Good Woodworking July 2015 PDF

MADE IN ITALY
Issue 294 £4.25

...Irwin blade
technology
The No.1 magazine for aspiring designer makers THE HOME OF WOODWORKING
www.getwoodworking.com
ARTIST...
uses laser-cut
wood to go 3D
BANDSAW...
Why Andy likes
PRAIRIE... this machine
BEST IN UK
GOING
House table
for you to make
PERFECT...
first dovetail
FOR GOLD
How this young man won
joint for drawer
his WorldSkills place
PLUS...
Build: Mike Jordan’s framed ledged & braced door
WOODWORKING GROUP
l New Designers show
1-4 July, London
l Carve: Edward Hopkins gets out his lettering chisels
l Turn: Les Thorne creates a stand for his wife’s jewellery
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CONTRIBUTORS
Andrea Hargreaves, Andy King, Stephen Simmons,
Jeff Gorman, Michael Huntley, Martin Aplin, Mike
Jordan, Edward Hopkins, Phil Davy, Les Thorne
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fine woodworking in the UK. Good Woodworking and sister magazine The
Woodworker are pledged to support this competition, surely the benchmark of
best practice for young woodworkers. Elsewhere I talk to an artist who uses
laser-cut wood in his designs, p66, we look at the intricate carving of a Rajasthani
family, p62, Michael Huntley makes drawers, p30, Martin Aplin recreates a Prairie
House table, p34, and Mike Jordan constructs a windowed cottage door, p41. http://twitter.com/getwoodworking
© MyTimeMedia Ltd. 2015

Andrea Hargreaves, Editor All rights reserved ISSN 0967-0009
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www.getwoodworking.com July 2015 GW294 3

Contents
July 2015
Tools Projects Techniques Advice
Techniques
MA DE IN ITA LY On the Making improbable real 24
Issue 294 £4.25
...Irwin blade
technology
cover Dave Roberts looks at the linenfold tradition
The No.1 magazine for aspiring designer

makers
50 In for long haul 26
Stephen Simmons restores chest drawers
THE HOME OF WOODWORKING
Off to Brazil
ARTIST...
Andrea Hargreaves Steamer kit 28
uses laser-cut
wood to go 3D
watches the final Jeff Gorman assembles bending kit
nail-biting hours of
BANDSAW...
Why Andy likes
the contest to First dovetail 30
PRAIRIE...
BEST IN UK
this machine
choose the young Michael Huntley sets out drawer joint
GO IN G
House table
for you to make
man who will
PERFECT...
first dovetail
joint for drawer
PLUS...
FO R GO LD
How this young man won
his WorldSkills place
represent the UK
at August’s
WorldSkills
People & places Subscribe to
Good Woodworking
WOODWORKING GROUP
New showroom 10
l Build: Mike Jordan’s framed
ledged & braced door New Designers show
1-4 July, London
l Carve: Edward Hopkins gets

out his lettering chisels
l Turn: Les Thorne creates a stand
for his wife’s jewellery Cover photograph
12/06/2015 09:09
by Mark Cass
Felder opens showroom and training centre
for a FREE
01 GW294ah 5.indd 1
Intricacy in India 62 Italian job 20 7 Piece Screwdriver &

We talk to a Rajasthani family who use How Irwin’s saw blades are manufactured
minuscule ulis to carve their work
Centrefold 46 Holesaw Set
Gateway to Clerkenwell Design Week
Laser-cut art 66 Go to
Graham Carter took his art into another WorldSkills contest 50 page 64
dimension when he started using wood From three hopefuls to only one
Take a letter 56
Edward Hopkins gets his big ‘I’ in
Carving without bounds 62
BIG
The Tiny tools for intricate work
Adventures in toyland 66
!
project
Artist incorporates laser-cut timber
Your favourites
Projects News 8
Little House on the Prairie? 34 Courses 12
Er, no: Martin Aplin’s table was inspired by
Frank Lloyd Wright’s grand Prairie Houses Readers’ ads 13
Window on the world 44 Letters/Makers' notes 68
When’s a stable door not a stable door? When Around the House 73
it’s Mike Jordan’s ledged & braced design
Next month 89
Now for the drawers 26 Finishing Touch 90
Stephen Simmons continues restoring a
battered chest, tackling the drawers
Steam bending 28
Jeff Gorman’s chair-making exercise calls for
steam-bending techniques
Going potty 74 WOW!
Phil Davy’s elegant garden pot tote is Andy King tests…
constructed from recycled oak
Gem of an idea 80
Trend Diamond Cross stones
Milwaukee M18 BLDD drill
15
16
Blade runner
Bracelets, necklaces and earrings are Charnwood BS350 Premium bandsaw 18 Andy sees Irwin blades
accommodated on Les Thorne’s stand
Phil Davy tests… made in Italy 20
4 GW294 July 2015 www.getwoodworking.com Skil Fox 2-in-1 sander 78
GW
295
ON SAL
24 JULYE
Clerkenwell
collaboration
How top maker and sculptor made
Design Week focal point 46
PERFECT... SWEAT... TOTE...

...first dovetails ...and tears ...for the garden
Michael says you need these It’s finals day for WorldSkills Phil makes his from recycled
for drawers 30 selection 50 oak 74
N A TOREW
LEG STANDS AVAILABLE
P D
O LF E FOR CTS11 & CTS10D
EN
O R
S S N
4" BELT/ £22.99 EX VAT FROM ONLY
W O 6" DISC TABLE £27.59 INC VAT £ .98
69EX.VAT
SAWS
CS4-6D
SANDER
CTS10D
£
83.98
INC.VAT
• Dust extraction
£
84.99
EX.VAT facility
£ • 4" x 36" belt tilts
101.99
INC.VAT
& locks 0-90°
• 225mm x 160mm
table, tilts 0-90° SUPERSTORES
• 370w, 230v motor NATIONWIDE
WHERE QUALITY INCLUDES LEFT

& RIGHT TABLE
COSTS LESS *Moulded base EXTENSION
MODEL MOTOR BLADE EX VAT INC VAT
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MULTI FUNCTION BANDSAWS POWER CTS11* 1500w 254mm £139.98 £167.98
6" BELT/ TOOL WITH HUGE PLANERS CTS10D 1500w 254mm £149.98 £179.98
£
9" DISC ACCESSORY KIT 109.98
EXC.VAT RANGE IN
SANDER • Great for sawing, cutting, sanding, polishing, £
131.98
INC.VAT
CATALOGUE FROM ONLY
chiselling & much more & ONLINE £
• Includes stand
• 250w motor £
FROM ONLY 47EX.VAT
.99
• 1 Hp/ 230v/
• Variable speed
21EXC.VAT
.99
WET
£
57INC.VAT
.59
1ph motor £
26INC.VAT
.39
& DRY
£
34EXC.VAT
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CS6-9C cutting VACUUM
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£
199.00 41INC.VAT
.99
width CLEANERS
EXC.VAT CEP1
£ • A range of
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INC.VAT MODEL INPUT DEPTH EXC.VAT INC.VAT compact, high
CBS250 POWER OF CUT performance
INCLUDES Clarke CEP1 650W 2mm £21.99 £26.39 wet & dry
STAND Einhell RT - PL82 ‡ 850W 3mm £49.98 £59.98 vacuum cleaners
CMFT250 B&D for use around the
KW750K - GB 750W 2mm £57.99 £69.59 home, workshop,
CPF13 MODEL MOUNT MOTOR THROAT EX VAT INC VAT ‡ was £65.99 inc.VAT garage etc.
CL CBS190 Bench 350w 190mm £109.98 £131.98
1" BELT & 5" ELECTRIC CL CBS250 Floor 370w 245mm £179.98 £215.98 CAPACITY EX.
DISC SANDER POWER DISC SANDER
MODEL MOTOR WET/DRY VAT INC. VAT
• Inc. 2 tilt/lock tables FILE (305MM) CVAC20P 1250W 16/12ltr £47.99 £57.59
INDUSTRIAL DEVIL
and mitre gauge 6003 Powerful, bench mounted disc sander 900W CVAC20SS* 1400W 16/12ltr £59.98 £71.98
• 300w motor ELECTRIC No load disc speed: 1490rpm 305mm Disc CVAC25SS* 1400W 19/17ltr £64.99 £77.99
FAN HEATERS Diameter (1 x 60 grit sanding disc included) CVAC30SSR* 1400W 24/21ltr £86.99 £104.39
Dimensions (LWH): £
• Variable
• Rugged fan heaters
for small to medium 440x437x386mm 119.98 EXC.VAT
* SS = Stainless Steel
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59EX.VAT belt speed sized premises • Tough Weight: 143.98 INC.VAT
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FROM ONLY
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£
44EXC.VAT
.99
• Adjustable heat
CONVERTERS
CBS1-5
£ • Run big 3 phase
*Black & Decker 53INC.VAT
.99 output with thermostat
woodworking
MODEL MOTOR EXC.VAT INC.VAT ‡ was FROM ONLY
CJS380 £ machines
CPF13 400w/230v £44.99 £53.99 £63.59 37EXC.VAT
.99
from 1 phase
£
KA900E*‡ 350w/230v £49.98 £59.98 inc.VAT 45INC.VAT
.59
CDS300B
supply
• Variable
FROM ONLY HEAT NOW output power
LIGHTWEIGHT £ .99 MODEL OUTPUT EX VAT INC VAT
ALUMINIUM 6EX.VAT Devil 6002 0.7-2kW £37.99 £45.59 ‡ was
to match HP
.39 of motor to
JIGSAWS QUICK RELEASE 8INC.VAT £
Devil 6003‡ 1.5-3kW £49.98 £59.95 £71.98 be run
Devil 6005 2.5-5kW £74.99 £89.99 inc.VAT
FROM ONLY ALUMINIUM SASH CRAMPS Devil 6009 4.5-9kW £129.98 £155.98 ROTARY
£
12EXC.VAT
.99
Devil 6015 5-10-15kW £189.98 £227.87 18V PRO
PHASE
CONVERTERS
*DIY #Professional £
15INC.VAT
.59 PC60
CORDLESS ALSO AVAILABLE
FROM ONLY
MODEL POWER DEPTH DRILL/DRIVERS
(W) OF CUT EX INC
CORDLESS 10mm chuck size
CONVERT 230V £
229.00
EX.VAT
(WOOD/STEEL) VAT VAT MODEL SIZE EX. VAT INC. VAT 2 Speed, Variable
1PH TO 400V 3PH £
274.80
INC.VAT
Clarke CJS380* 420w 55/6mm £12.99 £15.59 CHT374 600mm £6.99 £8.39 DRILL/ PSR18
DRIVERS control - 0-350/0-1250rpm MODEL MAX. FUSE EX VAT INC VAT
Clarke CON750# 750w 80/10mm £24.99 £29.99 CHT375 900mm £7.99 £9.59 21 torque settings
B & D KS600* 450w 60/5mm £29.98 £35.98 CHT376 1200mm £9.98 £11.98
FROM ONLY MOTOR HP
£
Bosch PST700* 500w 70/4mm £49.98 £59.98 34EXC.VAT
.99
FROM ONLY
PC20 2Hp 10amps £229.00 £274.80
£ PC40 3.5Hp 20amps £269.00 £322.80
BELT 41INC.VAT
.99
64EXC.VAT
£ .99
INCLUDES 12 PC60 5.5Hp 32amps £319.00 £382.80
£
SANDERS 77INC.VAT
.99
PIECE BIT SET
HUGE CHOICE
ENGINEER’S IN-STORE & ONLINE EXC. INC. TABLE
• Ideal for surface removal, MODEL BATTERIES VAT VAT SAW
DRILL PRESS sanding and finishing CON18Ni 2 x Ni-Cd £64.99 £77.99 Powerful 1800W Motor CTS13L
MODEL VOLTS BATTS EXC. VAT INC.VAT
• Tables tilt CCD180 18v 1 £34.99 £41.99 CON18Li 2 x Li-Ion £84.99 £101.99 5700rpm No
FROM ONLY ABRASIVE SANDING
0-45° left & right £ BELTS IN STOCK CCD240 24v 1 £39.98 £47.98 Load
• Depth gauge 59EXC.VAT
.98
Bosch PSR18 18v 1 £49.98 £59.98 SHEET SANDERS Speed
• Chuck guards 71INC.VAT
£ .98 Laser Guide for
accurate cutting
MODEL WATTS/ EXC.VAT INC.VAT CBS16 FROM ONLY With folding
SPEEDS CON300 £ legs and
CDP5EB 350/5 £59.98 £71.98 DRILL BIT SHARPENER 12EXC.VAT
.99
wheels
£
CDP101B 245/5 £79.98 £95.98 FROM ONLY Great for 3mm to 10mm 15INC.VAT
.59
- Large
.98 HSS drill bits 70W motor PRICE CUT
CDP151B 300/5 £106.99 £128.39
CDP10B 370/12 £169.98 £203.98
£
29EX.VAT Drill bit guide
930 x 640mm
Table
£
229.98
BS1 £
35.98 ensures
EXC.VAT
sharpening at the £21EXC.VAT

