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More Work With Studio D, Part 5

August 12, 2016

With the tops properly thicknessed, jointed, and cut to size, I began work on the butterflies. The first task was to make more butterflies. I began doing so with the remains of a small plank of bog oak I had left over from another project (a commission I have Caleb James, Planemaker working on). As I made some cuts to free butterflies from their matrix, I paused to admire how great a job my old bandsaw was doing.

Clean Bandsaw Cuts

Nice, clean cuts!

Apparently Karma thought I was getting cocky, because not two minutes later my blade broke.:\ The blade breaking was not in itself such a problem. It happens. It was an old blade and it broke at a patched weld. No, it was a problem because I had absolutely no idea where my other bandsaw blades were. At some point during my move into the condo, they were boxed up… and that’s all I knew.

I spent three hours looking through all of my boxes with woodworking equipment and tools for my other bandsaw blades – multiple times, actually – all to no avail. I growled in frustration and begrudgingly drove to Woodcraft to pick up a new blade.

An hour after installing the new blade, I found my other blades, in a box I’d checked three times but apparently hadn’t fully opened to see the blades quietly sitting on the top at the other end of the box.

Missing Blades Found

Masters of ‘Hide and Seek’…

*sigh* Regardless, I was back in business and quickly made a kaleidoscope of butterflies…

Kaleidoscope of Butterflies

A kaleidoscope of butterflies… (and some scrap off-cuts I probably won’t throw away)

After cutting them on the bandsaw, I use a bench hook and a sharp chisel to pare the sides smooth and add just the slightest chamfer towards the bottom of the butterfly on all sides. This chamfer is usually not more than one or two thousandths of an inch.

With butterflies all in order, I laid out some butterfly options to stabilize the split knot in the hall table. Everyone has their own methods for figuring out where to put these inlays – mine is to lay them out in various ways and take pictures, then examine and compare the pictures to see what looks best while also stabilizing the intended area.

In this case, I decided on two butterflies. Sticking them down in place with double-sided tape, I traced the bottom edges of the butterflies with my large Blue Spruce marking knife and then removed the inlays.

Hall Table 11

In order to properly delineate the edges of the mortises I needed to make, I chiseled out a wedge of wood along the entire border of each butterfly and used white pencil to highlight the wood to remain.

Hall Table 12

In preparation for removing the bulk of the waste with a (corded) router, I drilled a series of holes in each end of the butterfly. Chopping out the waste between the three holes leaves me a place to drop in my router bit. I have to do this because I’d rather use my smaller palm router, a Bosch 1608 edge trimmer, which does not have plunge capabilities, than my larger Bosch 1617.

Hall Table 13

After removing most of the waste with the palm router, I’m left with the smallest amount of wood along each edge.

Hall Table 14

This remaining waste is easily removed with a sharp chisel.

Hall Table 15

Once I have the waste removed, I fitted the butterflies in place and tapped them in about 1/8” or so to make sure they fit. They did, so I pulled them back out, added glue to all of the walls of the holes, and cautioned them to fall into place without a fight by showing them my joiner’s mallet. That didn’t work, so I had to resort to seating them with the mallet and a scrap of wood. They didn’t put up much of a fight and I could tell they were a very tight and pleasing fit.

Hall Table 16

They seated so well, in fact, that I didn’t wait but a minute to begin cutting them flush with my Veritas flush-cutting saw.

Hall Table 17

After a little bit of work with a block plane and some sandpaper, I’m left with this.

Hall Table 18

Not bad. I had a paper-thick gap on the end of the top butterfly and a tiny corner chip out on the near one; these things are easily fixed with a minor bit of epoxy later on.

Now to start on the smaller end table…


More Work With Studio D, Part 4

July 18, 2016

A few weeks ago, I borrowed a friend’s Festool AFT-55 (circular saw) and tracks so I could make some exact cuts on the hall table and end table. I love the precision of the Festool, but don’t yet use it enough to justify such a purchase. I would consider picking up something, though, if I continue with making large-ish things, like live edge tables. At $650+ for the new track saws, however, I might get more versatility from the Carvex jigsaw.

The only real problem I encountered with the AFT-55 was the depth of cut. The walnut planks were over 8/4 thick and the Festool could only cut about 1 7/8″. So I had to finish the rest with my Disston 26″ rip saw that was cleaned up and sharpened by Wentzloff & Sons (I got it, along with a crosscut, from Jon Zimmer , who still carries saws that are cleaned up and sharpened by Wentzloff).

