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Stool: Finished

May 25

Posted by Brian in Finishing, Projects | No Comments

This morning, I decided that the latest coat of varnish on the stool was dry enough, and that it should be the final coat. So I rubbed it out with #000 steel wool and mineral oil. I didn’t want to use rottenstone because I didn’t want it to be too smooth.

The result looks like a stool to me:

There are some glitches that I’ve described in previous posts. There’s a not-so-pretty spot on the inside of one of the stretchers that I could have leveled out, but didn’t bother to work on because it’s practically impossible to see.

The most important part is, of course, whether the thing actually works. Is it solid enough to stand on? It’s an interesting question for me, because this is my first project meant to bear someone’s weight.

Yeah, it works. It seems really solid. I jumped on it, too, but not too hard. I probably need a little more time to come to terms with the way it is constructed and how the stretchers distribute the load among four to eight joints that are already extremely strong. Yes, this is the way that it’s supposed to be, but going from theory to practice can sometimes be daunting.

This is not to mention that this also marks the finish of a project that I really wanted to build, a piece of furniture that I’ve wanted for a very long time. Aside from the utilitarian aspect (I’m not terribly tall, so sometimes I need a little help in reaching things), it seems that I grew up with the notion that everyone had to have one of these things.

However, this unfortunately wraps up my only project that was really active. My next project is a nightstand that I haven’t finished drawing yet–I’ve been having a particularly hard time with that. In the meantime, I’ve been doing minor work on the shop. I did some cleanup work on some shelves down there. I worked on sharpening a drawknife (but didn’t finish). I cleaned the last of the rust off of my #78 and made some ovolo trim with it in conjunction with the rounding plane I got in Taiwan (thanks for the tip, St. Roy). I picked about 25 plastic bags off the floor (how does that get that way?).

I’m at the point, though, where I can’t lollygag my way around the new project any longer. I suppose it starts this week.

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Bookshelf Prototype: Finished

May 9

Posted by Brian in Finishing, Projects | 2 Comments

After about four coats of varnish, I felt it was time to rub out the finish and call this project complete. There were many reasons, not the least of which was that we’ve run out of places on our other shelves and need to put something in service immediately. For rubout, I used the steel wool/rottenstone sequence, both lubricated with mineral oil. I’ve always been happy with the way that turns out.

Here’s the view from the left side:

Viewed from this side, it’s got “flames” (the cathedral patterns on the sides) and “racing stripes” (the sapwood strips in the back panel). However, viewed from the left side, the flames aren’t visible, other than a tiny little sliver on the inside right:

This is about all I could do with the yellow-poplar that I had on hand. I struggled for a while to figure out an arrangement that didn’t look totally horrible, and it turned out to a certain degree. I wouldn’t say that it’s something I would repeat. Actually, there are lots of things I wouldn’t repeat, so let’s start with the top:

Aside from the fact that I should have taken a couple of swipes with the smoothing plane on the top before glueup, I’d say that the dovetail contrast here tries, but does nothing. The very top should be a clean rectangle. Next time, I’ll use half-blind dovetails or even fully-blind mitered dovetails. Half-blind dovetails will mean giving up the mechanical strength advantage in this application, because I’ll have to put the tails on the sides, but with this much glue surface, it won’t pull apart any time soon.

The other thing that I will change in my next bookshelf project is the stretcher along the back shelves. I wanted to put the stretchers entirely below the shelves in this project and rabbet the shelves to the stretchers, but I didn’t have enough width in my shelf boards to do so. I am, however, very happy with the strength that the stretchers provide.

Then there is a question of the wood. In this project, I was trying to get rid of some of the stock that I had on hand, but next time, I’ll pick lumber specifically for this project. But which kind? Shelves can be big, and big shelves are heavy, so I don’t want to use something like oak, maple, or that beech that I have on hand, because they’re just too much. Cherry is a good choice because it is both durable and somewhat light, but I’m wary of using too much of it (not to mention that it costs a bazillion dollars a board-foot around here). I actually liked yellow-poplar for this, and while we’re talking about woods that are more prone to dents, I may as well mention the various pines and douglas-fir. And there’s stuff like paper birch, butternut, and sweetgum. Who knows? The only thing I know is that I’m trying to avoid darker woods.

For the moment, though, I have other projects to do, and so, here’s the prototype being taken for a test run:

And you can see that form follows function here, as the “racing stripes” won’t even be visible when the shelf is full. Hee.

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Shoe Rack: Finished

Nov 14

Posted by Brian in Finishing, Projects | 5 Comments

Remember the shoe rack I’d been working on for a while? The one I haven’t written about for a while? Well, it’s been in the finishing stage for the last month. I did a tung oil/varnish blend first, and after waiting the requisite million years for that cure, I put on three more coats of varnish.