CDP301B 510/12 £199.98 £239.98 INC.VAT £ .99 £
CDP451F 510/16 £239.98 £287.98 MODEL WATT M/MIN EX VAT INC VAT
*110V in stock 275 .98
INC.VAT
CDP501F 980/12 £429.00 £514.80 Clarke BS1 900w 380 £29.98 £35.98 correct angle 26INC.VAT
.39
MODEL SHEET SIZE MOTOR EX VAT INC VAT WAS £287.98 inc.VAT
Clarke CBS2 1200w 480 £69.98 £83.98 Saves cost of COS200 190X90mm 150w £12.99 £15.59
B=Bench mounted new drills C0N300 230X115mm 330w £29.98 £35.98 13" MINI
Makita 9911 650w 75-270 £94.99 £113.99
F=Floor standing Makita 112X102mm 200w £54.99 £65.99 WOOD LATHE
BO455* £
BISCUIT JOINER PORTABLE 129EX.VAT
.98
£
RANDOM ORBITAL 860W Motor THICKNESSER 1000MM VARIABLE 155INC.VAT
.98
SANDER 11000rpm Operating Speed • Max thickness SPEED WOOD LATHE

CROS1 14mm Cutting Depth capacity 130mm
£
27EX.VAT
.99
• Planing depths CWL1000V
33INC.VAT
£ .59 adjustable
from 0-2.5mm
• Powerful SUPPLED
1250w motor WITH CWL325V
• For sanding £
& polishing
£
• 8000rpm ROBUST
STEEL
239EXC.VAT
.00
• Ideal for enthusiasts/
• 125mm 49EXC.VAT
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STAND
£
286INC.VAT
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hobbyists with small workshops
diameter £ £
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sanding discs 59INC.VAT
.98
EX.VAT
• Large 350mm turning capacity • Variable speed • 325mm distance between centres • 200mm
• 4000-11000 opm INC 5 DISCS BJ900 £
215.98
INC.VAT CPT250 • Lockable tailstock • High quality cast iron build max. turning capacity (dia) • 0.2Hp motor
SAVE
BOLTLESS • Simple fast assembly PLANERS &
in minutes using only a 3 PCE CHISEL SET
SHELVING BENCHES THICKNESSERS
10%
hammer FROM ONLY WOODWORKING INCLUDED WITH
CWL1000
£ .98
29EX.VAT CPT800 LATHES
£
35.98
INC.VAT WHEN YOU BUY
ANY MIX OF 5 CWL1000
FROM THIS RANGE
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£17.99 INC.VAT
• Ideal for DIY &
CHOICE OF 5 COLOURS
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ALSO EXTRA WIDE
RED, BLUE, BLACK, finishing & sizing of
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INDUSTRIAL UNITS
SILVER & GALVANISED
STEEL
timber (CP-6 planer only) £
167.98 INC.VAT SEE CATALOGUE
AVAILABLE MODEL MOTOR MAX THICK. EXC. INC. FOR ACCESSORIES
(evenly (evenly MODEL SHELF DIMS CAPACITY VAT VAT
MODEL CENTRE TO TURNING TURNING EX INC
3
distributed) distributed) CP-6 1100w * £139.98 £167.98 FROM ONLY
WxDxH(mm) EX VAT INC VAT CENTRE (mm) CAP. SPEEDS VAT VAT £
Strong 9mm Strong 12 mm 150Kg 800x300x1500 £29.98 £35.98 CPT600 1250w 120mm £169.98 £203.98
CWL1000 1016 350mm 4 £114.99 £137.99 114EX.VAT
.99
CPT800 1250w 120mm £189.98 £227.98 £
fibreboard
PER SHELF shelves PER SHELF
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CPT1000 NEW 1500w 120mm £269.98 £323.98 CWL12D 940 305mm 5 £189.98 £227.98 137INC.VAT
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INC.VAT most hard & soft 143.98
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• 1800w FROM ONLY ACCESSORIES IN POT BELLY
WV7 £ STOCK
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MODEL MOUNTING JAW • Laser guide £
65INC.VAT
.99 £
(WIDTH/OPENING £ 89.98 EXC.VAT
/DEPTH)mm EXC.VAT INC.VAT

129EXC.VAT
.98
11.8kW
£
107 .98
INC.VAT
£
Clarke Bolted 150/152/61 £13.49 £16.19 155INC.VAT
.98
TH-SM 2534 • Powerful WAS £113.98 inc.VAT
CHT152 750w motor
Stanley Clamped 72/60/40 £16.99 £20.39 CMS10S2 • Quality Range of Mitre saws and blades available
MODEL BLADE DIA MAX CUT EX. INC. • 56 litre bag capacity
Multi Angle • Flow rate of 850M3/h
Record V75B Clamped 75/50/32 £18.99 £22.79 MITRE SAW BORE (mm)DEPTH/CROSS VAT VAT
6.9kW
Clarke WV7 Bolted 180/205/78 £24.99 £29.99 STAND Einhell 210/30 55/120mm £54.99 £65.99 FLOW BAG
TH-MS 2112 MODEL MOTOR RATE CAP. EX VAT INC VAT
WHETSTONE Fury 3 210/25.4 60/200mm £119.98 £143.98 CDE35B 750w 850 M3/h 56Ltrs £119.98 £143.98 BARREL
Einhell 250/30 75/340mm £159.98 £191.98 £
SHARPENER CFMSS1 TH-SM2534
CDE7B 750w 850 M3/h 114Ltrs £139.98 £167.98 209EXC.VAT
.00
£
• Produces accurate CWS200
£ Makita 260/30 95/130mm £199.98 £239.98 250INC.VAT
.80
razor sharp cutting 64EXC.VAT

.99
LS1040
edges on chisels, £
77INC.VAT
.99
ROTARY TOOL CIRCULAR SAWS
scissors, tools etc DUST CDE1000 FROM ONLY
• 120w motor • Suitable for most KIT EXTRACTOR
Great range of DIY £
34EXC.VAT
.99
• Grinding disc 200mm sizes/makes of saw and professional £
• Wet bath • Leather • Inc. outriggers & rollers CRT40 • 50 litre tank capacity saws Ideal for 41INC.VAT
.99
£ • 183 m3/h flow rate bevel cutting

honing £
wheel 109EX.VAT
.98 29EX.VAT
.98
• 1000W (0-45°)
£
131INC.VAT.98
DOVETAIL JIG
£
35INC.VAT
.98
input OTHER £
99.98
EX.VAT
wattage MODELS CON185
• Simple, easy to set up & use for producing Kit includes: AVAILABLE 119.98
£
INC.VAT
TURBO AIR a variety of joints • Cuts work pieces with a • Height adjustable stand with clamp • Rotary tool *Includes
COMPRESSORS thickness of 8-32mm • Includes a 1/2" comb • 1m flexible drive • 40x accessories/consumables
BENCH GRINDERS laser guide
template guide & holes for bench mounting 6" BENCH GRINDER
• Superb range HUGE RANGE PRICE CUT
& STANDS MODEL MOTOR MAX CUT
ideal for DIY, £ WITH SANDING BELT • Stands come 90/45
hobby & semi-
OF AIR TOOLS
IN STOCK
54EXC.VAT
.99
complete with
6" & 8"
AVAILABLE (mm) EXC.VAT INC.VAT
professional
£
65 .99
INC.VAT • For sanding/shaping £
49.98
EX.VAT bolt mountings WITH LIGHT Clarke
wood, CCS185B 1200W 65/44 £34.99 £41.99
use WAS £71.98 inc.VAT
plastic
£
59.98
INC.VAT
and feet
anchor holes Clarke
& CBG6SB STAND AVAILABLE FROM CC52 1300W 60/45 £59.98 £71.98
CLARKE 8MM CDTJ12 FROM ONLY ONLY £41.99 EX.VAT
metal £ Clarke
AIR HOSE Router not • Supplied 27EX.VAT
.99
£50.39 INC.VAT
CON185* 1600W 60/40 £59.98 £71.98
FROM ONLY £
£5.99 EX VAT
included with coarse 33INC.VAT
.59
£7.19 INC VAT grinding HARDWOOD

