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	<title>Galoototron &#187; New Tools</title>
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		<title>Yearly Tool Haul 2012: Japan and Taiwan</title>
		<link>http://www.galoototron.com/2012/01/13/yearly-tool-haul-2012-japan-and-taiwan/</link>
		<comments>http://www.galoototron.com/2012/01/13/yearly-tool-haul-2012-japan-and-taiwan/#comments</comments>
		<pubDate>Sat, 14 Jan 2012 03:10:36 +0000</pubDate>
		<dc:creator>Brian</dc:creator>
				<category><![CDATA[Chisels]]></category>
		<category><![CDATA[New Tools]]></category>
		<category><![CDATA[Planes]]></category>

		<guid isPermaLink="false">http://www.galoototron.com/?p=1974</guid>
		<description><![CDATA[This year&#8217;s annual transpacific trip included Japan as well as Taiwan. Unfortunately, I didn&#8217;t get to see too much in the way of wood/woodworking stuff; there was just too much on the agenda. However, I did get to go to &#8230; <a href="http://www.galoototron.com/2012/01/13/yearly-tool-haul-2012-japan-and-taiwan/">Continue reading <span class="meta-nav">&#8594;</span></a>]]></description>
			<content:encoded><![CDATA[<p>This year&#8217;s annual transpacific trip included Japan as well as Taiwan. Unfortunately, I didn&#8217;t get to see too much in the way of wood/woodworking stuff; there was just too much on the agenda.</p>
<p>However, I did get to go to the Meiji Jingu shrine, and the second gate (torii) on the path there is one of the largest wooden ones around, and happens to be made of Taiwan Yellow Cypress:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2012/01/japan_gate_taiwan_yellow_cypress.jpg"><img class="alignnone size-full wp-image-1976" title="japan_gate_taiwan_yellow_cypress" src="http://www.galoototron.com/wp-content/uploads/2012/01/japan_gate_taiwan_yellow_cypress.jpg" alt="" width="550" height="434" /></a></p>
<p>(The sign says &#8220;hinoki from Taiwan&#8221;&#8211;They consider the wood to be interchangeable.)</p>
<p>I didn&#8217;t have enough time to research tool shops in Japan, much less visit them, so I limited tool-buying to the home center-style stuff. To be honest, little odds and ends are all I really need right now. That&#8217;s a lucky thing, too, because the tools you get at the home center there are about a million times better than the ones you get in the US. Here&#8217;s the first batch:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2012/01/japan_homecenter_tools.jpg"><img class="alignnone size-full wp-image-1977" title="japan_homecenter_tools" src="http://www.galoototron.com/wp-content/uploads/2012/01/japan_homecenter_tools.jpg" alt="" width="550" height="340" /></a></p>
<p>At the top, a small mallet (wanted to see what it would do as a plane adjuster, plus I break the <a href="http://www.galoototron.com/tag/mallet-project/" target="_blank">Thagomizer</a> on a regular basis now&#8211;need to make another). Then there&#8217;s one of those milled-tooth files, that I&#8217;m going to try out as a half-round complement to the <a href="http://www.amazon.com/mn/search/?_encoding=UTF8&amp;x=0&amp;tag=galoototron-20&amp;linkCode=ur2&amp;y=0&amp;camp=1789&amp;creative=390957&amp;field-keywords=shinto%20saw%20rasp&amp;url=search-alias%3Daps" target="_blank">Shinto saw rasp</a> that I like so much. Next is a diamond feather-edge file, because it looked like it might come in handy. And on the bottom is a general-purpose knife that I&#8217;m going to try out in my seemingly endless search for a marking knife that I like. That knife is nothing special, just the kind that a schoolkid might have used for sharpening pencils as described in <a href="href=&quot;http://www.amazon.com/gp/product/0941936465/ref=as_li_ss_tl?ie=UTF8&amp;tag=galoototron-20&amp;linkCode=as2&amp;camp=1789&amp;creative=390957&amp;creativeASIN=0941936465" target="_blank">Odate&#8217;s book</a>.</p>
<p>Next is a couple of small squares:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2012/01/japan_squares.jpg"><img class="alignnone size-full wp-image-1978" title="japan_squares" src="http://www.galoototron.com/wp-content/uploads/2012/01/japan_squares.jpg" alt="" width="550" height="335" /></a></p>
<p>The 4&#8243; Lee Valley double square is at the top for size comparison. The 10x5cm square seemed like a handy size to me, and the tiny try square (made in Sanjo City) was too cute to resist. Note that even though these tools were not bought from a specialty shop, their accuracy is still guaranteed, and indeed, both are right on. You just can&#8217;t get that kind of thing from a home center in the US, and the price of these squares really isn&#8217;t excessive. We&#8217;re talking about $10 here.</p>
<p>I wish I could have gotten one of those larger framing squares that have the beveled face, but it would have not survived the airport baggage-handling gorillas. I suppose I can get those here, anyway.</p>
<p>Next up is a couple of sharpening implements:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2012/01/japan_sharpening.jpg"><img class="alignnone size-full wp-image-1979" title="japan_sharpening" src="http://www.galoototron.com/wp-content/uploads/2012/01/japan_sharpening.jpg" alt="" width="550" height="366" /></a></p>
<p>I really have no idea what that thing on the top is, but it was cheap and it&#8217;s really coarse, so I figured that if nothing else, it could maybe be used to rough up the surface of my Sigma Power #120. I got the diamond plate on the bottom primarily for conditioning my waterstones.</p>
<p>Oh yeah, I got some shoji paper, too.</p>
<p>After leaving Japan, I went to the now-familiar <a href="http://www.jctool.com.tw/">tool shop</a> in Taipei, and it turned out that I wasn&#8217;t quite done with Japan yet. I decided to buy my first Japanese chisel there for the hell of it (and to make <a href="http://giantcypress.net/" target="_blank">Wilbur Pan</a> gloat or something):</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2012/01/japanese_chisel_first.jpg"><img class="alignnone size-full wp-image-1980" title="japanese_chisel_first" src="http://www.galoototron.com/wp-content/uploads/2012/01/japanese_chisel_first.jpg" alt="" width="550" height="266" /></a></p>
<p>And I was looking for a smallish/medium smoothing plane, and got this typical Japanese-blade/Taiwanese body hybrid:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2012/01/small_plane_jp_tw.jpg"><img class="alignnone size-full wp-image-1981" title="small_plane_jp_tw" src="http://www.galoototron.com/wp-content/uploads/2012/01/small_plane_jp_tw.jpg" alt="" width="550" height="553" /></a></p>
<p>Annoyingly, the face of the blade on this thing was not flat when I got it&#8211;it had a very (very) slight convexity on one half of the edge. For those of you familiar with this kind of steel, though, you know that lapping it away is basically an exercise in futility, and it took me an embarrasingly long time to remember this.</p>
<p>So I <a href="http://giantcypress.net/post/5446904360/tap-tap-revenge" target="_blank">tapped it out</a>. I&#8217;d never done that before, and it was as nerve-wracking as everyone says it is, but I have to say that it worked like a charm.</p>
<p>Finally, the tool I was most looking forward to buying was a plain-jane Taiwanese-made rabbet plane:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2012/01/taiwan_rabbet_plane.jpg"><img class="alignnone size-full wp-image-1982" title="taiwan_rabbet_plane" src="http://www.galoototron.com/wp-content/uploads/2012/01/taiwan_rabbet_plane.jpg" alt="" width="550" height="364" /></a></p>
<p>Why? Because I&#8217;m fed up with my Stanley #78&#8211;a torturer of left hands since 1885. The one here doesn&#8217;t have a depth stop, though I could make one or clamp one on. And it seems that the convexity demon from the blade on the preceding plane infected this one, too. So I tapped out this one, too, this time with a little more confidence. Yay!</p>
<p>The maybe-not-so-strange thing about this plane is that it&#8217;s designed to be used left-to-right. I&#8217;m not sure it&#8217;s going to make much of a difference, but it might give me an excuse to buy an antique Western rabbet plane to complement it.</p>