Hall Table 05

This is the underside. I did that so it looked like I was a ripping beast.

While I had the Festool saw in my possession, I decided to rip two of the reclaimed Checkerdome douglas fir planks to proper size so I can make some headway on the workbench, as well. Those beams are almost 3″ thick. That meant ripping over 1″ with the rip saw. It might not seem like a lot, but those old beams are very dense and heavy and it took a lot of effort to saw through them.

Checkerdome Slab 06

Although I’d be a lot happier with a longer top, say something more like 8′, having a proper bench of even 6′ long will be a welcomed change. This is a good idea of how it will look, about 6′ long, 22″ wide, and just under 3″ thick.

Checkerdome Slab 08

The top of the new bench…

With the tops cut to size, I went to my friend Scott’s shop Saturday morning to put some time in on his 52″ “friend maker” (wide belt sander). I spent more time with the end table top than the other three because it had so much cup. I was able to get it perfectly flat and still retain 1 3/8″ thickness. The hall table was a lot straighter and I was able to keep it to 1 5/8″ thick. I’m not at all worried about this; I think the end table needed to be a little thinner than the hall table, anyway. If it was too thick, it would look chunky.

Checkerdome Slab 09

Douglas fir after a few trips through the 52″ sander…

End Table 07

End table top after many trips through the sander…

Hall Table 08

Hall table top after several trips through the sander…

Some of you might recall I talked about saving the cut-offs from the bog oak butterfly keys I inlaid into the conference table I made last year. Turns out, they came in very handy (once I was finally able to locate them, after sorting through many boxes of stuff)! I was able to lay them out on the tables, not to use as actual templates for inlay (because each one is individually scribed and inlaid), but just to give me some idea as to what it would look like.

Using these, I can easily adjust positions and determine the best design layout and evaluate what I need to make.

I still have some spare bog oak keys left over from last year – one large one and three smaller ones – so I’ll make up a few more and maybe even make some medium-sized off-cuts using two of the larger ones to see if having three sizes might show better.

Hall Table 10

Proposed butterfly inlays for hall table…

End Table 08

Not bad, but I want to see how it looks with a transitional size between the two…

More to come later…


More Work With Studio D, Part 3

July 8, 2016

Over the years, I’ve learned that my initial gut instinct is usually right. This was no exception.

After spending a half hour cutting cardboard and using blue tape, it didn’t take two seconds for me to realize I needed to trim the end table on the crotch side and not the straight live edge side when I set it up against the slab.

Framed End Table 01 Cropped

If it was trimmed on the straight live edge…

Framed End Table 02 Cropped

If it was trimmed on the branch live edge…

Trimming the branch side off will still leave me with plenty of awesome grain in the crotchal region while allowing me to create a usable table top.

I did not have a strong initial impression of whether or not 12″ was enough depth for the hall table. This gives something of an idea of what it might be, though I would probably keep all of the live edge and not chop it like that. Or maybe I could make the live edge more of a straight-line reference for the front of the table for consistency.

Framed Hall Table 01 Cropped

I did not have time this morning to adjust the frame to 15″ to see what a deeper hall table might look like. I will do that this evening, though, as I think it is important to see. Looking at it framed out the way it is, I’m afraid I’m not getting enough depth. Also, I need to check with the photos of where the table will go again. If the hall table ends up with one end being deeper, because of the live edge, I need to know which end it should be as I can control that based on which side of the plank I take the waste from.

Oh, I updated the last post, but wanted to mention here as well that my wood supplier in Evansville, IN is Joe Schneider. His website is The Wood Slab King. If you’re in need of large pieces of wood at a great price and you’re within 4 hours of Evansville, he’s definitely worth checking out.

More to come…


More Work With Studio D, Part 2

July 7, 2016

Over the holiday weekend, I took a trip to Evansville, IN, to visit one of my wood suppliers, Joe Schneider. He has a great selection of wood and the price is better than anything I can find within 50 miles of the Greater Saint Louis area, so it’s worth the trip.

This time I was after an 8/4 plank of walnut that was 98″ long, about 20″ wide for most of its length and then about 30″ wide at the crotch. There were several slabs to choose from, so I picked the one I felt was best suited for the project.

Once again, there were those who doubted I would be able to fit the wood into my Toyota Venza…


Not even the German Shepherd had faith in my car!