wheel WORKBENCH
ROUTERS & sanding belt CBG8W Includes bench dogs and guide holes for
features variable work positioning 2 Heavy Duty Vices
CR1C 8" whetstone & Large storage draw Sunken tool trough
FROM ONLY 6"drystone. LxWxH 1520x620x855mm
£ # With sanding belt
79EXC.VAT
.98
FROM ONLY
£
95INC.VAT
.98
8/250
£ .98
39EX.VAT CR2 ROUTER MODEL DUTY WHEEL
DIA. EX VAT INC VAT
MODEL MOTOR CFM TANK EX VAT INC VAT £
47.98
INC.VAT
£
109.98
EX.VAT
CBG6RP DIY 150mm £27.99 £33.59
Tiger 8/250 2Hp 7.5 24ltr £79.98 £95.98 ACCESSORIES
£
131.98
INC.VAT CBG6RZ PRO 150mm £37.99 £45.59 CHB1500
Tiger 7/250 2 Hp 7 24ltr £89.98 £107.98 IN STOCK • Powerful heavy CBG6RSC HD 150mm £47.99 £57.59
Tiger 8/36 1.5 Hp 6.3 24ltr £109.98 £131.98 duty machine CBG6SB# PRO 150mm £49.98 £59.98
£
Tiger 11/250 2.5Hp 9.5 24ltr £119.98 £143.98 ideal for CBG6RWC HD 150mm £54.99 £65.99 129EXC.VAT
.98
Tiger 8/510 2Hp 7.5 50ltr £129.98 £155.98 * DIY trade use CBG8W (wet) HD 150/200mm £55.99 £67.19 £
Tiger 11/510 2.5Hp 9.5 50ltr £149.98 £179.98 MODEL MOTOR PLUNGE EX VAT INC VAT • Variable 155INC.VAT
.98
Tiger 16/510 3 Hp 14.5 50ltr £219.98 £263.98 (W) (mm) speed control from
Tiger 16/1010 3 Hp 14.5 100ltr £269.98 £323.98 CR1C* 1200 0-50 £39.98 £47.98 7,400-21, 600 rpm • 2100w motor • 0-60mm 5PCE FORSTNER
Bosch 1400 0-55 £74.99 £89.99 plunge depth. CR3 Router with 15 Piece Bit Set BIT SET
TABLE SAW WITH POF1400ACE also available only £94.99 Contains 15, 20, 25, 30 &
£113.99 255mm 35mm bits Titanium
CTS14
EXTENSION SCROLL SAWS INCLUDES 15 MULTI- nitride coated for
TABLES (250mm) PIECE SET WORTH PURPOSE improved
Ideal for cross cutting, OVER £20 cutting finish
ripping, angle and FROM ONLY TABLE
mitre cutting
£
64EXC.VAT
.99 SAWS 9EXC.VAT
£ .98
ROUTER TABLE FURY 5 ONLY £
Easy
release
£
77INC.VAT
.99
CRT-1
£
149 EXC.VAT.98 11INC.VAT
.98 CHT365
/ locking •120w, 230v Router not £
NEW mechanism motor • 50mm included 179 .98
INC.VAT
WAS £191.98 inc.VAT
for table max cut thickness
• 400-1,700rpm variable MODEL MAX TABLE EXC. INC.
extensions 0-45° tilting DEPTH CUT SIZE (mm) VAT VAT
blade Cutting depth: speed • Air-blower removes
dust from cutting area CSS16V 45° 90°
72mm at 90° / FURY5* 54mm 73mm 625x444 £149.98 £179.98
£
119EXC.VAT
.98
65mm at 45°
MODEL MOTOR RPM
SPEED EX
VAT
INC
VAT
£
56EX.VAT
.99 RAGE5‡ 55mm 79mm 868x444 £269.00 £322.80
£ 230V/50Hz,
143INC.VAT Motor:
.98
1800W, CSS400B 85w 1450 £64.99 £77.99 • Converts your router £
68INC.VAT
.39 *FURY power: 1500w (110V available) MUCH MORE
No load speed: 4700rpm CSS16V 120w 400-1700 £79.98 £95.98 into a stationary router ‡RAGE power: 1800w/230V (110V available)
CSS400C* 90w 550-1600 £99.98 £119.98 table • Suitable for most table extensions included WOODWORKING
Shown with optional leg kit
CLK5 £22.99 exc.VAT £27.59 inc.VAT * Includes flexible drive kit for grinding/polishing/sanding routers (up to 155mm dia. Base plate) * was £191.98 inc.VAT ‡ was £334.80 inc.VAT ONLINE
V
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SAT 8.30-5.30, SUN 10.00-4.00 *NEW STORE OPEN 7 DAYS
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CAMBRIDGE 181-183 Histon Road, Cambridge. CB4 3HL 01223 322675 LEEDS 227-229 Kirkstall Rd. LS4 2AS 0113 231 0400
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CHESTER 43-45 St. James Street. CH1 3EY 01244 311258 LONDON CATFORD 289/291 Southend Lane SE6 3RS 0208 695 5684 SOUTHEND 1139-1141 London Rd. Leigh on Sea 01702 483 742
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News Comment, insight, views and news of
woodworkers from around the globe
Triton T12
range expands
Equipped with the latest Mabuchi motors and
robust, all-metal gearing, Triton’s T12 compact
tools are powered by two 1.5Ah Li-ion
Samsung-cell batteries. The included 1-hour
Festool launches
charger delivers a 30-minute charge to 80%
capacity.
Built-in LED worklights provide clear
visibility in murky conditions, and moulded
cordless saw
grips allow easy handling and control over
extended periods.
The T12DD drill driver (£129.33 inc VAT)
features a 10mm (3⁄8in) removable single-
Festool is expanding its 18V cordless range with a compound mitre saw system, the HKC 55, sleeve keyless chuck and
which comes with a 5.2Ah battery pack and brushless EC-TEC motor. It is designed for work provides 22Nm torque
such as roofing. with 17-stage
The new FSK trimming rail comes in three lengths, and an integrated rubber spring torque
automatically brings the saw back to the starting position ready for more cross-cutting. adjustment
For convenience and safety it is equipped with a hinged cover. An internal lever causes the for a variety
pendulum hood to slide back, providing a clear view of the saw blade and enabling easy of materials and
sawing, even when performing mitre cuts. The cross-cut, rip-cut and fine-cut saw blades are screw sizes.
designed for fast changing thanks to the FastFix system. The starting price is £326.40. For The T12ID impact driver
more info go to www.festool.co.uk/hkc (£139.99) delivers 90Nm of
sustained torque and 3000
impacts-per-minute, and the 6mm
(1⁄4in) hex bit holder allows rapid,
Build your perfect plane single-handed bit changes.
The T12AD angle drill (£108.95) delivers
Axminster Tools & Machinery has just different options that could be applied to just 18Nm of torque through the 90° drill head with
introduced a new and innovative range of one plane. Multiply that by the five planes in low-profile Sanou 10mm (3⁄8in) keyless chuck.
Veritas bevel-down bench planes. The range, the range (Nos.4, 4½, 5, 5½ & 7) and it equals Featuring a variable speed of 0-3,400spm
which is made in Canada but put together to 540 different permutations. Plane parts can be with 12.2mm stroke length, the T12RS
make complete planes in the UK, is exclusive purchased online at axminster.co.uk or from reciprocating saw (£107.12) comes with
to Axminster and allows the craftsperson to one of the company’s seven stores. Once uni-directional blades suitable for single-
select from a number of different components potential users have selected the components handed operation, or bi-directional blades for
and build their own unique plane. (body size, blade, frog, front knob and rear higher speed 2-handed operation can be
There are two blade tote), trained staff at fitted. Benefits include easy tool-free blade
options (O1 and PM-V11), AT&M will assemble the change and a 1⁄2in universal shank to suit a
six variations on a rear tote, customised plane. It can wide range of saw blades.
three for the front knob then be taken away from a The T12OT oscillating multitool (£108.63)
and three for the frog. store or will be dispatched. features precision metal gearing and blade
Number crunching the More info on mounting, with variable oscillating speed
figures www.axminster.co.uk from 6,300 to 16,000opm with six
reveals that graduations.
there are 108 For more info visit www.tritontools.com
8 GW294 July 2015 www.getwoodworking.com

News
The Felder UK team on the mezzanine level of the new showroom and training centre
Felder opens new

training centre
Huge success last year has fuelled Felder Group UK’s growth and showroom is bright and effective and lets you focus on the machines.
development with the opening of a state-of-the-art showroom giving The whole renovation project has come together and the showroom
its Milton Keynes HQ an extra 500sq ft in which to show off some great looks amazing.”
new machinery. The first customers to use the new training facilities have recently
At an opening ceremony in April attended by Sales and Marketing purchased a Format 4 profit H08. Mr Bloo Ltd manager Ian Parkinson
Director Hansjörg Felder who had flown in from Austria, and UK MD said: “The training is very interactive and we can’t wait to use our H08
Matthew Applegarth, Felder UK showcased a new extended showroom once we are back at our workshop.”
with a mezzanine floor, office and training centre. On a more homely level Mark Kilroy treated himself to a C3 31
The facilities are equipped with the latest technology, compressed Comfort combi machine with which he has made kitchen components,
air specialists Air Power UK providing the air supply and Woodwork a desk and a veneered chest of drawers. He said it was a decent and
Dust Control Company the dust extraction. The renovation also reliable saw with an amazing planer and spindle. “Doing it well is really
includes a brand new kitchen, boardroom table and reception desk, important and this machine has enabled me to push myself to become
which were manufactured by Felder customers Edward Williams better at what I do. With most machines there is always something
Furniture and Greenacre Property Ltd. that lets it down, but this one has no vices and is easy to operate.”
Edward Williams’ owner Adam Howe commented: “The new For more info visit www.felder-group.co.uk or call 01908 635 000