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		<slash:comments>2</slash:comments>
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		<title>Goofs Illustrated: Too Many Planes</title>
		<link>http://www.galoototron.com/2011/07/31/goofs-illustrated-too-many-planes/</link>
		<comments>http://www.galoototron.com/2011/07/31/goofs-illustrated-too-many-planes/#comments</comments>
		<pubDate>Sun, 31 Jul 2011 19:24:36 +0000</pubDate>
		<dc:creator>Brian</dc:creator>
				<category><![CDATA[New Tools]]></category>
		<category><![CDATA[Old Tools]]></category>
		<category><![CDATA[Planes]]></category>
		<category><![CDATA[goofs]]></category>
		<category><![CDATA[mistakes]]></category>

		<guid isPermaLink="false">http://www.galoototron.com/?p=1802</guid>
		<description><![CDATA[I&#8217;m going to start a new feature that will appear irregularly, meaning &#8220;whenever I have material.&#8221; Essentially, when I have enough explanation for something that I messed up, I&#8217;ll write about it. I was originally going to call these &#8220;mistakes,&#8221; &#8230; <a href="http://www.galoototron.com/2011/07/31/goofs-illustrated-too-many-planes/">Continue reading <span class="meta-nav">&#8594;</span></a>]]></description>
			<content:encoded><![CDATA[<p>I&#8217;m going to start a new feature that will appear irregularly, meaning &#8220;whenever I have material.&#8221; Essentially, when I have enough explanation for something that I messed up, I&#8217;ll write about it. I was originally going to call these &#8220;mistakes,&#8221; but I realized that they aren&#8217;t that serious (and <a href="http://villagecarpenter.blogspot.com/2011/07/i-refuse-to-call-these-mistakes.html" target="_blank">Kari Hultman agrees</a>). It&#8217;s an important distinction because I don&#8217;t want to give the impression that you can&#8217;t get anything done if you goof up, goof off, or whatever. I&#8217;ve completed several projects while doing the &#8220;wrong thing.&#8221; The contradiction is that in woodworking, completing a project is essentially never the wrong thing to do. Just ask your significant other.</p>
<p>So here we go with the most obvious one: I bought too many stupid bench planes, and didn&#8217;t know what to do with them. You&#8217;re going to see a lot of confessions like this (if you haven&#8217;t already) due to the release of Schwarz&#8217;s <em>The Anarchist&#8217;s Tool Chest</em>, where he goes into detail about this. It is a recurring thing, though&#8211;seems that everyone has to go through it because otherwise, you really don&#8217;t know for yourself.</p>
<p>Let&#8217;s start with jack planes. I knew that I needed a jack plane and I got a pair of metal Bailey-style models early on because they were not expensive. I got one working well as a general-purpose plane and I was really happy that I was able to get the thing to take nice shavings. So far, so good, but that didn&#8217;t stop me from buying more. I ended up with four #5-size ones. I don&#8217;t know why, because I use only one of them. I&#8217;m currently thinking about adapting a second to shooting-board use, so that would still leave two extras. And that #5 1/4-size plane I picked up? I&#8217;ve used it maybe once, but it sure is cute.</p>
<p>What&#8217;s probably worse is that I didn&#8217;t put a serious camber on my jack plane until, what was it, <a title="Bookshelf: Making Panels" href="http://www.galoototron.com/2010/03/17/bookshelf-making-panels/" target="_blank">three years after I got it</a>? That was almost a year and a half ago. Stock prep has never quite been the same since. I&#8217;d made a <a href="http://www.galoototron.com/tag/scrub-plane/" target="_blank">scrub plane</a>, which is great for getting really icky boards into shape, but it never occurred to me that I should have something somewhere between that and a straight edge.</p>
<div id="attachment_1826" class="wp-caption alignnone" style="width: 460px"><a href="http://www.galoototron.com/wp-content/uploads/2011/07/too_many_jack_planes.jpg"><img class="size-full wp-image-1826" title="too_many_jack_planes" src="http://www.galoototron.com/wp-content/uploads/2011/07/too_many_jack_planes.jpg" alt="" width="450" height="212" /></a><p class="wp-caption-text">What was I thinking?</p></div>
<p>So I&#8217;m happy with that thing, but am I finished with jack planes?</p>
<p>Oh well, the answer doesn&#8217;t matter. Let&#8217;s talk about smoothers now, because we have to. At my peak, I had five metal #4-sized smoothers. I&#8217;m down to three: one that does what it&#8217;s supposed to do when it&#8217;s sharp, one that I don&#8217;t use so much, and another that I&#8217;m prepping to give to a friend. I have a wooden <a title="This Year’s Tool Haul from Taiwan" href="http://www.galoototron.com/2011/02/01/this-years-tool-haul-from-taiwan/" target="_blank">Taiwanese plane</a> that works wonders as a smoother, and I&#8217;m thinking about rehabbing a coffin smoother because wooden planes are awesome. And there&#8217;s the #3 size that I&#8217;ve got, too. It works great but I never use it.</p>
<div id="attachment_1827" class="wp-caption alignnone" style="width: 460px"><a href="http://www.galoototron.com/wp-content/uploads/2011/07/smoothing_planes.jpg"><img class="size-full wp-image-1827" title="smoothing_planes" src="http://www.galoototron.com/wp-content/uploads/2011/07/smoothing_planes.jpg" alt="" width="450" height="353" /></a><p class="wp-caption-text">This would be a nice set. The coffin smoother isn&#39;t tuned, though.</p></div>
<p>At least smoothing planes are small, though. I don&#8217;t have as many as a hardcore addict, so they&#8217;re easy to stow away and sort of forget about. Unlike jointer planes.</p>
<p>I&#8217;ve owned five jointer planes. I had two metal Bailey #7-size examples and they worked okay, but I was never terribly happy with them. I gave one to a friend. I also had a #8 that needed some work. I gave that one to a fellow <a href="http://www.calast.com/personal/ken/BAGsFAQ.htm" target="_blank">BAG</a> when I realized that I hadn&#8217;t gotten it to work yet because I never really wanted it to.</p>
<p>And I was still in jointer hell. The one that remained and I actually used, I didn&#8217;t like very much. There was just <em>something</em> about it that bugged me, so this year, I bought two more at about the same time. One of these was a woodie that a friend picked up at the flea (thanks, again, Kirk!). The other is Veritas bevel-up jointer (BUJ). Now that there is a serious plane&#8211;and I think it cost more than all of my other bench planes combined. I flattened the sole of the woodie with the BUJ, set the woodie for a thicker shaving (kind of like a fore plane), the BUJ for a fine shaving, and maybe, just <em>maybe</em>, I&#8217;ve escaped jointer hell. I found stock prep on the nightstands v2 project to be much less of a chore with these. Remember the phrase, &#8220;coarse, medium, fine?&#8221; The woodie is medium and the BUJ is fine. On thin boards where the blade is wider than the stock, you don&#8217;t need to use a smoother.</p>
<div id="attachment_1828" class="wp-caption alignnone" style="width: 460px"><a href="http://www.galoototron.com/wp-content/uploads/2011/07/current_jointer_planes.jpg"><img class="size-full wp-image-1828" title="current_jointer_planes" src="http://www.galoototron.com/wp-content/uploads/2011/07/current_jointer_planes.jpg" alt="" width="450" height="221" /></a><p class="wp-caption-text">If I&#39;m lucky, this will be the end of the jointer debacle.</p></div>
<p>Oh yeah, and of course, I have two Bailey #6-size planes. I never use them because I&#8217;ve found that I prefer the jack plane size as a fore plane. Why? The #6 is too heavy for my weight. When I make a diagonal stroke with one, it&#8217;s too much effort to lift it back toward me. I&#8217;ve noticed that guys who like the #6 size for this sort of thing tend to outsize me. So, would a wooden plane be better, or should I just stop fooling around and be happy with my jack plane?</p>