Since I knew the rough dimensions I needed, however, we just cut it into two pieces there and I only had to drop down half of the back seat.

Walnut Live Edge Slab 2016

Before we left town, we were directed to a place called “Carrie Jen’s” (which seemed an odd name until we realized it was an Amish-based restaurant called the Carriage Inn) for some delicious fried chicken and bumbleberry pie with ice cream. I think the beard suits me. I’m amazed it has taken me so long to get around to growing one.

July 2016

The beard isn’t too bad; the pie was delicious.

Now that I have the pieces home, I’ll make some cardboard frames of the table dimensions (5’6″ long by 12″ deep for the hall table and 24″ x 24″ for the end table) and figure out the best place to make my cuts. Having the visual reference always helps me to determine how to make such important cuts. I will take the opportunity to get the client’s opinion, as well, in this case.

I think they might want the hall table to be a bit deeper than the indicated 12″ and the crotch is about 30″ wide, so I’ll have to trim off 6″ from one of the live edges. But do I trim it from the left side, with the relatively straight live edge? Or from the right side, where there is some nice crotch figure? My initial instinct is from the right, because I think it will look better with the straighter live edge on the front of it, even though it will mean losing some of that beautiful figure, but I’ll have a better idea when I frame it out. This must be decided first; there is a bit of cup to the end table section, so I’m going to cut it to size before I flatten it to retain as much thickness as possible.

I’m not at all worried about the split, even though it looks rough. I will be stabilizing it with several bog oak butterfly keys and it is still quite solid on the far end. This table will be a first for me in that some of the keys will be exposed in the gap. This means I will treat at least part of each bog oak key as if it is a finished surface (planed smooth) and will need to figure out how to clean out the inside of the crevice (I’m thinking pressurized air for starters).

Stay tuned for more…


More Work With Studio D, Part 1

June 29, 2016

Funny how life works. You think you have a plan set up, at least short term, to get something done (in this case, organizing my tools and shop space and making some much-needed shop storage and a workbench) and something comes up that is terribly difficult to turn away.

Just as I was moving back into my old condo last month, I got an email from the owner of the marketing design firm I made the conference table for last year. They have need of a long sofa table and an end table. They want them in a way that is congruent with the conference table (walnut, live edge, some bog oak butterflies, fabricated legs) and wanted to know if I was interested in making them.

Jeeze, I can hardly say no to such an offer, right? Yes, of course I will!

After some negotiating, I have the commission. After some design conversations back and forth and another email off to my wood supplier in Evansville, IN, I have some ideas in place and a few large slabs of wood waiting for me to peruse after a 3 hour drive.

image 02

Rough now, but I get to make it look good!

And I get to add some more pictures to the Shit-I-Can-Put-In-My-Venza photo album! What fun!

Now I just need to figure out where I can get all of this work done…



Making Space, Part 2

June 24, 2016

I spent about three hours throwing around boxes of tools and lumber the other night. It didn’t feel like I made much progress, unfortunately, but I have to remind myself it will feel like that at first and I just need to keep plugging away.

I’ve decided the first order of business is to get a proper workbench made. The workbench will be the foundation upon which everything else is built, both literally and figuratively speaking. As previously mentioned, I have acquired lumber for several different benches (now down to two). One group of lumber consists of reclaimed heart pine from a local barn. The beams have been planed to even thicknesses, but they aren’t jointed well so it will take some work to get them to glue-up point. These were the pieces I’d set aside for my workbench.

Bench Lumber 03

An old picture of the barn beams in my now-gone workshop.

The other bench is one I was planning on making for my son. But what I might do is make his first and then after I’ve organized the shop spaces a bit more and have the room to maneuver the unwieldy barn beams, I’ll build the second one. One of the reasons I want to build the smaller one first is because the top is mostly done; it will be just two pieces of wood that are already mostly flat and surfaced on one face. With limited shop time, the more I can do to save time, the better.

Checkerdome Slab 05

Three slabs of old growth Douglas Fir courtesy of the Checkerdome!

If you haven’t figured it out yet, I love wood with character and history. I love wood that can tell me a story. These are sections of Douglas Fir ceiling joists from the old St. Louis Checkerdome. My friend (Scott Wunder, of Wunderwoods, by the way) who secured the reclaimed heart pine beams for me is the same one who had these sections of Douglas Fir in his lumberyard (he mills lumber as part of his woodworking business). I saw them and immediately visualized a bench top. The only problem is they are just 6’ long, which is a bit shorter than what I wanted for my workbench. But it would make a great bench for my budding woodworker son.