News
Students at Peter Sefton’s Furniture School learn on Felder’s Hammer

machines. Peter said he was very impressed with their engineering
quality. The range includes the K3 panel saw, the F3 spindle moulder, the
N4400 bandsaw and the A3 41 planer/thicknesser
The new reception desk shown off by Felder’s Abra Nkrumah at the
launch party was made by Edward Williams Furniture
01684 594683
www.woodworkersworkshop.co.uk
The Threshing Barn, Welland Road,
Upton upon Severn, Worcestershire, WR8 0SN
The very besT

woodworking Tools
Sourced by woodworkers
for woodworkers
Mark Kilroy with his combi Quality tools from the finest
UK, US & Canadian manufacturers

COURSEDIARY
July heralds the start of holiday season, so
why not take a break on one of these
courses and top up your skills.
July
1-2 Beginner woodturning (Axminster)
10 Fine bowl turning (Axminster)
Showtime in Brighton
14 Pen making (Axminster) The list of big-brand exhibitors who will be at
16-17 Beginner routing (Axminster) Tool Show 2015 at the American Express
17 Pen making (Sittingbourne) Stadium, Brighton on 25 and 26 July is
21-22 Beginner woodturning staggering, from Bahco to Wera, and from
(Sittingbourne) Makita to Milwaukee. Bosch, for example,
Axminster Tool Centre along with other companies, promises great
Unit 10 Weycroft Avenue show deals and an excellent array of mains
Axminster and cordless power tools – watch out for its
Devon EX13 5PH charging system. Expect to see lots of new
Tel: 0800 975 1905 tools and machines, like Fein’s range of
multitools that is getting its first airing at the Busy scenes from last year’s show
5-10 Projects, advanced furniture making show. You could also get a chance to win the
12-17 Wall cabinet, beginners, intermediate new DeWalt 18V collated screwgun, and enjoy is threatening to make something while you
17-19 Portable bookcase, beginners, pitchside – this is the home of Brighton & look on, and will be sharing tips.
intermediate Hove Albion FC after all – masterclasses from The show is being staged by the city’s own
West Dean College Festool and DeWalt. tools, fixings, repair, workwear and hire
West Dean Oh, and we’ll be there too, along with sister company, PR Industrial. For more info go to
Nr Chichester mag The Woodworker’s Editor Mark Cass, who www.prindustrial.co.uk
West Sussex PO18 0QZ
Tel: 01243 811301
22-24 Safe operation of wood machines

Anarchy in summer
27-31 Dovetailing & drawer fitting New English Workshop, a group of professionals and enthusiasts passionate about furniture
Peter Sefton Furniture School making, are repeating last year’s summer school success with a different take on building the
The Threshing Barn Anarchist’s toolchest.
Welland Road Once again Chris Schwartz will be building with only hand tools one of the lightweight
Upton upon Severn chests with which woodworkers of old practised their craft, but says it will be a new version on
Worcestershire an old theme. Joining him will be Deneb Puchalski, Roy Underhill, David Barron, Tom Fidgen
WR8 0SN and Peter Follansbee. There are courses to suit the genuine first timer on limited funds up to
advanced practitioners looking to hone their skills. To be part of the hand-made revolution visit
August www.newenglishworkshop.co.uk and book a place at Bridgwater College, Somerset or
1-7 Sculptural carving in wood Warwickshire College from 13 to 24 July.
30 Aug-3 Sept Furniture repair & care
West Dean College
West Dean
Nr Chichester
Jorvic turners help injured troops
West Sussex PO18 0QZ Jorvik (York) Woodturners have been working work towards gaining woodworking skills and
Tel: 01243 811301 alongside the Phoenix House Recovery Centre qualifications which may help them forge new
in Catterick. This specialist centre is run by the careers. Part of the project involved
3-4 Beginner woodturning (Axminster) charity Help for Heroes and forms part of the renovating an old Axminster M950 lathe.
5 Pyrography (Axminster) Defence Recovery Capability. The project was Earlier this year, the club approached
7 Sharpening with Tormek (Sittingbourne) driven by Help for Heroes volunteer Chris Axminster for some spare parts for it and
13-14 Beginner routing (Axminster) Morgan who runs the recovery centre. fortunately these were still available.
24-25 Wood machining (Axminster) The club has been helping to set up the Axminster donated these to the club, enabling
28 Intro to turned boxes (Axminster) Woodshed woodturning shed at Phoenix them to continue renovating the lathe ready
Axminster Tool Centre House. The new workshop will provide a for use.
Unit 10 Weycroft Avenue setting where injured troops and veterans can The hard work and efforts of Chris Morgan
Axminster and the Jorvik volunteers came to fruition
Devon EX13 5PH when the opening ceremony was attended by
Tel: 0800 975 1905 the Master of the Worshipful Company of
Turners, Colonel John Bridgeman.
Chris, together with three Jorvik volunteers,
4-7 Veneering & laminating
will supervise the workshop. Professional
10-11 Sharpening
turners including Tony Wilson and Margaret
Peter Sefton Furniture School
Garrard have also pledged their support to
The Threshing Barn
provide assistance with the training.
Welland Road
Such has been the success of the project so
Upton upon Severn
far that there is now talk of other Woodsheds
Worcestershire
opening at Help for Heroes recovery centres in
WR8 0SN
Interior of the new Woodshed Colchester and Plymouth.

OFFCUTS News
Warwickshire College furniture crafts students’ work can be seen at the college New wood apprenticeship standard
until 3 July between 10am and 4pm on weekdays, with a preview evening on James Latham and Proskills UK Group are to lead the
Friday 26 June, 6-8pm. development of a new wood apprenticeship standard as
part of the government’s Phase 4 Trailblazers – groups of
nnn
leading large and small employers within a sector who
Silverline has been appointed official tool supplier of the Red Bull Soapbox Race, work together to develop new apprenticeship standards.
which returns to the UK on 12 July with an Industrial Revolution theme. The event The group will be chaired by Piers Latham and the new
takes place at Alexandra Palace, London and is expected to attract a global apprenticeships will be employer led and focused on
audience of 20,000 watching 70 teams race homemade soapboxes quality. They will be graded on completion to mark the
level of achievement.
nnn
Jonathan Ledger, Managing Director of Proskills UK
The Turners Company is offering talented UK-resident turners bursaries worth up Group, said: “It is fantastic that so many Wood
to a combined value of £10,000. Turners whose work is well regarded are invited employers have decided to lead the way in developing
to put forward a clear plan of how the award would advance their work, the this new breed of apprenticeships. Employers are by far
boundaries of the craft of turning and raising the profile of the craft. For more info the best source of technical expertise and strategic
go to www.turnersco.com direction needed to design the best apprenticeships for
their industry.”
Machinery Woodturning
DeWalt DW1251 radial arm saw, excellent condition, hardly used, includes Graduate bowl lathe, c/w Axminster chuck, Varispeed, sundry faceplates, etc,
legstand, buyer collects, £250 £550 ovno, buyer collects
David Banks, Cheshire 01606 551747 Franklin, Cambridgeshire 01353 663949
Scheppach Basato 3 bandsaw, 6in depth of cut, 13in width of cut, used lightly by Coronet Major lathe, 30in between centres on metal stand with many extras,
hobby turner to cut mainly bowl blanks, as new condition, spare blades, £250 tools and wood, hobby use only, £350 ono
Davey, North Oxfordshire 07707 242948 FW Bates, East Sussex 01424 882775
Scheppach planer/thicknesser HMS 3200 CI, 12in cast-iron tables, very little use, Record CL2 36-18 wood lathe plus bench, new condition, Axminster chucks, set
perfect working order, possible delivery, £600 Ashem Crafts rounding & trapping plane for chairmaking, set Record turning
Mr K Hambridge, Warwickshire 01675 464074 chisels, collet chuck system set, £500 Mr JF Hall, Kent 01304 268836
Hand tools Miscellaneous

Blades/cutters for Stanley 45 plough plane, prices on application 250 Good Woodworking magazines 1995 to 2007 mostly in sequence, mint
K Kay, Lancashire 01772 613044 condition, £20
Woodworking hand tools, various prices, collection only Mr LJ Hall, Derby 01332 512228
Mrs M Cooper, Leicestershire 0116 278 3264 Woodworker annuals, 1947-1949, 1951-1955, Volumes 60-69, 70-79, 80-89, 90-91,
slight tears on dust jackets, good condition, sensible offers only please
S Markland, Merseyside 0151 924 7479
Book your I am a private advertiser. Please enter my advertisement in the Reader Ads in the following category:
FREE
Wanted or For Sale under the following heading
Hand tools Power tools Timber
Machinery Turning Miscellaneous
My advertisement reads as follows:
ad here
...........................................................................................................................................................................
...........................................................................................................................................................................
Simply fill out this form, including your name ...........................................................................................................................................................................

and address, and post it to:
...........................................................................................................................................................................
Reader Ads, Good Woodworking, Enterprise
My advertisement is for more than £500. I enclose a cheque for £10 made payable to My Time Media Ltd
Way, Edenbridge, Kent TN8 6HF
If you don’t want to cut up your magazine, you Name...............................................................................................................................
can photocopy this coupon or simply write out
your ad on a sheet of paper and send it to us. Address............................................................................................................................
Alternatively, if your advertisement is for goods .......................................................................................................................................

worth less than £500, you can email the details
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SAVE .O.ORWM£ 459.96
ALLYa

£70 #ODE502867
First choice for sharpening

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Stone Grader grades the Square Edge Jig for AngleMaster sets jig Truing Tool makes grindstone
stone for a 1000 grit finish plane irons and wood chisels to any angle from 10°-75° exactly round and flat
For more information call 03332 406967 or visit brimarc.com

Prices include VAT and are valid until 9th July 2015
Kit & Tools
New products, tools and tests