<div id="attachment_1829" class="wp-caption alignnone" style="width: 460px"><a href="http://www.galoototron.com/wp-content/uploads/2011/07/metal_fore_planes.jpg"><img class="size-full wp-image-1829" title="metal_fore_planes" src="http://www.galoototron.com/wp-content/uploads/2011/07/metal_fore_planes.jpg" alt="" width="450" height="191" /></a><p class="wp-caption-text">Too heavy.</p></div>
<p>That final question is why I&#8217;m still in the goofing-off stage with bench planes. There are two sides to this. On one hand, goofing around with tools can seriously detract from projects that you&#8217;re supposed to be working on (and believe me, those are my top priorities). On the other hand, there are certain tools that can save you a lot of time on your projects if you spend enough time goofing around with them.</p>
<p>I have slight excesses of other tools, but the plane surplus is the one I&#8217;m embarrassed about. So this will probably be the only goof episode about too many tools.</p>
<p>&nbsp;</p>
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		<title>Marking Gauge Stability Tweak</title>
		<link>http://www.galoototron.com/2011/07/10/marking-gauge-stability-tweak/</link>
		<comments>http://www.galoototron.com/2011/07/10/marking-gauge-stability-tweak/#comments</comments>
		<pubDate>Sun, 10 Jul 2011 18:53:27 +0000</pubDate>
		<dc:creator>Brian</dc:creator>
				<category><![CDATA[New Tools]]></category>
		<category><![CDATA[marking gauge]]></category>

		<guid isPermaLink="false">http://www.galoototron.com/?p=1790</guid>
		<description><![CDATA[Back when I made this marking gauge, I thought I pretty much had it all figured out with the mistakes I made there (see the bottom of the post). But it turns out that one of them was kind of &#8230; <a href="http://www.galoototron.com/2011/07/10/marking-gauge-stability-tweak/">Continue reading <span class="meta-nav">&#8594;</span></a>]]></description>
			<content:encoded><![CDATA[<p>Back when I made <a title="Making a Marking Gauge" href="http://www.galoototron.com/2010/09/02/making-a-marking-gauge/">this marking gauge</a>, I thought I pretty much had it all figured out with the mistakes I made there (see the bottom of the post). But it turns out that one of them was kind of unresolved; how to get the arm to have no play whatsoever (as it was, the arm would swivel a little horizontally because its hole wasn&#8217;t a perfect fit). I&#8217;d thought of a bunch of stupid ideas, from making the arm trapezoidal to mounting the tightening screw diagonally, but mostly, I forgot about it because it still &#8220;kinda&#8221; worked and that&#8217;s all I cared about.</p>
<p>Then when I was milling the frame components for the new <a href="http://www.galoototron.com/tag/nightstands-v2/" target="_blank">nightstands v2 project</a>, I needed more than one gauge, so I grabbed one of my old Stanleys and noticed that the arm didn&#8217;t budge at all. Neither did my other old Stanley. Both of these were rectangular-like arms tightened with a screw from above, like the one I&#8217;d made. What did they do that I didn&#8217;t?</p>
<p>I flipped them over and found the answer.</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2011/07/stanley_marking_gauges.jpg"><img class="alignnone size-full wp-image-1791" title="stanley_marking_gauges" src="http://www.galoototron.com/wp-content/uploads/2011/07/stanley_marking_gauges.jpg" alt="" width="450" height="303" /></a></p>
<p>The bottoms of the arms are slightly convex and the hole in the marking gauge stock is slightly concave. The gauge on the right is a Sweetheart-era Stanley and is a really good fit.</p>
<p>Upon realizing this, I immediately knocked the wedge and blade of out the arm of my shopmade gauge, pulled the arm out of the stock, and used my <a title="Taiwan: More Tools, Sitou" href="http://www.galoototron.com/2010/01/26/taiwan-more-tools-sitou/" target="_blank">Taiwanese shave</a> to put a slight radius on the bottom of the arm. Then I put a rasp into the stock and made a mating surface, and the result looks like this:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2011/07/marking_gauge_tweaked.jpg"><img class="alignnone size-full wp-image-1792" title="marking_gauge_tweaked" src="http://www.galoototron.com/wp-content/uploads/2011/07/marking_gauge_tweaked.jpg" alt="" width="450" height="348" /></a></p>
<p>The fit doesn&#8217;t look terribly appealing to the eye, but doing just this much instantly solved the problem, and I&#8217;m really lovin&#8217; this gauge now. At that point, I figured that I&#8217;d better get back to milling rather than try to make this dorky tool look better. That was a couple of days ago. I finally got around the taking the photos today. It took about five times as much time to take the photos and write this post than to actually fix the problem. Peh.</p>
<p>(And maybe someone else out there has already figured this out and posted something that I haven&#8217;t read.)</p>
<p>[<em>Edit (17 June 2011): OK, so I finally bought The Anarchist's Tool Chest by Christopher Schwarz, and unsurprisingly, on page 118, he talks about this problem. His solution is to do the wedge-jams-the-arm-into-a-corner thing. That works, but he gives short shrift to thumbscrew-tightened models, which is, of course, an injustice, because they work fine after you do what Stanley (and whoever they stole the idea from) did. Also, he says that the thumbscrew is knurled brass. Well, I couldn't source any brass for mine, and a lot of new ones sure aren't solid brass, if they contain any at all. I think a wooden thumbscrew is best (Stanley used these), but I don't have a tap and threader, so I couldn't do this. Anyways, it's another datapoint.</em>]</p>
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		<title>This Year&#8217;s Tool Haul from Taiwan</title>
		<link>http://www.galoototron.com/2011/02/01/this-years-tool-haul-from-taiwan/</link>
		<comments>http://www.galoototron.com/2011/02/01/this-years-tool-haul-from-taiwan/#comments</comments>
		<pubDate>Wed, 02 Feb 2011 05:12:53 +0000</pubDate>
		<dc:creator>Brian</dc:creator>
				<category><![CDATA[Chisels]]></category>
		<category><![CDATA[New Tools]]></category>
		<category><![CDATA[Planes]]></category>

		<guid isPermaLink="false">http://www.galoototron.com/?p=1522</guid>
		<description><![CDATA[When preparing for this year&#8217;s trip to the tool shop, I decided to try to concentrate on purchasing tools that I believe I actually need (imagine that). I had a few ideas already, and I started out with a pile &#8230; <a href="http://www.galoototron.com/2011/02/01/this-years-tool-haul-from-taiwan/">Continue reading <span class="meta-nav">&#8594;</span></a>]]></description>
			<content:encoded><![CDATA[<p>When preparing for this year&#8217;s trip to the tool shop, I decided to try to concentrate on purchasing tools that I believe I actually need (imagine that). I had a few ideas already, and I started out with a pile of Taiwanese carving tools&#8211;primarily outchannel gouges, but also a V tool and some other stuff:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2011/02/tw_carving_tools.jpg"><img class="alignnone size-full wp-image-1523" title="tw_carving_tools" src="http://www.galoototron.com/wp-content/uploads/2011/02/tw_carving_tools.jpg" alt="" width="450" height="192" /></a></p>
<p>I also got a big pile of hollowing and rounding planes:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2011/02/tw_hollows_rounds.jpg"><img class="alignnone size-full wp-image-1524" title="tw_hollows_rounds" src="http://www.galoototron.com/wp-content/uploads/2011/02/tw_hollows_rounds.jpg" alt="" width="450" height="282" /></a></p>
<p>Of course, right away, I might be straying from the &#8220;buy what you need&#8221; mantra, because I&#8217;m not sure I really need all of these. However, they&#8217;re so much fun and so cheap (less than $10 each) that it&#8217;s hard to resist. And as usual, the blades are great: forge-welded cutting steel on softer metal with hollowed faces that take just a minute or two to flatten. I sharpened and tested all of these in almost no time at all.</p>