I started today by rubbing out the finish. That’s always pretty hard work. I used 320, 600, and 1500 grit sandpaper dry at first. In retrospect, the 1500 was not necessary, because I hit it with #000 and #0000 steel wool lubricated with mineral oil afterwards. Why do I always forget what an amazing difference that makes? I did not use rottenstone as a final step this time, because this is a shoe rack and does not need a super-fine glassy finish.

Then I set out drilling holes for the assembly hardware. The sides were relatively easy–just pop them under the holdfasts, mark out, and go crazy with the brace and bit:

shoe_rack_finish_1

(Yeah, Dan, that’s one of my Millers Falls #2 eggbeaters on the right. It’s got a countersink chucked in. Just sayin’, ‘cuz it seems to be eggbeater season.)

The shelves were a lot trickier. I had to bore parallel into the stretchers for a place to insert the screw-in nuts. That’s difficult to do without splitting the wood, so here’s my solution. With scraps protecting each side, one end goes in the vise, the other is held tight with a handscrew:

shoe_rack_finish_2

So what hardware am I using, you ask?

It’s the same kind I used for my saw handles–those furniture connector bolts with the really wide heads that are screwed in with hex drivers. (I like these things, obviously. Very 20th century, I realize.)

Then it was time to see if everything went together okay. It did:

shoe_rack_finished

Oddly, it looks just like I wanted it to. Not so oddly, it’s already full. The SO had a job to do here, you see.

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Mortise chisel: Part 2

Jul 29

Posted by Brian in Chisels, Finishing, Old Tools | No Comments

I marked out the angles on the mortise chisel by “feel,” just by sort of looking at all of the pictures I’ve seen and guessing. With two sides cut away, it looked like this:

I cut out these sections with my larger rip saw. It would have taken forever with anything else. Then I used a block plane to smooth around the oval. I nicked the blade of the plane against the chisel bolster doing that. Boo. Grinding that stuff out is always such a pain.

Following the plane, I used a spokeshave to further smooth the oval shape, then, finally, progressive grits of sandpaper on a block to do the final smoothing. This sequence was quick.

A couple of oil/varnish blend applications later, along with the requisite sharpening, it was ready to use. Here it is with its first test mortise-and-tenon joint (upper left, not that stuff to the right):

It’s a lot of fun to use. Best of all, it’s fast.

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Various handles and knobs

Jul 8

Posted by Brian in Finishing, New Tools, Old Tools, Planes, Saws | No Comments

I’m in the process of varnishing four saw handles, a plane tote, and a plane knob. Here are half of the pieces.

As usual, I’m not being terribly speedy here. It’s been seven months since I started working on that tenon saw handle in the center. Things happen but I like to think that sooner or later, I get back to this stuff. (Especially since I’ve had the saw blade sharpened almost since I started on the handle and it’s otherwise ready to go.)

The larger hand saw handle in the rear is for a Disston D-8 that will become one of my new rip saws, somewhere at around 7TPI. This will be in addition to a No. 7 (I think) that’s going to be a larger 4.5TPI rip saw. The handle for that one is also in this batch, thankfully. Both of these handles were glopped over with some awful green paint that I needed to strip before the refinishing process started. What is it with the green paint?

The initial finish on these two handles was a mix of “colonial maple” stain, some satin polyurethane, and tung oil, for an oil/varnish blend (this makes the rays in the beech look nice). After a few coats of that, I’m now putting on satin polyurethane. I like the way that a top coat of polyurethane feels on the other handles I’ve done (as opposed to alkyd varnish and oil/varnish blends), and it seems to hold up better. It takes a little more effort to get polyurethane to look decent, but it’s not that bad.

I think I need one or two more coats on the handles.

The knob is from a Millers Falls #22 jointer plane that’s been waiting for restoration. I did not use the oil/varnish blend on this (or its accompanying tote), because the ray structure in this tropical wood did not seem worth bringing out. I may be done with the plane parts; I’ll evaluate that later.

Dovetailed box, finished

Dec 2

Posted by Brian in Finishing, Projects | No Comments

Well, this is more or less done. I haven’t decided if I should apply varnish over the oil/varnish blend that I put on it, but it looks decent enough right now.

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Apple handle and small tenon saw: Finished

Jun 21

Posted by Brian in Finishing, New Tools, Saws | No Comments

I spent about a million years applying varnish to the handle, and despite many distractions, I finished and rubbed it out today:

Since I was on a roll, I decided to finish the job today, too. First, I cut off the old handle, filed out the notch where the back fits into the handle, and drilled the holes:

Finally, I filed off the rough edges, put the blade into the saw, and inserted the mounting hardware.

I haven’t had time to really test it out yet, but it seems to feel okay in the hand.

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Scrub plane: Starting the finish

Jan 29

Posted by Brian in Finishing, New Tools, Planes | No Comments

I did the final shaping and glue-up of the scrub plane’s tote a while back. That, along with the edge chamfering, left me with this:

I tested it, and found it much to my liking.