Andy King, Technical Editor
andy.king@mytimemedia.com
Budget diamonds
This range is cheaper but
will it be as durable?
▲ The grips prove useful for honing ▲ Smaller credit card hones work ▲ The bench stone has plenty of ▲ The bench stone proved flat
larger blades such as this adze well for touching up router cutters surface area for honing chisels when tested with this pre-
and planes flattened chisel
T
he Trend diamond bench stone has been bonded with different grits of 1000 fine and I found the longer double-handed file type
my ‘go to’ stone since I first reviewed it 300 coarse diamonds equivalent to 15 and 50 especially useful for going over a bigger edge
10 years back. Those stones are pricey microns. where working over a stone is difficult; it
though, so this new range, called Diamond However, this stone quickly raises a wire worked a treat on my adze.
Cross thanks to their relief pattern to help move edge as well as backing off and polishing the
the slurry and swarf, has been designed to offer backs but I guess the questions will be about Conclusion
the same more durable monocrystalline durability and flatness compared with the If you are looking for a good range of diamond
diamonds, but at a lower cost. original. The first is tricky to test in a short honing options at an affordable price then
It offers stones suitable for honing small space of time, but checking the flatness Trend has hit the mark. The only issue is the
tools as well as a bigger 8 x 23⁄4in bench stone against a chisel pre-flattened on my original durability of the diamonds to the stainless steel
that could interest those looking for a way into Trend showed it to be of equally decent stead, plate, but with a 3-year warranty on all the
diamond honing of chisels and plane irons maintaining the same flatness. range, you have plenty of time to find out!
without breaking the bank – but it does have a The smaller and more specialised stones all
cut-price construction compared with my have a somewhat tacky small handle or two
trusty stone of old. bolted to them, but each of the 1.5mm-thick The Verdict
The Diamond Cross plate is a 3-part stainless steel diamond-bonded plates is cut
+ Various profiles available; finger grips on
construction with a precision-ground tool steel out to include lugs that are sandwiched by the
smaller hones; big area on bench stone
core with two thin stainless steel plates plates and prove to be pretty useful.
– Finger grips look a little cheap; time will tell
for durability
Prices How we rate…
Our product prices reflect ★ Don’t get your hopes up or your wallet out! Rating
typical values as we go to Typical price: £18.95 for smaller hones;
★★ Well, it works but really needs improvement
press. We cannot guarantee £59.95 for 8in bench stone
these prices, though, and ★★★ Performs well, but you will find better
★★★★ Great performance and value for money Monocrystalline diamonds
thoroughly recommend Grit sizes in coarse and fine
that you shop around. ★★★★★ So good, even Andy would get his wallet out!
Stainless steel plates

Kit & Tools Milwaukee M18 BLDD
Top performer it It doesn’t shirk its responsibilities at the
chuck end though; this is a 13mm-capacity
may be but Andy’s all-metal single sleeve keyless version, and of
excellent quality. The drill also has Milwaukee
in a bit of a RedLink circuitry to monitor and optimise the

drill and battery to prevent overload while still
quandary maintaining performance.

At only 174mm long this drill is pretty
diminutive, the brushless motor trimming the
Er, where
length down but still able to put out 60Nm
of torque.
With its second speed of 1800rpm it’s no
slouch for drilling smaller-diameter holes, and in
does it fit?
its lower 450rpm gear it will drill 38mm holes in
timber so it is good for chippies fitting Yale-type
cylinder door locks for instance. It will also drill
up to 13mm in steel, but this particular model is
drill driver only; there’s no hammer function
although there is a slightly longer version with
identical specifications that includes the
hammer function.
The variable-speed trigger is responsive and it
also acts as the switch for the bright worklight.
It performed well piloting and running in
screws up to 100 x 6mm gauge on a decking
M
ilwaukee’s 18V platform comprises and fencing project, and a swift change to a
standard brushed machines and the 30mm Forstner was equally impressive in both
brushless Fuel range so this new hard- and softwood.
model is a bit of an oddity: it has a brushless Switching to a 32mm auger in beech showed
motor but is not a Fuel tool. However, this is the need for a side handle as the torque
still a top performer built to the same external generated on the low speed is enough to pull
tank-like robustness. and twist the drill from your grip, but it
The difference may be in the gearing: Fuels certainly is good testimony to the power it
▲ A top slider switches between the gears; max boast all-metal construction and the internal generates. Softwood was easier and I could
speed is nippy gearing here may not be. control the pull without the high wrist strain.
Conclusion
This drill sits well if you want technology
without increased weight, but with some
trade-off of overall drilling capacities in timber.
But is a standalone drill/driver valid nowadays?
Before impact drivers, a drill/driver for the
fastening work alongside a combi drill was
more commonplace, but now the market
seems to go for combi drill and impact
packages the drill/driver could be a harder
product to shift with the inclusion of the
Milwaukee combi drill in the same
configuration, and I’d err towards that just for
▲ A worklight is activated by pulling the trigger ▲ There’s a single collar to switch between drill the extra versatility. Either way, Milwaukee has
and torque control a compact, powerful, well-made and
competent drill here.
The Verdict
+ All metal chuck; brushless motor for longer
runtime; bright worklight
– Drill/driver functions only are limiting;
description of metal gear casing implies
internal gearing may not be; no side handle
Rating
Typical price: £179.00 (body only)
Weight: 2kg with battery fitted
Speeds: 0-450, 0-1800rpm
▲ Constructing some decking with 100 x 6mm ▲ An auger into beech didn’t stall the drill but it Chuck capacity: 13mm
screws was a breeze needs a side handle! Torque: 60Nm

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Kit & Tools
Bearing up well
Designed for light use, this
machine nevertheless sports
some good engineering
F
alling into the price band that errs towards affordability over
robustness, Charnwood has a range of three saws sharing
identical components and design to suit both budget and
capacity needs.
You still get a good bandsaw for your money, and a good blade – far
too often companies make do with a cheap one that comes with the
saw, only to get complaints that the saw doesn’t work properly.
The one fitted on all three of these is British made, and in my testing
of the biggest model it made short work of the 175mm-thick oak off
which I sliced a few 3mm-thick veneers without struggle.
Aluminium features heavily in its build, from the band wheels to the
guide post and fence assembly so this saw will be more at home in a less
demanding environment. The two bigger machines are targeted as Light
Trade and the entry level one as Hobby.
Double bearings
The main difference over any bandsaw I’ve looked at over the years is the
use of double bearings for the side support. This now gives four bearings
on the upper guide, and it’s replicated below; this is a
decent feature as the lower guides are often more
simplistic. By doubling up the bearings the blade has
additional support on wider blades to minimise any
twist as you turn tighter corners as well as better
support on standard straight cutting.
Adjustments are a combination of small knobs and
hex key. I thought these to be a little on the small side
for a really good nip up to ensure the settings remain constant, more so
for older or less strong fingers.
The guide post itself has a double-function locking knob, the internal
ring acting as the lock, with the outer adjusting the height accordingly.
This works well, although the overall quality of all the adjusters is where
cost savings have been made, plastic being used instead of nylon.
Blade tensioning is the now almost standard tensioning wheel and
tracking knob backed up with a quick-release tensioning lever for fast
blade swaps. You have to remove the fence running rail to remove the
blade but the wingnut release below it makes it a doddle to do so, so you
can swap a blade in a matter of a minute or so.
Through the doors

The Verdict A basic indicator needle shows the
tension as a ballpark figure, which
+ Twin roller bearings; worklight; neat dust can be read through a small window
collector; two speeds in the upper door so you don’t need
– Light build; cheap plastic knobs to open it to check the setting.
Rating A look inside the upper door
Typical price: £579.00 reveals a spoked aluminium wheel
Max cutting depth: 225mm with a small spring and bracket to
Throat width: 340mm tension the blade; certainly not as
Motor: 1100W beefy as some, but about par for
Blades: 6mm-25mm this price band.
Cutting speeds: 800 & 370mpm Open the lower door – both are
Weight: 75kg micro-switched for safety while
Web: www.charnwood.net working with them open – and the

Charnwood BS350 Premium bandsaw
▲ A neat feature is the use of double bearings ▲ Twin trunions support the table and allow ▲ This post allows the table to be set perfectly
for blade support quick angle setting square to the blade
▲ A tensioning lever allows fast blade swaps ▲ Tensioning can be assessed with the indicator ▲ You can check the setting through the
viewing window in the top door
▲ Initial tensioning is achieved with the ▲ The height post is set with the double- ▲ The fence rail removes easily for
top adjuster function knob blade swapping
▲ The blade dealt with oak consistently ▲ As an indication of the collection feature, this ▲ Using the basic mitre fence it’s very easy to
and cleanly is from one rip cut cut a tenon in a minute or so
lower wheel is linked to an external knob that A further handy feature common to all the standard, but is sufficient for general use.
slackens the drive belt for a second speed option saws is the switchable worklight on a handy The slots aren’t standard though, so an
when working in other materials. It also reveals flexible stem. The final area to consider is the aftermarket fence won’t fit if you are looking
a neat feature shared by all three saws in the cast-iron work table. This is flat and well to upgrade.
range: slots in the bottom of the saw allowing finished with mitre slots for the supplied mitre
the dust to drop into a small drawer in the base. fence, which along with the sliding fence Conclusion
The rear dust port has a cover cap to keep allows a variety of cuts to be easily made. I did So although not the heaviest of builds out there,
the dust within the base so that it drops into a few quick tenons to check out both fence nonetheless the Charnwood pulls its weight and
the drawer if you don’t use an extractor. It does options and was pleased enough with the comes up with decent performance, but it needs
a decent job although there was a bit of dust results although there is some play in the to be looked after in the more robust light trade
on the floor. mitre slot as the fence isn’t of top-end environment for which it is badged as suitable.