<p>When I saw this compass plane, I realized that I didn&#8217;t have one and that this was probably a good time to get one:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2011/02/tw_compass_plane.jpg"><img class="alignnone size-full wp-image-1525" title="tw_compass_plane" src="http://www.galoototron.com/wp-content/uploads/2011/02/tw_compass_plane.jpg" alt="" width="450" height="325" /></a></p>
<p>This plane exhibits a very common scenario for the better planes sold in Taiwan: a blade made in Japan (supposedly) and a body made in Taiwan. There is also a double-convex version of this plane, <a href="http://tw.myblog.yahoo.com/harimau-blog/article?mid=3477" target="_blank">as seen on this blog</a> (I hope to feature some more from the author at some point).</p>
<p>It&#8217;s a wicked fun plane to use. I had to try it out; I first gouged out a curve in some wood and then smoothed it out with this thing. It&#8217;s really remarkable how easy this goes when everything is tuned correctly. Although this wasn&#8217;t the cheapest tool in the shop at about $30, it&#8217;s really hard to beat the performance at any price.</p>
<p>The final tool that I&#8217;m going to talk about for this year&#8217;s trip is another plane. I got to wondering what a full-sized Taiwanese bench plane would be like. However, as I mentioned before, most bench planes in Taiwan are either wholly from Japan or have a Japanese blade with a Taiwanese body. The shop had one bench plane with all-Taiwanese components, though, and at $35, it was about a third of the price of the hybrids, so I bagged it:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2011/02/tw_bench_plane.jpg"><img class="alignnone size-full wp-image-1528" title="tw_bench_plane" src="http://www.galoototron.com/wp-content/uploads/2011/02/tw_bench_plane.jpg" alt="" width="450" height="266" /></a></p>
<p>I didn&#8217;t have to wait long to use it, either, because while I was still in Taipei, Uncle had a cabinet door that didn&#8217;t fit. So I sharpened the blade with the same sandpaper that I used for the chisel on the <a href="http://www.galoototron.com/2011/01/08/an-antique-eastern-cabinet/" target="_blank">old cabinet</a>.</p>
<p>It worked fine for this purpose, but it was a job that didn&#8217;t need finesse&#8211;I wouldn&#8217;t have had the time for that, anyway. Not only was the sandpaper (&#8220;Matador&#8221; brand, 1200 grit) not quite as fine as I had wanted, but the body was new and probably needed some tweaking. I also set the blade for a rather thick shaving.</p>
<p>When I brought it back home, however, I had time to tune the plane. So because it&#8217;s somewhat similar to a Japanese bench plane, I dug into Odate&#8217;s book and looked at <a href="http://giantcypress.net/post/1422532807/japanese-plane-set-up-ii-sole-conditioning" target="_blank">Wilbur Pan&#8217;s blog</a> for his experience first, then looked at what I had in front of me.</p>
<p>The first thing I did was to sharpen the blade on my waterstones, and I got a wonderful edge in no time. However, I also noticed something that I still need to think about&#8211;this blade was fairly well-cambered, so its initial grinding had it set up as sort of a jack plane.</p>
<p>The type of plane is important because you&#8217;re supposed to set up the sole differently depending on its purpose. The rougher the cut, the more you&#8217;re supposed to hollow the sole, or so the story goes. However, I don&#8217;t need another jack plane, and because the mouth on this one is ultra-tight, I decided that I might want to keep my options open and proceed with caution.</p>
<p>However, <em>something</em> needed to be done to the body because it appeared that the wood had moved slightly since production, causing some of the sole in front of the mouth to protrude a little from the level of the mouth and end. I suspected that I was having trouble with this because my shavings were not of a consistent thickness. I verified this with a straightedge using the method that Odate describes, and quickly marked the high spots. He says to use a scraper plane or something of that nature to take down the high spots (and form a hollow). Wilbur Pan likes to use a card scraper, and I would have done that as well, except that I am silly and haven&#8217;t actually gotten around to making one.</p>
<p>I ended up carefully using my Veritas low-angle block plane to knock off the high spots. I didn&#8217;t really hollow the sole because I would rather use a scraper for this. But it was enough for a semi-serious test of what the plane can do, and it does make a delightful shaving. A little more work on flattening out the camber on the blade, and this thing could easily be my go-to smoother.</p>
<p>This brings up an important question: <em>What exactly am I doing?</em> After all, I have more bench planes than I can shake a stick at. It seems to be, though, that the more I use wooden planes, the more I like them. It doesn&#8217;t seem to matter if they&#8217;re western or Asian planes&#8211;I simply like the way wooden planes feel, and I&#8217;m really starting to appreciate how easy it is to adjust them. Perhaps I will downsize a few of my metal planes sometime.</p>
<p>Someone (who?) once said, &#8220;Wood on wood&#8211;sure feels good!&#8221; There&#8217;s a lot of truth to that.</p>
<p>PS: In case you&#8217;re wondering what the rectangular hole underneath the blade is, for, the plane comes with a removable handle. When fit, it looks like this:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2011/02/tw_bench_plane_handle.jpg"><img class="alignnone size-full wp-image-1529" title="tw_bench_plane_handle" src="http://www.galoototron.com/wp-content/uploads/2011/02/tw_bench_plane_handle.jpg" alt="" width="450" height="286" /></a></p>
<p>I believe this is for getting a sturdy grip to pull when using the plane for tougher work, but I&#8217;m not too sure. I don&#8217;t think it&#8217;s the sort of thing you&#8217;d use two hands on because it&#8217;d be hard to control like that. I likely won&#8217;t be using it.</p>
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		<title>Making a Mortise Gauge</title>
		<link>http://www.galoototron.com/2010/11/19/making-a-mortise-gauge/</link>
		<comments>http://www.galoototron.com/2010/11/19/making-a-mortise-gauge/#comments</comments>
		<pubDate>Fri, 19 Nov 2010 21:07:48 +0000</pubDate>
		<dc:creator>Brian</dc:creator>
				<category><![CDATA[New Tools]]></category>
		<category><![CDATA[marking gauge]]></category>
		<category><![CDATA[mortise gauge]]></category>

		<guid isPermaLink="false">http://www.galoototron.com/?p=1426</guid>
		<description><![CDATA[I&#8217;d like to say that I&#8217;ve been off designing a new project for the last three weeks, that I&#8217;ve made a new workbench, or that I&#8217;ve been moving, or something like that. But no, I&#8217;ve been making a new mortise &#8230; <a href="http://www.galoototron.com/2010/11/19/making-a-mortise-gauge/">Continue reading <span class="meta-nav">&#8594;</span></a>]]></description>
			<content:encoded><![CDATA[<p>I&#8217;d like to say that I&#8217;ve been off designing a new project for the last three weeks, that I&#8217;ve made a new workbench, or that I&#8217;ve been moving, or something like that.</p>
<p>But no, I&#8217;ve been making a new mortise gauge, and yes, it took me nearly three weeks (mainly because I haven&#8217;t spent much actual time in the shop due to an acute case of laziness). This is based on the <a href="http://www.galoototron.com/2010/09/02/making-a-marking-gauge/" target="_blank">marking gauge I made a while back</a>, but I wanted to solve some of the deficiencies of that one.</p>