Checkerdome Slab 04

A little short, but look at that tight grain!

Built in 1929, the Checkerdome’s original purpose was as a livestock hall. But over the years it had been home to the St. Louis Blues and the St. Louis Steamers (soccer or, rather, proper football) and hosted monster truck shows, circuses, and figure skaters. And concerts. Lots of concerts. About 500 or so, between 1967 and 1994, including Performances by Prince, Queen, The Who, Van Halen, and so on. Billy Joel reported that the acoustics were pretty terrible in the place. I don’t doubt it! It was a livestock hall; sheep don’t need to hear their own bleating!

Old Checkerdome

Unfortunately, it’s time had passed. Leaking expense and upkeep costs like a sieve, a series of 70 explosive charges rocketed through the Checkerdome on February 27th, 1999, bringing it down on itself. I’m not really sure if the beams were removed prior to the explosion in order to help bring it down or if they were removed from the rubble (and maybe that’s why they are only six feet long). The long edges on them are not parallel, so they will need some slight trimming to square them up.

Old Checkerdome Imploding 01

But with just a few cuts of a (borrowed) Festool circular saw, I’ll be able to join one of the larger pieces, at 15” wide, with a 6” wide section of the smaller one, giving me a 21” wide top.  Keeping with the recycled theme, the legs and stretchers will come from some old Kubota tractor pallets I salvaged many (15?) years ago. They are some unknown species of pine, 3.5″ square, and averaging about 5′ long.

Pallet Legs 05

I should be able to cut around the bad parts and have enough for legs and stretchers.

I’m not sure what I’ll do with the other pieces from the Checkerdome. Technically, I guess I could make a second workbench top. Or the top for a joinery bench. Or I guess if I really wanted to, I could double it all up and have a top that is just a little narrower (20”) but 6” thick!

Now there’s an idea…

Making Space, Part 1

June 15, 2016

It’s interesting to see just how much material stuff you’ve collected over the years when you have to examine it in great detail (or when you have to move it). It’s also interesting to note just how unimportant much of it suddenly becomes when you find yourself running out of room and trying to organize it better!

I don’t need help in organizing my stuff. I need to reduce the amount of stuff I have.

With that in mind, I examined the lumber I hauled over from the house to the new condo (old? New-Old? Ummm… it’s a little confusing since I’ve lived there before. Apparently confusing to the utility company, as well, since they keep messing up my account). I realized I had three groupings of lumber that were all destined for workbenches.

SYP For John 02

1-of-3 masses of workbench lumber

I’m not sure how I got to that point, but I’m there. And “there” includes a large stack of very wonderfully garage-kiln dried (you know, when you have lumber in your improperly vented garage for several summers, properly stacked and stickered, and it gets supremely dry because of the cycles of heating it goes through) southern yellow pine. It wasn’t a big deal in an oversize two-car garage. But in a standard-size one-car garage, it takes up a lot of space.

Last weekend, that lumber was delivered to Jon, a chap from England who has lived in St. Louis for several years and recently got the woodworking bug. He has shop space in the old Lemp Brewery (jealous!) and needs a workbench.


Space! Well, a little bit, anyway…

For a reduced price on what I paid for it, he got ready-to-go lumber delivered to his shop. I got some space back in the garage. And I got to take another picture for my album called, “Shit I Can Put In My Car”. Oh, and a little bit of cash to throw towards a future woodworking project.


232bf of SYP

I’m also a big believer in paying it forward. I’ve had so much good come to me over the years, especially the last six months, and I feel it is only proper to put “good” back out there for others.

Workbench book

1st Edition, Double-Signed Workbenches book

I recently picked up the revised edition of Workbenches by Chris Schwarz. My original copy was special to me because it had a rare signature drawing by a then-7 Katy Schwarz right next to her dad’s signature. But… I don’t need two copies of the same book. And I figured Jon would get some good use out of one of them. So I gifted him my prized first edition double-signed book.

He more than made up for the gift by giving me a quick tour of just two floors of the old Lemp Brewery. Man, oh man, I could spend hours there, snooping around and taking pictures of things like original track doors that are perfectly balanced with counterweights and metal spiral stairs.




And hopefully I’ve started a good friendship with a new woodworker in the area.


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