Kit & Tools
They have
the technology
Being given the
opportunity to see
how Irwin makes
its saw blades was
right up Andy’s
street. Better still,
he had to travel to
Italy to see the
setup! Initial work starts with flat plates that are laser or plasma cut to the correct parameters
I
rwin enrolled the manufacturing It all starts with the steel, bought in from
expertise of saw blade specialists FLAI to Germany as plate thicknesses and widths to
make its premium blades in Udine, suit specific blade diameters and designs. The
north-east Italy, taking control of the facility factory’s 35 or so employees turn out around
around three years ago, and has invested in 1.2m blades per year.
new and specialist own-designed machines; First, the blades are cut to their respective
around 60% of the machinery has been diameters, arbor bores, tooth count and
installed since the acquisition, with around additional work such as expansion slots and
$10m of investment. resin holes for sound deadening, on CNC-
Responsible for designing many of the blades guided plasma cutting machines or the newer
is Ken Hall who guided us around the process. and quicker laser cutters.
Once the blades are cut, each is put through
a machine that presses a groove into them.
This gives the blade tension under load, but Blades go onto this machine to check them for
still needs to be checked for true to prevent it true after tensioning
wobbling or binding as it cuts.
Each type and diameter of blade needs a Tipping the blades
different tension ring position as well as different Tipping the blades is next with either a direct
pressure to get it right and it took around weld or brazing used to achieve the bond, with
seven months of researching to come up with differing types of tips utilised depending on the
the data to get each blade correctly tensioned. material that the blade is designed to be used on.
The process of running the groove imparts a There are some big investments here with a
minute dishing to the blade, so each is new machine costing around €250,000 sitting
assessed for true, a display indicating any alongside some of the older ones, but capable
anomalies after the laser has scanned it. Then of faster and more complex operations.
it’s down to the expertise of the operator to I asked why some blades were brazed while
fine-tune any discrepancies with a deft tap or others were welded, a technology that was
two of a planishing hammer to tweak it to ported over from tipped bandsaw blades. Ken
within the tolerances set up. explained: “Brazed teeth allow for a larger
A further check for trueness on another grain of carbide which is ideal for stationary
machine shows any imbalance around the machines where resharpening can be
blade edge, which is again deftly managed by important. Welding is a stronger bond so is
This machine runs a tensioning ring into each grinding away minute amounts to balance it more effective on handheld machines where
blade to keep its tracking true before it moves on to the next stage. blades are seen as a more disposable item.”

Irwin saw blade manufacture
Close up of blade on machine A laser reads to blade surface indicating any The skill of the workforce then comes into play
minute anomalies, shown up on screen as a by tapping the blade to address any irregularity
different colour
If you need to know anything about saw blades, No, not an industrial washing machine, but an Various machines tip the blades, some more
Ken Hall is your man! Here he’s talking Teflon oven for annealing the blades complex than others in their ability
Sharpening & profiling metal state to emerge in the bright Irwin blue use on a daily basis, this one has a really sharp
Irwin has also invested heavily in tip sharpening Teflon coating. almost needle point, akin to a fleam-sharpened
and profiling. Alongside older machines that The blades are tempered in an annealing handsaw.
grind the tips in a more basic style, newer fully oven over 18 hours, then left to cool over- Pushing through both melamine board and
automated robotic-armed machines were night. This process is to balance the steel as it cross-cutting veneered MDF, the finish was so
spinning and moving the blades through the has localised hardening from the laser and clean and free of chipping and feathering it
machining processes to make all the grinds plasma cutting processes that make the steel looked like it had been planed rather than sawn.
that set up a blade for a particular cut. brittle in key areas such as the gullets. It’s here where you see the true investment,
If the blade is to be a standard bare metal with such a high-quality finish within the
finish it goes through aluminium oxide blasting Blades on test blades’ construction as well as from the finish
and cleaning processes to clean off any oxides A small woodworking workshop is used to and performance they achieve.
and to remove the discoloration from the check blades. While I’m pretty au fait with the I came away with a new insight into how
brazing and welding process for a uniform and usual tooth pitch, geometry and what they are high-quality blade manufacturing revolves
bright finish. designed to do, there was one that was new to around embracing technology, using quality
Elsewhere, other blades go into a huge me. Although it was an alternate top bevel, as materials and attention to detail; all are in
carousel for the Teflon coating and baking is the standard for the majority of blades we abundance here.
process, Teflon helping prevent resin build up,
helping to dispel heat build up and being a
brilliant rust proofer.
This particular area of the factory was off
limits to my camera, but we were allowed to
go inside where a huge snaking train of blades
was slowly weaving its way through the unit to
gain their slick coatings.
Although the blades go into the Teflon plant
unfinished, complete with oxides and other
contaminants on them, the facility does a
pre-wash, scrub and steam-clean operation
before the Teflon is sprayed on. It takes around Each tip is induction heated to form a solid bond Close up of a blade being ground
two hours for each blade to go from its bare to the blade

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NE0 palogue on
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Birds Royd Lane, Brighouse, West Yorkshire, HD6 1LQ A re
A higher plane?
...T
o hiding secret drawers and
I’ve recently been chatting to compartments in bureaux. In a
similar way, it’s tempting to think
a company that specialises not of the fluidity of the ‘cloth’ represented in
so much in building illusions linenfold decoration on panels as the freehand
work of a wood carver, but received opinion
as making the improbable seems to be that, from the outset, the addition
real, and the part that wood of this design has been more of a
cabinetmaking operation. Just as panelling (or
plays in its work, about all of wainscotting) began to be ‘productionised’ in
which more next month – the 15th century through the development of
frame-and-panel construction, so the use of
with luck and a following moulding planes made the creation of linenfold
wind. During the course of the reliefs more a matter of machining than craft.
Its relative ease and speed of production
conversation, however, one of may go some way to explaining why it Linenfold created courtesy of Wealden Tool
the points made was that, featured so widely in north European Company’s cutters
woodwork between the 14th and 16th
“things don’t need to be what centuries. Or then again, maybe people just around these folds, their ends then need to be
they appear to be,” which, liked it: perhaps linenfold was the perennially shaped with chisel and gouge to complete the
popular Laura Ashley print of its day? After all, impression of loosely gathered fabric.
when you think about it, is the oak, in which linenfold was frequently used, Juggling act though it sounds, this
charter for creativity that has a distinctive grain that suggests the play of combination of cutters affords complete
light on a woven fabric; moreover, oak – freedom in designing variety into those folds,
underlies all sorts of especially when it’s figured with medullary but when applied to solid timber panels it’s
woodworking practices, from rays – doesn’t require the level of detail that’s also a process that commits you to reducing a
needed to bring, say, a fruitwood’s grain to lot of that timber – quartersawn oak, perhaps,
veneering or using man-made life, meaning that linenfold is a relatively if you’re after maximum stability and brightest
boards for carcassing, say… simple way to create a striking effect. And 600 figuring – to woodchips. And if you’re making
years later, the router has only made that folds that are, say, 10-12mm deep, that’s quite
effect even easier to achieve. a lot of heat and wasted material. The
alternative would be create the moulding in
Drape made easy thinner stock and then glue it to the panel, but
Now, I’ve read an account explaining how it’s still a procedure that involves a lot of
Dave Roberts, Consultant Editor linenfold’s peaks and troughs can be built up bit-swapping, setting out and handwork –
on panels using a large-diameter cutter to drawbacks, as some would see them, that are
create the hollows and crests, a dovetail cutter neatly resolved by the linenfold cutter from
to undercut the folds, and a V-groove bit to Wealden Tool Company, the Kent-based
chamfer edges. After removing the waste from producer of router and moulding plane cutters

Too good to burn: rescued from the bonfire, this
desk pedestal scrubbed up quite well, and the
freshly applied workshop livery doesn’t look too
bad against the wall’s new paint, either, don’t A few bob for some new handles, a bit of elbow The drawer boxes are tidily built from
you think? It’s gone from ’70s office to ’80s grease – it’s the stuff that early evening drawerside ply with machine-cut dovetails
Docklands television is made of and Blum runners
(www.wealdentool.com). drawer boxes, meanwhile, are made of

Intended for use in a router table, Wealden’s drawerside ply (hardwood ply the grain of
linenfold cutter (T2931, available with either whose layers runs in the same direction rather
8mm and 1⁄2in shanks) combines the effect of than alternating), are fitted with Blum
the wide and V-profile bits above in a single runners, and have fronts of hefty birch ply and
profile that will mould strips of material more oak veneer.
3in/76mm wide; along with the cutter come OK, so it’s only mass-produced officeware,
templates and instructions for making the but these pieces, which had been thrown out,
necessary jigs to trim the ends of the strips – are not only in good shape even after a period
though there’s nothing to say you can’t cut of service and their unceremonious dismissal,
them square – and, using its linen radius cutter but better made than some of the things I’ve
(T2932), shape the ends of the mouldings to seen being carried into homes let alone offices.
complete the ‘gathered’ effect. What interested me most was the
While Wealden’s profile won’t create the The second pedestal in preparation: the particleboard (or chipboard, or whatever it’s
dramatically undercut fold produced by a carcase’s materials and construction – three- called this week): the three-layer variety has a
dovetail cutter – though with a little thought layer ply, solid timber edging (rather than tape), core of coarse strands that’s sandwiched
this could be selectively applied in a further and veneer – are visible here between two layers of finely chopped particles
pass over the table using a second bit – the bound – and here I refer to my copy of Jackson
beauty of Wealden’s approach is that the strips Waifs & chipboard strays & Day – in a resin so as to create a surface
its cutter produces can be made quickly, then I’m not sure who Andrea had in mind last month whose smoothness and stability makes an
butted together to build up a run of linenfold when she referred to, ‘hoarders of offcuts and ideal veneering substrate. It is, as the
of the required width, and glued to the panel; strange stain experiments in jam jars’ in her venerable Ernest Joyce said in the late 20th
Wealden suggests using odd numbers of strips leader, but I’m sure that I heard something that century, a ‘valid material in its own right, well
to build up the effect, but it’d also be possible sounded rather pointed ricochet around my worthy of new methods and applications’.
to introduce narrower strip to break the step of own workshop walls while I was messing Some things are much more than what I lazily
a long run of linenfolds, and so avoid too about with my latest piece of ‘hoardage’. supposed them to be.
obvious a repetition of the pattern. Moreover, Living as I do not unadjacent to some Suffice to say, I invited this homeless
while the mouldings can be made from solid business units whose tenants change from furniture back to my workshop where – for the
timber, there’s nothing to say that the panel time to time, I’m sometimes amazed by what price of eight castors, half a dozen drawer
itself can’t be a man-made material veneered appears on the farm bonfire. The latest jetsam handles and the labour required to effect a few
to match the strips. was a pair of three-drawer pedestals and a repairs, convert the desktop into bases, make a
In fairness, Wealden Tools would be the first desk top, the sort of oak-veneered furniture pair of new tops, and prepare the whole lot for
to point out that this cutter isn’t the newest that’s been the unremarkable mainstay of painting to match my workshop livery –
profile in its extensive catalogue, but it’s new office decor for decades. What struck me, they’re ready to do robust service as moveable
to me, and – simple soul that I am – I’m always though, is the soundness of its construction: storage units for more of my stuff.
excited to discover a tool for a job that I 3-layer particleboard edged with 1⁄4in oak, and And did you notice that I managed to tell
haven’t yet thought of trying. veneered with bookmatched leaves of oak. The you all that without saying ‘upcycling’. Go me.