Because the tote will likely see heavy use, I decided to varnish it, and before doing that, I decided to stain it. I had a can of “golden pecan” (a pigment stain) in the cabinet, so I tried it out on a test piece of beech. It didn’t seem horrible, so here is the plane after two coats (with sanding between):

There is a little blotching. I believe that I should have probably done a washcoat. It seemed to have avoided a lot of problems on that old saw handle.

Though passable now, I feel that I should sand and do another coat of stain. The second coat evened things out a lot, so a third should do it most of the rest of the way?

After that step, I would like to even it out with clear varnish. Satin polyurethane again? It’s worked well for me so far.

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Winchester Saw: Finished

Dec 9

Posted by Brian in Finishing, Old Tools, Saws | No Comments

My Winchester No. 16 handsaw has been sitting around waiting for me to do something to it since time began. I’ve had this saw for nearly five years. When I finally decided to do something about it, it was back in March, when I discovered that it was a Winchester:

I didn’t know what to do with it at that point. It’s a mildly rare saw, so one option was to try to sell it for something useful, for example, a pile of Disston D-8s. But the handle was in crap condition, and it had the less-snazzy “Warranted Superior” medallion, so I decided to restore it and keep it as a user. I don’t know when I decided to do that, but it was a long time ago, and as such, I’ve had the blade sitting around, derusted and waxed, waiting for sharpening. I took the handle off, and procrastinated on the refinishing.

About three weeks ago, I decided to do something about it. I finished today:

The saw was filed to 6TPI. That’s pretty coarse for a crosscut saw, so I was originally going to make this a ripsaw to replace my beat-up D-7. However, the handle has that funny notch on the top that would make ripping uncomfortable with two hands, so I figured decided that this would, in fact, remain a crosscut saw. The rake angle is 15 degrees, with the fleam angle at 20 degrees. I had initially filed a 20-degree rake angle, but I screwed up pointing it (of course), so on my second try, I decided that since it was so coarse that I should make it a little more aggressive. It was probably a good idea; it does saw very efficiently. The cut is fairly clean for 6TPI.

I spent about a million years refinishing the handle. It was dented, nicked, and beat up. This photo also shows how the top horn was mangled:

The first thing I did (several months ago) was strip the original finish. At the same time, I cleaned the sawnuts:

And then it sat. And sat. And sat, until about three weeks ago. Even after stripping the original finish, it was still really uneven, so I sanded around the curved parts. For the flat parts, I just skimmed it with a smoothing plane. At this time, I also learned what the wood in the handle was for the first time–American Beech (fagus grandfolia). OK, well, that’s not a big surprise.

Then there were decisions. Should I stain it? With what? I finally settled on few thin coats of a “Colonial Maple” pigment stain. I used a washcoat beforehand. Though it would result in accented nicks and dents, it would even out the flat parts, and who’s going to try to hide the fact that this saw hasn’t been used, anyway?

Finally, I decided to use the same flat-sheen polyurethane that I used on the mallet as a protective top layer. I went from a thin coat to thicker coats, then back down to thin coats for the final one. Several coats were necessary, because the varnish would run down the surfaces that were vertical, depending on the way you held the handle. I did the first coats with the handle held upright, then the later ones held flat. A close-up of the finished handle:

I used a progression of 320 grit sandpaper, #0000 steel wool, 1500 grit sandpaper, and rottenstone, all lubricated with mineral oil, to rub out the finish. There’s still a scratch here and there from the coarse-grit paper (because polyurethane is tough), but overall, it looks nice, and it’s very smooth to the touch.

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Mallet: finished

Nov 10

Posted by Brian in Finishing, New Tools | No Comments

In a previous episode, I had just given the mallet an oil/varnish blend finish to give it its color. Then I left for two weeks of vacation, and a week ago, I came back, ready to hit it with some polyurethane.

I wanted to use polyurethane for two reasons: first, I’d never really done much with varnish before, and I thought it was about time to start. Second, it’s good stuff against dirt and sweat, and it’s tough. So off I went and thinned it way too much, so it took a week to get all of the coats on.

I used a “satin sheen” on it, because I’m not big on shiny stuff. Today, I was able to finally hit it with some rottenstone and get the final result:

It’s sitting on top of a piece of the same roughsawn european beech board that it was made from. I guess that’s progress.

Here’s a shot of the top. I managed to get the ray fleck there, so I left it as-is. I’m fairly pleased at the way the end grain turned out.

There are a few flaws. But this is, after all, a striking tool, and I don’t know how pretty it’s gonna look after a period of using it as intended. Incidentally, I am pleased at how it has performed in a few tests so far. The real test comes when I try to make a mortise and tenon (or pretty much anything) again, and I reach for this thing.

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