<p>I should also mention that the whole reason I wanted a new mortise gauge was to correct an irritating problem in the two-armed Asian-style gauge that I have now: there&#8217;s only one thumbscrew to secure the whole thing, and the two arms are separated by a little metal plate. When you&#8217;re trying to adjust one arm, the plate moves, moving the other arm slightly. It takes a lot of dorking around (at least for me) to get both adjusted to the correct length. So I resolved that I would fix that by making a two-armed version with two independent thumbscrews.</p>
<p>I started by making the stock out of some of that pacific madrone that I&#8217;ve got hanging around, using the same technique as in that earlier post. This is the view after I&#8217;d cut the mortises, drilled the small guide holes, and shaped the top:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/11/mortise_gauge_stock.jpg"><img class="alignnone size-full wp-image-1427" title="mortise_gauge_stock" src="http://www.galoototron.com/wp-content/uploads/2010/11/mortise_gauge_stock.jpg" alt="" width="450" height="282" /></a></p>
<p>When I set about making the arms (out of beech, for whatever reason), I fine-tuned them to fit the mortises tightly using the old &#8220;plane clamped upside down in the vise&#8221; trick that was featured on what I think was a fairly recent episode of <a href="http://www.pbs.org/woodwrightsshop/" target="_blank">St. Roy&#8217;s show</a>:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/11/mortise_gauge_arm_fitting.jpg"><img class="alignnone size-full wp-image-1428" title="mortise_gauge_arm_fitting" src="http://www.galoototron.com/wp-content/uploads/2010/11/mortise_gauge_arm_fitting.jpg" alt="" width="450" height="306" /></a></p>
<p>Just watch that you don&#8217;t plane your fingers! When the arms were fit, I had this:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/11/mortise_gauge_arms.jpg"><img class="alignnone size-full wp-image-1429" title="mortise_gauge_arms" src="http://www.galoototron.com/wp-content/uploads/2010/11/mortise_gauge_arms.jpg" alt="" width="450" height="301" /></a></p>
<p>Then it was time to put in the screw inserts for the thumbscrew securing mechanism. Sometimes this can be a real pain, and it was a really big pain this time. I started by enlarging the guide holes with a #5 auger bit:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/11/mortise_gauge_insert_holes.jpg"><img class="alignnone size-full wp-image-1430" title="mortise_gauge_insert_holes" src="http://www.galoototron.com/wp-content/uploads/2010/11/mortise_gauge_insert_holes.jpg" alt="" width="450" height="269" /></a></p>
<p>The problem was, however, that a #5 bit was too small for an insert (seen behind the vise above), and a #6 was too large. Furthermore, the screw inserts were brass, which means that they are very easy to mangle. I used a round file to enlarge the holes slighty, then gently drove in the inserts with a bolt. (Prayer may also have been involved; I do not remember.)</p>
<p>With that part done, I made the holes for the blades, the wedges to secure the blades, and finally, the blades themselves (out of spring steel again). Remembering my goof from the previous marking gauge, I put the wedges on the outsides of the blades this time. The wedges were also fine-tuned using the clamped-plane method described above.</p>
<p>Then I made the &#8220;saddle pieces&#8221; that I described in the <a href="http://www.galoototron.com/2010/09/02/making-a-marking-gauge/" target="_blank">marking gauge post</a>. This time, I bought a thinner strip of brass so it was easier to hammer to shape. Then, to design around the problem of the saddle getting in the way, I marked where the blades hit the saddle:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/11/mortise_gauge_mark_saddle.jpg"><img class="alignnone size-full wp-image-1431" title="mortise_gauge_mark_saddle" src="http://www.galoototron.com/wp-content/uploads/2010/11/mortise_gauge_mark_saddle.jpg" alt="" width="450" height="361" /></a></p>
<p>Then I sawed and filed out a notch in each saddle so that the blades could be brought flush to the stock:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/11/mortise_gauge_saddles_done.jpg"><img class="alignnone size-full wp-image-1432" title="mortise_gauge_saddles_done" src="http://www.galoototron.com/wp-content/uploads/2010/11/mortise_gauge_saddles_done.jpg" alt="" width="450" height="386" /></a></p>
<p>At that point, there was nothing left to do but trim the thumbscrews and wedges down to size, and call it done:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/11/mortise_gauge_finished.jpg"><img class="alignnone size-full wp-image-1433" title="mortise_gauge_finished" src="http://www.galoototron.com/wp-content/uploads/2010/11/mortise_gauge_finished.jpg" alt="" width="450" height="303" /></a></p>
<p>Initial tests seem to indicate that it works.</p>
<p>[<em>Edit: If you're thinking about making a marking gauge, see <a title="Marking Gauge Stability Tweak" href="http://www.galoototron.com/2011/07/10/marking-gauge-stability-tweak/" target="_blank">this post</a> for an important tweak that helps resolve a certain annoyance in this style of marking gauge. This one doesn't have that issue, but bigger ones tend to.</em>]</p>
<p>[<em>Edit: Bob Rozaieski put up a video of making a French style marking gauge on the same day that I posted this! Check it out <a href="http://www.logancabinetshoppe.com/1/post/2010/11/episode-29-making-a-marking-gauge.html" target="_blank">here</a>.</em>]</p>
<p>﻿﻿</p>
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		<title>New Joinery Saw</title>
		<link>http://www.galoototron.com/2010/09/16/new-joinery-saw/</link>
		<comments>http://www.galoototron.com/2010/09/16/new-joinery-saw/#comments</comments>
		<pubDate>Fri, 17 Sep 2010 03:08:50 +0000</pubDate>
		<dc:creator>Brian</dc:creator>
				<category><![CDATA[Joinery]]></category>
		<category><![CDATA[New Tools]]></category>
		<category><![CDATA[Saws]]></category>
		<category><![CDATA[cherry handle 1]]></category>
		<category><![CDATA[dovetails]]></category>

		<guid isPermaLink="false">http://www.galoototron.com/?p=1302</guid>
		<description><![CDATA[In my last post, I was cutting the teeth on a new saw. This one&#8217;s got a plate that&#8217;s 10&#8243;x3&#8243;, .020&#8243; thick, and has a milled brass back that has a 1/4&#8243;x3/4&#8243; profile. These parts came from Mike Wenzloff, to &#8230; <a href="http://www.galoototron.com/2010/09/16/new-joinery-saw/">Continue reading <span class="meta-nav">&#8594;</span></a>]]></description>
			<content:encoded><![CDATA[<p>In my last post, I was cutting the teeth on a new saw. This one&#8217;s got a plate that&#8217;s 10&#8243;x3&#8243;, .020&#8243; thick, and has a milled brass back that has a 1/4&#8243;x3/4&#8243; profile. These parts came from <a href="http://www.wenzloffandsons.com/" target="_blank">Mike Wenzloff</a>, to whom I owe a lot of thanks for not only accommodating what turned out to be kind of a crazy order, but also for providing tips on how to attach the back and other matters.</p>
<p>I&#8217;m not sure what to call this saw because it&#8217;s somewhere between a dovetail saw and a carcase/small tenon saw. As I mentioned before, it&#8217;s got 16 teeth per inch, which is in the range of most dovetail saws, as is the sawplate thickness, but its plate depth is a bit more than more of those.</p>
<p>My goal was to replace the trusty Crown gents saw that I&#8217;ve been making most of my joints with. I&#8217;ve been happy with the way that saw cuts, and indeed, I&#8217;ve made most of my furniture with it, but I wanted more weight and a &#8220;nicer&#8221; handle. So since I want to cut most of my joinery with this saw, I&#8217;m calling it a joinery saw, I guess.</p>
<p>So with the teeth cut, the back shaped and attached, and the blade waxed up, I grabbed the cherry handle from <a href="http://www.galoototron.com/2008/12/02/carcase-rip-saw-with-cherry-handle-finished/" target="_blank">this saw from before</a>, put holes in the right spots, and it was done:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/joinery_saw.jpg"><img class="alignnone size-full wp-image-1307" title="joinery_saw" src="http://www.galoototron.com/wp-content/uploads/2010/09/joinery_saw.jpg" alt="" width="450" height="209" /></a></p>