Solutions
Sound principles
The watch phrase
for dealing with
drawers is ‘one at
a time’, advises
Stephen Simmons
H
aving fitted new bracket feet last
month, I’m going to concentrate
on the drawers this time. They are
the heart of the matter and as they
take a lot of stick their restoration has to be
robust and based on sound principles.
But first, it’s always best to reduce the
number of loose pieces whenever logically
possible. As I had a lovely old but rather fragile ▲ Pic.1 G-clamps: the right tool for the job but keep them well padded, even on the inside of the carcase
strip of mahogany for one section of side
facing, that was the obvious candidate. The Pic.3 Vacuum
▲
original facing was glued rather than pinned power: the

and so to follow suit gluing and clamping it had rub-joint is a
to be. G-clamps are ideal: they’re far more wondrous
effective than using clumsier sashes over the thing for fixing
width of the cabinet side (Pic.1). runners, in one
When working on drawers deal with one at a length or a
time: it saves a lot of clutter and avoids the risk number of
of mixing the parts; note their position should shorter
they be the same size, especially the top left- sections
and right-hand ones.
Seeing what you’ve got ▲ Pic.2 Back to the future: likely originals are
There can be more constituent parts to a so much more elegant than Victorian
drawer than first meets the eye. Here there replacements
Tip were nine elements: the two linings (sides),

back, front, slide-in base, runners,
Drawer runners
All the drawer runners were worn and needed
When dealing with a complex project cockbeading, handles, escutcheons and locks. replacement; some were so bad that the
attention to detail is just as important as The greatest relief was that the only things drawers were jamming in the stops. When
keeping your eye on the big picture. A good not needing attention – apart from cleaning runners wear so do the drawer linings and it’s
example is the method of fixing the – were the escutcheons, and I had decided always easier to build them up with the
cockbeading. Here it was just glued but from the outset not to bother about replacing drawers dismantled. All but one drawer needed
sometimes it is pinned, or both, or fixed missing locks. dismantling and these could be tapped apart
with pointed oak pegs, known as coaks. Logic suggests that worn runners should be quite easily but a couple needed water
Always fit replacements as per the original. tackled first because, like the carcase, injecting into the joints to dissolve the glue.
dismantling is involved. However, it’s worth A bonus was that each bottom was only
investigating the knobs/handles sooner rather secured with a couple of pins and slid out
than later so that you can start looking for readily after removal.
appropriate replacements. You’ll get clues The best order of work is to build up the
about the originals in the form of holes for drawer linings first, reassemble front, back and
various forms of fixing and impressions of their sides and then slide the bottom back into place
outlines, hidden here behind the Victorian straight away so that everything is pulled
knobs. I was lucky to have some suitable square before the glue cures. The new runners
▲ Little things matter: you don’t meet coaks
candidates of exactly the right size and quality are fitted last.
everyday but replace like with like when you
do; note the mitre in pewter and brass… but only four. At least I I find replacing drawer runners eminently
knew what I had to look out for (Pic.2). satisfying. There’s nothing more complicated

Drawer restoration
▲ Pic.4 Simple but effective: bent pins make excellent mini-clamps and ▲ Pic.5 …wax the new runners so that they glide from the outset
after removal…
▲ Pic.6 Utilitarian as well as decorative: there’s a missing section of ▲ Pic.7 45° for security: new sections of beading are better fitted with a
cockbeading to the left of the dead butterfly…and note the ghastly scarf rather than just butted; corners are mitred
handle botch
than a rub joint in the angle formed by the project (Pic.4). The remaining pin holes in the a decision based purely on personal preference
bottom and sides, a little less than a right runners are immaterial and will soon fill up and aptitude; use what you feel most
angle if a thick bottom is chamfered to fit into a with beeswax or candle wax when you wax the comfortable with in similar circumstances.
narrower rebate (Pic.3). runners (Pic.5). I also decided to re-veneer the whole top
The originals varied between a single length Cockbeading is the protective strip round the rather than patch the original; it was too badly
of oak and several short sections butted drawers (Pic.6). It’s advisable to work on it after damaged and could be re-cycled for other
together which are much easier to work as rub the runners as it can get damaged when projects. With animal glue, a steam iron and a
joints. Don’t be tempted to use pins rather dismantling the drawers, but I treated myself veneer hammer there was no need for any
than glue as the permanent fixing; you’ll only to a few sections beforehand on the one that form of clamping. Such a large area can be
be storing up trouble for the future as could remain intact (Pic.7). As last time, I like to quite challenging as a first project; it’s
inevitable wear sets in and the pins begin to splice in new sections at an angle of 45° for a something that needs practice but it’s not
protrude and gouge. more secure fit. I also like to fit them slightly impossible and is definitely worth aspiring to.
proud and plane them down , only forming the The whole project took seven years which
Clamps and cockbeading rounded profile when the glue has cured. isn’t as daunting as it sounds. There were long
There is, however, a way of using pins as Colouring and polishing can be left until later, periods of inactivity including a full 18 months
temporary clamps. Make some small squares certainly after cleaning the drawer fronts, to while we packed up the workshop and moved
of ply with a fine hole drilled through them, ensure that you match to the right colour. to France… and remember that full-time
drill more holes through the runners professional restorers need to get out and do
themselves and when they are glued into place At long last… something else in their free time.
drive pins through the holes into the drawer With the drawers all but complete – I still only
bottom but bend the heads over onto the ply
to apply pressure.
had four replacement handles – the end was in
sight. To form the section of moulding for one
Next Month
Stephen looks at the restoration of animal
When the glue has cured remove the pins side and the front of the base I used a scratch-
and god figures
with pincers, illustrated here from a different stock rather than a router or moulding planes,

Solutions
Bend it like Jeff

Jeff Gorman’s chair-making project provides
an exercise in steam bending
▲Pic. 2 Hold the bending jig in the vice with a longitudinal batten screwed
to its underside
▲Pic. 1 Working in the workshop doorway keeps most of the steam

away from the tools
B Tip
ending the legs and rail of my
design-as-you-go chair was a
straightforward job (GW206:26), Be safe — never
but making and obtaining the use harmful fluids
supporting kit took more time than the actual in anything that
bending. Although my steaming chest (Pic.1) could possibly be
was made from 20mm water and boil-proof mistaken for a
plywood, I could have used almost any poor drinking vessel.
heat conductor that could safely contain
steam at atmospheric pressure.
I happened to fit the steam supply tube into ▲Pic. 3 The central divider helps to fold the webbing round the legs
a plumber’s tank connector, though directly
poking it through a snugly fitting hole would (not wetting) certain woods render them This time, I decided that since the tension on
have served quite well. A pair of transverse compressible, but not stretchable. To prevent these fibres should not be very great, I’d try
bearers support the work and allow good the outer fibres of some bends (like Windsor applying pressure to the bend by using a
circulation of the steam. chair backs) from breaking out, they need to be ratchet cargo strap (Pics.2 & 3).
The guide for steaming time is roughly pressed together by some means, though this is
¾hour per inch of thickness (1.8 minutes per less essential on mild bends such as mine. Bending jig
mm). To be certain of thorough heating, I Pic.3 shows how the central divider controlled
allowed 11⁄4 hours for the 11⁄4in (32mm) Bending in practice the webbing. Screwing the ratchet mechanism
diameter workpieces. To preserve the heat, the job needs to be done to the jig helped to keep things under control.
as swiftly as possible. When working single- The webbing – which in the photo has gone a bit
Bending principles handed on the earlier chair, I lost time while awry – wraps right round the jig, passing
When a beam is bent, the material on the inside struggling with two G cramps needed to hold through a gap in the batten fixed to the jig’s
of the bend is compressed while the outer side down the two curved blocks intended to hold underside. The bending drill simply involves
is put under tension. Steam heating or boiling down the fibres on the outside of each bend. donning water and heat-resistant gloves, fishing

Steam bending
▲Pic. 4 Here Jeff bends the steamed rails against a former ▲Pic. 5 His Stanley 113 compass plane was made between 1912 and 1918
Tip
To draw the curves on the back rail former,
get somebody to bend a thin lath while
you draw around it. Also, overtightening G
cramps can permanently distort the frame.
Drilling for back spindles

Using a pair of dividers and starting with an
estimated setting, I repeatedly walked the
points from the left-hand tenon shoulder
marks, adjusting their span until the final step
landed on the right-hand shoulder, thereby
dividing distances a-b (or c-d) in Pic.7 into six
equal parts. This simple technique has, to
▲Pic. 6 Adjusting this plane involved both hands some minds – and as you can readily see – the
as he worked defect that when these points are used as hole
centres, the outer spaces turn out wider than
the legs from the steamer, slipping each under the others by half the diameter of the spindles.
the strap, passing them through the fixed block I’m quite happy with this, but had I wanted
(Pic.2), tightening the webbing, fitting the loose even spacing, I would have calculated the
pad, bending the pair by operating the G cramp ▲Pic. 7 On the unfinished chair, spacing the distance a-b minus five times the spindle
and then checking the tightness of the strap. back spindles raised an arithmetical problem diameter, and divided the result by six. Let’s
say the result was ‘X’mm. Starting from say,
Bleaching Back rails the left, I would have set out Xmm, then the
When the ash had thoroughly dried, I found There’s not a great deal to report about the spindle diameter, moving along Xmm again
that it had acquired a green tint that I removed bending – Pic.4 almost says it all. Prior to and so on.
by brushing with a mild wood bleach steaming, the stuff was planed to size. I
consisting of a solution of three teaspoons of
oxalic crystals to 100ml of hot water. Oxalic
decided I could use the G cramps without
protective pads since any marks from the Information
acid is a well-known standby for other metal shoes would be planed out when the rail Previous Chair – http://www.amgron.
workshop jobs such as cleaning cramp and ends were thinned to fit the leg mortises, or clara.net/projects/Chairs/
other stains from tannin-rich timbers such as removed with the oxalic acid. TomSuttonChair.htm
oak, but being labelled ‘harmful’ it needs to be Pic.5 shows my compass plane smoothing Oxalic Acid MSDS – http://ptcl.chem.
used with care (see the Information box, left). the raised grain on the concave surface. ox.ac.uk/~hmc/hsci/chemicals/oxalic_
The effect was not immediately observable, Actually I mostly used it on the outside of the acid.html
so I left the legs to dry and found that the green bend to taper the ends to fit directly into their
tint had disappeared while apparently having mortises. As the taper developed, I found that I
little effect on the colour of the ash itself. I
found that the wood surface had acquired a
coating of fine crystals that had to be washed
needed to modify both the setting of the front
knob and the cut as I worked, and had to be
careful not to turn the knob when I pressed
Next Month
Fine tenoning as Jeff’s chair nears
away with plain water, otherwise sanding down on the plane’s toe. I sharpen the blade completion
would have liberated the crystals into the air. with the usual 30° sharpening angle.

