friend, Sal, asked me to look at the heirloom clock he and his wife have. The desk clock was made by the E. Ingraham Co. If the hand written date is to be believed, it dates back to 1928.

The clock door.

The clock is in very good condition for its 84 year age. The only damage, besides a generally worn finish, is broken bit of veneer on the face and missing fasteners for the rear door hinge.

Because I’ll reattach the hinge using small brass screws in place of the tacks it was originally attached with, I focused on the damaged veneer which will be much harder to repair.

The damaged veneer.

I began by testing dyes on a sample board. I used General Finishes Medium Brown and Dark Brown. After much experimentation I found that five (5) coats of Dark Brown dye was an almost perfect color match. Two coats of spray lacquer finished it nicely.

The dye samples.

With the finish sorted, I thought about how to make the new veneer and settled on simply resawing the face off of my sample board. To do this I attached a sacrificial fence to the table saw and used my Woodpecker 1/32’” Setup Block to set the distance from the sacrificial fence. After a quick test cut, I ran the dye sample board through and had a perfectly thicknessesed veneer to make the repair patch out of.

Unfortunately, as soon as I made the cuts, I realized I had the wrong edge of the test board on the saw and therefor cut into the test board from the wrong side. This meant that my veneer was not as wide as it should have been. I did not want to make another piece of veneer from scratch, so I elected to leave the small piece of existing clock veneer which separated the two damaged sections in place.

The patches first fit.

I cut two (2) oversized pieces from the veneer using an X-Acto knife. Then, using the pieces as a guide, I marked around them with the X-Acto knife and deepend the damaged areas with a sharp chisel. Once the veneer patches fit flush with the face of the clock, I glued them in using Nexabond.


All went will with the glue up, except for the unsightly gaps around the veneer patches. As of this writing I’ve applied 5 coats of Dark Brown dye to the unfinished wood in the gaps. That now makes them nearly invisible to the camera. I’m still debating if I’ll leave it like this, try to patch the voids or remove the existing veneer patches and start over. Regardless of how I address the gaps, I’m ready to move on. The clock repair has languished in my shop, and I can only conclude that is because I’ve got no desire to work on it.

Though hard to make out in this photo, the patches are still clearly visible.

Don't forget about the Modern Woodworkers Association Podcast. We talk woodworking with Guests from around the world of woodworking every other week. Subscribe to the RSS feed or iTunes today

Saturday, August 2, 2014

2014 August Shop Tour

It's August, and the shop sucks!

I've finally gotten my dust collector to a working state. I'm using (and liking) the Rockler Dust Right accessories between the collector and the equiptment. For the exhaust, rather than use the filter that came with it, I'm exhausting it into the front garden. I'll setup a filter when it gets cold.

I've also managed to re-arrange the shop a bit and I can finally walk around.


Don't forget about the +Modern Woodworkers Association Podcast. We talk woodworking with Guests from around the world of woodworking every other week. Subscribe to the RSS feed or iTunes today.