<p>Then I tested it out by slicing the end of a piece of something-or-other to ribbons:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/joinery_saw_test.jpg"><img class="alignnone size-full wp-image-1308" title="joinery_saw_test" src="http://www.galoototron.com/wp-content/uploads/2010/09/joinery_saw_test.jpg" alt="" width="450" height="306" /></a></p>
<p>I have to admit, that was a lot of fun.</p>
<p>But projects awaited this saw, so I had to get going on them. The first one I worked on was this box:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/az_cypress_box.jpg"><img class="alignnone size-full wp-image-1309" title="az_cypress_box" src="http://www.galoototron.com/wp-content/uploads/2010/09/az_cypress_box.jpg" alt="" width="450" height="321" /></a></p>
<p>It&#8217;s a small box meant to hold cards the size of index cards. The walls are made from a block of Arizona Cypress (thanks to Roger Van Maren for bringing this in to Bagathon!), about 3/8&#8243; thick. The bottom is redwood, about 3/32&#8243; thick, sawed out with the frame saw.</p>
<p>I&#8217;m not sure what in the world I was thinking, because this wood kind of &#8220;crumbles out&#8221; rather than tears out. The grain reverses like crazy. I had to make a scratch stock-like tool to scrape out the groove for the bottom. But I guess once you get the hang of it, the end result is nice. And the new saw worked really well for those teeny dovetails.</p>
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		<title>Cutting New Saw Teeth</title>
		<link>http://www.galoototron.com/2010/09/09/cutting-new-saw-teeth/</link>
		<comments>http://www.galoototron.com/2010/09/09/cutting-new-saw-teeth/#comments</comments>
		<pubDate>Fri, 10 Sep 2010 03:34:21 +0000</pubDate>
		<dc:creator>Brian</dc:creator>
				<category><![CDATA[New Tools]]></category>
		<category><![CDATA[Saws]]></category>
		<category><![CDATA[saw sharpening]]></category>

		<guid isPermaLink="false">http://www.galoototron.com/?p=1288</guid>
		<description><![CDATA[When I remark that I&#8217;ve cut teeth entirely from scratch on many of my saws, some people think that it either involves stamping, a machine, or some sort of magic trick. It&#8217;s nothing of the sort. If a klutz like &#8230; <a href="http://www.galoototron.com/2010/09/09/cutting-new-saw-teeth/">Continue reading <span class="meta-nav">&#8594;</span></a>]]></description>
			<content:encoded><![CDATA[<p>When I remark that I&#8217;ve cut teeth entirely from scratch on many of my saws, some people think that it either involves stamping, a machine, or some sort of magic trick. It&#8217;s nothing of the sort. If a klutz like me can do it on the abomination of a saw vise that I have, anyone can.</p>
<p>It&#8217;s actually quite simple because it&#8217;s derived from normal saw-sharpening practice. You start with a file with a handle and flat block of wood as described in <a href="http://www.amazon.com/gp/product/1561581259?ie=UTF8&amp;tag=galoototron-20&amp;linkCode=as2&amp;camp=1789&amp;creative=390957&amp;creativeASIN=1561581259" target="_blank">Lee&#8217;s book</a> and any <a href="http://www.vintagesaws.com/" target="_blank">saw sharpening site</a> out there. To get the tooth spacing, make yourself a little guide. I wrote my own PostScript program to do it (check the <a href="http://www.galoototron.com/plans-and-guides/">Plans and Guides page</a> for PDF versions), but I imagine that there are plenty of ways you can do it with several packages.</p>
<p>Get some reading glasses; they help a lot.</p>
<p>Fold the guide over the front jaw of the vise, put the blade in, just peeking over the top, and make a first pass with the file, just filing in a little notch over the top of each line (sorry about the fuzziness, but I just don&#8217;t have a macro lens):</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/cut_teeth_first_pass.jpg"><img class="alignnone size-full wp-image-1289" title="cut_teeth_first_pass" src="http://www.galoototron.com/wp-content/uploads/2010/09/cut_teeth_first_pass.jpg" alt="" width="450" height="309" /></a></p>
<p>Notice that I&#8217;m not really getting the spacing spot-on; you can tell from the flats at the tips of the newly-formed teeth. Don&#8217;t worry about this on your first pass&#8211;you&#8217;re going to refine it later on. You don&#8217;t even have to worry much about the file itself on the first pass. The one I&#8217;m using here is way too big for the final tooth size (this will be a 16TPI saw that I will reveal later). I&#8217;m doing this because I don&#8217;t want to put unnecessary wear on a relatively expensive small saw file.</p>
<p>After you&#8217;re done with the first pass, do a second pass to go deeper. Make an attempt to correct for uneven spacing by putting a little pressure left or right as you&#8217;re filing, but use a very light touch; don&#8217;t make any extra strokes with the file just to even it out, and don&#8217;t press harder than you normally would. You still want to be fairly consistent in the newly-cut tooth valley size. The unevenness will disappear as you make more passes with the file.</p>
<p>In the saw above, the teeth are so small that I went most of the way with my second pass, this time using a file that&#8217;s appropriate for the pitch. You can see that the teeth are slightly uneven, but not by extreme amounts:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/cut_teeth_second_pass.jpg"><img class="alignnone size-full wp-image-1290" title="cut_teeth_second_pass" src="http://www.galoototron.com/wp-content/uploads/2010/09/cut_teeth_second_pass.jpg" alt="" width="450" height="194" /></a></p>
<p>I then set the teeth, jointed them, and did a final filing. At that point, the teeth were quite even. It&#8217;s important to joint and file after you set the teeth because the act of setting the teeth dramatically alters the orientation and shape of the cutting edges. In addition, you&#8217;ll often accidentally set the teeth more than you need. A final pass at sharpening helps reduce the set. For the saw above, I used a fine-tooth saw set at its minimal setting, and it was still too much!</p>
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		<title>Frame Saw: Endless Tweaking</title>
		<link>http://www.galoototron.com/2010/09/06/frame-saw-endless-tweaking/</link>
		<comments>http://www.galoototron.com/2010/09/06/frame-saw-endless-tweaking/#comments</comments>
		<pubDate>Tue, 07 Sep 2010 02:32:15 +0000</pubDate>
		<dc:creator>Brian</dc:creator>
				<category><![CDATA[New Tools]]></category>
		<category><![CDATA[Saws]]></category>
		<category><![CDATA[frame saw]]></category>

		<guid isPermaLink="false">http://www.galoototron.com/?p=1280</guid>
		<description><![CDATA[Just when you thought it was safe to go out again, here I go again with the frame saw. This time, I wanted to fix some of the problems I&#8217;ve had with the blade-holding hardware. The basic problem is that &#8230; <a href="http://www.galoototron.com/2010/09/06/frame-saw-endless-tweaking/">Continue reading <span class="meta-nav">&#8594;</span></a>]]></description>
			<content:encoded><![CDATA[<p>Just when you thought it was safe to go out again, here I go again with the frame saw. This time, I wanted to fix some of the problems I&#8217;ve had with the blade-holding hardware. The basic problem is that the bolts I was using were too small for anything reasonable as a cross pin to secure the blade. I bought some 3/8&#8243; bolts and threaded rod to go into the frame, then some stainless steel #4-40 machine screws and nuts to serve as cross pins. I used the same procedure to adapt the hardware as before, so I won&#8217;t repeat that.</p>
<p>I thought that I had to enlarge the holes in the frame for the new hardware, but it turns out that I needed to do it to just one of the sides&#8211;the other was already big enough (I don&#8217;t remember doing it this way). But enlarging the holes means that there&#8217;s even more of a weak point in the wood at the very point where it is getting the most stress. Beech is very strong for this application, but I didn&#8217;t really want to take any chances, so I resawed and shaped some scraps to bolster that point:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/frame_saw_bolsters.jpg"><img class="alignnone size-full wp-image-1282" title="frame_saw_bolsters" src="http://www.galoototron.com/wp-content/uploads/2010/09/frame_saw_bolsters.jpg" alt="" width="450" height="296" /></a></p>
<p>Then I glued them to the frame (with liquid hide glue, of course):</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/frame_saw_bolsters_glue.jpg"><img class="alignnone size-full wp-image-1283" title="frame_saw_bolsters_glue" src="http://www.galoototron.com/wp-content/uploads/2010/09/frame_saw_bolsters_glue.jpg" alt="" width="450" height="412" /></a></p>
<p>A couple of days passed (while I was working on other stuff), and I figured it was best to let the glue cure a fair amount anyway. When I came back to it, I decided that I&#8217;d also do something about the difficulty I&#8217;d been having keeping the blade straight while tensioning. It turns out that there&#8217;s a simple solution. I grabbed a cutoff from the stack (looks like this came from saw handle project) and sloppily cut a kerf halfway down the center:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/frame_saw_blade_securer.jpg"><img class="alignnone size-full wp-image-1284" title="frame_saw_blade_securer" src="http://www.galoototron.com/wp-content/uploads/2010/09/frame_saw_blade_securer.jpg" alt="" width="450" height="239" /></a></p>
<p>To use it, just slide it over the blade when you&#8217;re tightening it up:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/frame_saw_tightening_blade.jpg"><img class="alignnone size-full wp-image-1285" title="frame_saw_tightening_blade" src="http://www.galoototron.com/wp-content/uploads/2010/09/frame_saw_tightening_blade.jpg" alt="" width="450" height="352" /></a></p>
<p>With these changes in place, I can get the blade much tighter with less work.</p>
<p>Oh, in case you&#8217;re wondering why there is a the hole in the blade securer, it&#8217;s an experiment in keeping everything together while in storage:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/frame_saw_securer_tote.jpg"><img class="alignnone size-full wp-image-1286" title="frame_saw_securer_tote" src="http://www.galoototron.com/wp-content/uploads/2010/09/frame_saw_securer_tote.jpg" alt="" width="450" height="273" /></a></p>
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		<title>Making a Marking Gauge</title>
		<link>http://www.galoototron.com/2010/09/02/making-a-marking-gauge/</link>
		<comments>http://www.galoototron.com/2010/09/02/making-a-marking-gauge/#comments</comments>
		<pubDate>Thu, 02 Sep 2010 19:44:23 +0000</pubDate>
		<dc:creator>Brian</dc:creator>
				<category><![CDATA[New Tools]]></category>
		<category><![CDATA[marking gauge]]></category>

		<guid isPermaLink="false">http://www.galoototron.com/?p=1263</guid>
		<description><![CDATA[I made a marking gauge a while back, complete with captive wedge and everything. For a long time, I didn&#8217;t have a cutter for its arm, so it wasn&#8217;t very useful. Then at some point, I made a cutter out &#8230; <a href="http://www.galoototron.com/2010/09/02/making-a-marking-gauge/">Continue reading <span class="meta-nav">&#8594;</span></a>]]></description>
			<content:encoded><![CDATA[<p>I made a marking gauge a while back, complete with captive wedge and everything. For a long time, I didn&#8217;t have a cutter for its arm, so it wasn&#8217;t very useful. Then at some point, I made a cutter out of a section of an old saw, and it was then a working tool. The problem was that I never used it, and after a while, I realized that I never used it because I was always reaching for my gauges with thumbscrews. I guess I didn&#8217;t like the captive wedge.</p>
<p>To fix this, I decided to ditch the wedge and retrofit a thumbscrew. I bought all of the hardware necessary and immediately proceeded to bore too small of a hole for the screw insert, and this ultimately ruined the fence part of the gauge. I removed the screw insert, gave up for the day, and sulked:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/marking_gauge_messed_up.jpg"><img class="alignnone size-full wp-image-1264" title="marking_gauge_messed_up" src="http://www.galoototron.com/wp-content/uploads/2010/09/marking_gauge_messed_up.jpg" alt="" width="450" height="263" /></a></p>
<p>The next day, I milled a new piece of beech to thickness, cut it to size, and mortised a new hole for the fence:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/marking_gauge_mortising.jpg"><img class="alignnone size-full wp-image-1265" title="marking_gauge_mortising" src="http://www.galoototron.com/wp-content/uploads/2010/09/marking_gauge_mortising.jpg" alt="" width="450" height="316" /></a></p>
<p>Standard through-mortise procedure applies: Cut halfway through on each side. Easy enough; then I roughed out the fence shape with my new saw (I&#8217;m using it more than I thought I would):</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/marking_gauge_sawshape.jpg"><img class="alignnone size-full wp-image-1266" title="marking_gauge_sawshape" src="http://www.galoototron.com/wp-content/uploads/2010/09/marking_gauge_sawshape.jpg" alt="" width="450" height="386" /></a></p>
<p>I finished the shaping with my saw rasp and some sandpaper&#8211;nothing new there.</p>
<p>In all of the thumbscrew-model marking gauges I&#8217;ve seen (the metal screws, that is), there&#8217;s a piece of metal acting as a guard between the screw and wooden parts. I don&#8217;t know what to call this, so I&#8217;m calling it a &#8220;saddle,&#8221; because it&#8217;s usually a U-shaped thing that fits over the wood.</p>
<p>I cut off a piece of brass from some stock I had lying around, put it in a vise, and smacked it with a hammer to try to form it. I guess I was expecting it to be a lot softer, because nothing much happened when I did that. So I took out my little sledgehammer and gave it a pounding. I don&#8217;t know if this is the way you&#8217;re &#8220;supposed&#8221; to do stuff like this, but it worked:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/marking_gauge_shapeplate.jpg"><img class="alignnone size-full wp-image-1267" title="marking_gauge_shapeplate" src="http://www.galoototron.com/wp-content/uploads/2010/09/marking_gauge_shapeplate.jpg" alt="" width="450" height="398" /></a></p>
<p>After some filing, it fit perfectly.</p>
<p>Then I turned my attention to boring the hole for the screw insert. I had already drilled a small pilot hole before shaping, so keeping the bit straight wasn&#8217;t a problem, and I&#8217;d also learned from my previous hamfistedness that I needed to use a #7 bit, not a #6 bit. Fortunately, I had one:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/marking_gauge_bore.jpg"><img class="alignnone size-full wp-image-1268" title="marking_gauge_bore" src="http://www.galoototron.com/wp-content/uploads/2010/09/marking_gauge_bore.jpg" alt="" width="450" height="289" /></a></p>
<p>Notice the finished saddle piece at the right here.</p>
<p>After going to the correct depth with the #7 bit, I finished going all the way through with a #5 bit, then I used a large furniture connector driven by a ratchet to drive in the screw insert:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/marking_gauge_fit_insert.jpg"><img class="alignnone size-full wp-image-1269" title="marking_gauge_fit_insert" src="http://www.galoototron.com/wp-content/uploads/2010/09/marking_gauge_fit_insert.jpg" alt="" width="450" height="360" /></a></p>
<p>To finish it, all I had to do was hack the thumbscrew to a proper length and put everything together:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/09/marking_gauge_finished.jpg"><img class="alignnone size-full wp-image-1270" title="marking_gauge_finished" src="http://www.galoototron.com/wp-content/uploads/2010/09/marking_gauge_finished.jpg" alt="" width="450" height="275" /></a></p>
<p>Immediately after putting everything together, I realized that maybe the marking gauge with a thumbscrew and wedged cutter is not as simple of a tool to make as it seems. That&#8217;s because there is a limitation of this particular configuration that I hadn&#8217;t thought about before, namely, that the cutter can&#8217;t be set less than about 3/16&#8243; away from the fence. There are two causes here:</p>
<ul>
<li>I put the wedge on the <em>inside</em> of the cutter rather than the outside.</li>
<li>The saddle introduces yet more buffer space. That wouldn&#8217;t have been a problem if I put the saddle on the side, like some other marking gauges, but I didn&#8217;t like the fact that the arm had a little play in that configuration.</li>
</ul>
<p>How interesting! I know how to overcome both of these issues, but I&#8217;m not going to bother for this particular gauge. It&#8217;s done and ready to use.</p>
<p>[<em>Edit: See <a title="Marking Gauge Stability Tweak" href="http://www.galoototron.com/2011/07/10/marking-gauge-stability-tweak/" target="_blank">this post</a> for how I fixed the second problem listed above</em>.]</p>
<p>[<em>Edit: Bob Rozaieski has put up a video of making a French style marking gauge. Check it out <a href="http://www.logancabinetshoppe.com/1/post/2010/11/episode-29-making-a-marking-gauge.html" target="_blank">here</a>.</em>]</p>
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		<title>Rip Panel Saw: Finished</title>
		<link>http://www.galoototron.com/2010/08/25/rip-panel-saw-finished/</link>
		<comments>http://www.galoototron.com/2010/08/25/rip-panel-saw-finished/#comments</comments>
		<pubDate>Wed, 25 Aug 2010 18:44:56 +0000</pubDate>
		<dc:creator>Brian</dc:creator>
				<category><![CDATA[New Tools]]></category>
		<category><![CDATA[Saws]]></category>
		<category><![CDATA[rip panel saw]]></category>

		<guid isPermaLink="false">http://www.galoototron.com/?p=1248</guid>
		<description><![CDATA[Progress on my new little saw was puttering along, but with the nightstand finished, I found the time to proceed. The handle was done, the sawplate was pretty much to size but not toothed or sharpened, and then there was &#8230; <a href="http://www.galoototron.com/2010/08/25/rip-panel-saw-finished/">Continue reading <span class="meta-nav">&#8594;</span></a>]]></description>
			<content:encoded><![CDATA[<p>Progress on my new little saw was puttering along, but with the nightstand finished, I found the time to proceed. The handle was done, the sawplate was pretty much to size but not toothed or sharpened, and then there was the matter of the hardware. I decided to tackle this last matter first.</p>
<p>I wanted to do something a little special for this project because the handle is a more traditional style. However, I still wanted to use the furniture connectors that I&#8217;d used for my other saws because, well, I like them. Some time ago, and somewhere in the dark corners of my mind, I began to think of a plan to spice up those things. And out of whatever means, I came up with a ridiculous scheme to make sort of a pseudo-lathe out of an eggbeater drill.</p>
<p>The following is what happens when you do unholy things to a Millers Falls #2:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/08/mf_2_as_pseudo_lathe.jpg"><img class="alignnone size-full wp-image-1249" title="mf_2_as_pseudo_lathe" src="http://www.galoototron.com/wp-content/uploads/2010/08/mf_2_as_pseudo_lathe.jpg" alt="" width="450" height="296" /></a></p>
<p>A few notes on this hand-cranked bit of absurdity:</p>
<ul>
<li>I removed the side handle (seen in the back above) and bolted this through a spacer and a dog hole with a threaded rod and a wingnut.</li>
<li>I used the hacksawed-off tip of the sawplate for this project as a washer underneath. Turns out that the hang hole is useful for something!</li>
<li>The connector bolt is chucked directly into the drill.</li>
<li>I used a pretty coarse file for sizing the head, and a finer one for polishing.</li>
<li>The calipers were really handy for getting a consistent size.</li>
</ul>
<p>I don&#8217;t know why this worked, but it was surprisingly effective. Here&#8217;s the transformed hardware (with an original nut next to the handle in the background):</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/08/rip_panel_hardware.jpg"><img class="alignnone size-full wp-image-1250" title="rip_panel_hardware" src="http://www.galoototron.com/wp-content/uploads/2010/08/rip_panel_hardware.jpg" alt="" width="450" height="338" /></a></p>
<p>It turns out that the &#8220;antique bronze&#8221; finish had a bit of copper plating underneath, and when I put some very fine-grit sandpaper to the head while it was turning in the drill, it exposed a decent-looking surface.</p>
<p>Notice that one of the nuts and one of the bolts have bigger heads. Those are my &#8220;medallions&#8221; to match the original. Although, I suppose that if I were being ultra-correct, I&#8217;d size the bolt down to the other ones because the bolts on saws are all the same size. Meh, too much work now&#8211;I should have thought about that sooner.</p>
<p>I sprayed a protective coat of lacquer on the hardware and then set out to finish the sawplate. For whatever reason, it took me longer to sharpen this one because it was difficult to get past the remnants of the original teeth. Maybe I wasn&#8217;t paying attention. Then I sized up the heel of the plate, drilled the holes for the hardware (with that same eggbeater), and put it together. It was finished:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/08/rip_panel_finished.jpg"><img class="alignnone size-full wp-image-1251" title="rip_panel_finished" src="http://www.galoototron.com/wp-content/uploads/2010/08/rip_panel_finished.jpg" alt="" width="450" height="236" /></a></p>
<p>It&#8217;s a little difficult to get a sense of scale from the preceding photo. This is a small saw, having just a 16&#8243; blade. Here&#8217;s a photo of how it compares in size to my 28&#8243; No. 7:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/08/rip_panel_compared_to_no7.jpg"><img class="alignnone size-full wp-image-1252" title="rip_panel_compared_to_no7" src="http://www.galoototron.com/wp-content/uploads/2010/08/rip_panel_compared_to_no7.jpg" alt="" width="450" height="140" /></a></p>
<p>And here&#8217;s a close-up of the handle, showing the ray pattern of the nearly-quartersawn pacific madrone that it&#8217;s made from, as well as how that goes with the hardware (if it actually goes):</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/08/rip_panel_handle_closeup.jpg"><img class="alignnone size-full wp-image-1253" title="rip_panel_handle_closeup" src="http://www.galoototron.com/wp-content/uploads/2010/08/rip_panel_handle_closeup.jpg" alt="" width="450" height="317" /></a></p>
<p>I guess this is all fine and good, except there&#8217;s one question that I might not have answered so well: What&#8217;s this silly little thing used for?</p>
<p>In some earlier posts, I&#8217;d mentioned that I&#8217;d been having a little trouble ripping panels and drawer bottoms (I use my Pax saw for crosscutting them). Although this is not a frequent operation for me, every time I did it, it was annoying. And I&#8217;m happy to say that it works wonderfully for this type of thing, as shown in the test cut below:</p>
<p><a href="http://www.galoototron.com/wp-content/uploads/2010/08/rip_panel_test_use.jpg"><img class="alignnone size-full wp-image-1254" title="rip_panel_test_use" src="http://www.galoototron.com/wp-content/uploads/2010/08/rip_panel_test_use.jpg" alt="" width="450" height="551" /></a></p>
<p>All of this said, I would not have made this if not for two things. First, I&#8217;d wanted to make that saw handle for as long as I&#8217;ve had the original saw. And second, I had that &#8220;Kobalt&#8221; saw sitting around the shop doing nothing but taking up space. If neither of these had been true, I may have just bought a ryoba for the task.</p>
<p>I will mention, however, that if this saw were filed crosscut, it would make a nice kid&#8217;s saw.</p>
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