Woodwork foundations
No pressure...
The two Ds, dovetails and drawers, usually equate to Ds
for difficult, but follow Michael Huntley’s exercise and
it’s really not so bad…
T
here is a goodly number of ways that some doors on it or some drawers in it. Hinging larger openings divided by rails into which a
drawers are made. In historical terms doors will be covered in the future, but for now small box could slide. Those boxes were
one can often date a piece of furniture by let’s make a simple old-fashioned drawer. actually drawers. Early drawers either sat on a
the drawers. I am going to try to describe floor of boards or were hung with a groove in
some of the varieties starting with the simplest – Construction history the side that fitted into runners nailed to the
and oldest – and finishing with modern The earliest drawers were not really drawers carcase. The drawers themselves were usually
construction. It may take a couple of articles! but little compartments in coffers that were nailed together, the sides being rebated into a
But once you can make a carcase as described called tills. As coffers developed into chests thick front. Runners were sometimes added
in GW293, then probably you would like to put with carcases, compartments appeared with underneath to raise the drawer up above the

Dovetails & drawers
▲ Pic.1 Planing edges square on shooting board

and, inset, showing bowed timber
▲ Pic.2 Marking tails ▲ Pic.3 Marking thickness of pin board on tail board
▲ Pic4 Cutting tails ▲ Pic5 Cutting shoulder of tails

Woodwork foundations
▲ Pic.6 Marking pin board ▲ Pic.7 Measuring thickness of tail board
▲ Pic.8 Transferring tail board thickness to pin board ▲ Pic.9 Marking perpendiculars on pin board
boards and front carcase rail. fitting it to the drawer back in such a way that
Tails or pins? By 1700 large dovetails were being used to
join the sides to the front and back. The
it could expand and contract by having the
screws holding the base to the back in slots. In
If you have already studied the making of
dovetails you may have an opinion about drawers began to be fitted onto runners that situation the drawer boards ran from left
which should come first, pins or tails. Well, beneath the drawer sides and because the side to right not front to back.
I trained as a restorer and sometimes we grooves were no longer needed, drawer sides In designing drawers you need to consider
had to cut replacement pins and themselves could be thinner. whether they are flush with the surface of the
sometimes replacement tails. It was no There was a problem though: even when you carcase or proud, perhaps to allow a finger grip
good saying, “Oh, I can’t do it that way!” put a moulding or veneer on top of the on the underside of the drawer front or as a
When teaching students I cut tails first ‘through’ dovetail it was still likely to show decorative feature because the drawer fronts
because tails are easier for the beginner to through. The answer was lapped dovetails, in are of particularly nice timber. Sides are usually
visualise. You cannot pull a wedge-shaped which the tail is housed into the drawer front. about 12mm, backs a bit less and fronts about
tail through a hole; therefore you cannot There is also an issue about drawer bottoms. 20mm. Bottoms are 4 or 6mm ply these days
pull the tail out. That is the purpose of In the early days they were nailed on. By the but used to be solid. Cedar was used to repel
dovetails, to be unable to pull the tails 18th century they were being rebated into the the moths.
through the holes in the other board. sides, the runners often being glued onto both
Therefore, when pulling a loaded drawer the side and the bottom boards. There was still Your first drawer
out you won’t pull the drawer front or the an issue about shrinkage though. The thin but As a first drawer, if you don’t already have a
drawer back off the drawer side. In design solid bottom boards would shrink and pull carcase, why not try making a drawer to fit an
terms dovetails are used to hold two away from the edges of the drawer. That was existing opening in a chest of drawers that you
components together mechanically. solved by gluing the drawer bottom to the do have? That way there is no pressure, it is
front, running it in grooves on the sides and just an exercise to get used to the techniques.

Dovetails & drawers
▲ Pic.10 Sawing waste with coping saw ▲ Pic.11 Cleaning up pin board
You can throw the practice pieces away. slopes on the back. Set the side in a vice and cut piercing saw (Pic.10). Using a large chisel, clean
Cut out the drawer front and bevel it slightly the sloping tails down to the gauge line (Pic.4). up the waste (Pic.11). Don’t try to go back to
so that it will sit in the aperture without falling Then cut the shoulders (Pic.5), using a the gauge line in one chop, but creep up on it
out. Cut the drawer-sides so that they just fit fine-toothed crosscut saw. Take care with your slowly until you are more practised at chisel
halfway. Don’t forget to allow for any lap. The sawing; the dovetail should fit straight from work. It is OK to under-cut slightly in the middle
first drawer to make is a simple one-tail the saw. of the board, but not at the outside faces.
dovetail. There are lots of rules for setting out You now want to mark the pins from the tail Finally, assemble your first through dovetail
dovetails but as an introduction just make up board (Pic.6). It is customary to rest the tail (Pic.12). Note that to get the lipping flush I
your own proportions. It is better if you have a board on a plane edge, but you could use any would need to house out the top of the side
dovetail gauge, but it is not essential. The dead true surface. Line the shoulders up with board of my prospective drawer.
proportions are 1:8 for hardwood and 1:6 for the edge of the pin board over tight by a whisker. Now cut off the tails and pins and practise it
softwood. As long as they match you could This will pull the joint up tight. Put a heavy all over and over again to give you lots of
use any slope from 1:5 to 1:8 so don’t be a weight on the board and mark with a pencil. sawing practice.
slave to formulae. Set the gauge to the thickness of the tail
The front and sides must be square (Pic.1); board and transfer the line to the pin board NEXT MONTH
you can see in the inset picture that I am using (Pics.8 & 9). On the pin board, drop Michael makes a lapped dovetail drawer
an old veneered drawer front. This is because I perpendiculars down to the gauge line (Pic.9). with more tails and pins, which is the
like recycling and someone knocked apart a Saw down the perpendiculars with a fine rip modern way of doing things.
chest-of-drawers and left it for me on their saw, then cut out the waste with a coping or
drive. I would have preferred it if they hadn’t
smashed it apart but they thought that they
were helping! Anyway, it serves to display some
of the issues found in drawer making. Note that
it has a top lipping which needs to be taken
account of when designing. Also it is seriously
bowed. This is what happens if you veneer on
one side of a board and not the other. The
veneer pulls the board into a cupped shape.
Anyway, I ripped it back to cut off the cupping,
but left the lipping for restoration practice.
Marking & cutting

Don’t spend ages marking it up, but get into
the habit of trying to cut a single dovetail in
five minutes at the start of each day, date the
dovetail and throw it in a bin. After a few weeks
of doing this you can get them all out and see
how much you have improved.
Mark the slope of the tail; cut a decent
distance from the top edge, 20mm in my case
(Pic.2). Do the same 20mm from the bottom
edge. Set a gauge to the thickness of the front
and mark all round, (Pic.3). Use a small square
to take the lines over the end and mark the ▲ Pic.12 Large old-fashioned dovetail assembled

The big project
Down on
the Prairie
Martin Aplin makes a hall table that was inspired
by the American Prairie Houses of Frank Lloyd Wright
“M
ake a small table in the Houses. We don’t have any such houses here was often referred to as ‘organic’.
style of Frank Lloyd in the UK or Europe, but in the New World While to find out all this was helpful it still
Wright please,” we (America, Australia, and New Zealand wasn’t the ‘steer’ we were looking for.
demanded of Martin, particularly) the Lloyd Wright Prairie House Fortunately it turns out Lloyd Wright was one
with typical (lack of) clarity. A quizzical style captured imaginations and would be of those architects who also designed the
expression leapt to his brow: “Who?” copied and modified over and over. interiors of his buildings, right down to the
For those in the dark, Frank Lloyd Wright There’s a hint of the Victorian villa in the furniture. And so, thankfully, there are plenty
was an early 20th century American architect, Prairie Houses, but they are typified more by of examples of Lloyd Wright-designed furniture
probably best known for designing the being long, low buildings with shallow, sloping to draw inspiration from. Like his houses, his
Guggenheim Museum in New York (completed, roofs, covered terraces and porches. They furniture also seems to be a matter of long and
after his death, in 1959). Only that modernist further differ from villas by being ostensibly low with shallow angles, clean in line, almost
style of design wasn’t what we had in mind. open plan – arguably the first open-plan like Modernist furniture, only made using
Instead we were referring to Lloyd Wright’s buildings. They can be differentiated from comfortable, warm timbers such as cherry.
much earlier work, namely domestic Modernist houses by virtue of their So there we have it. We wanted an
residences, that came to be known as Prairie comfortable, almost stately interiors. The style occasional table, probably in something that

American hall table
▲ Pic.1 Draw the table out full size on a sheet of

faced hardboard to produce a rod to aid the
setting out of joints
▲ Pic.2 Edge-joint the boards for the top with a rubbed joint. Apply glue to ▲ Pic.3 Cramp the boards together, alternating each side to equalise the
one edge which then needs rubbing against the mating part cramping force
approximates cherry, echoing the styles seen One feature I have seen on some items of being a salmon pink when first cut but soon
in comfortable middle-class American houses Lloyd Wright furniture is what I refer to as the darkening to a nutty brown, a fascinating
in and around the 1920s. Martin, can you give collars, around the legs at mid rail level. They transformation. It also has an interesting and
us what we want? are often fitted around the legs at lower rail attractive grain and is quite easy to work,
level but I thought this broke the line too much though it can have a habit of splitting.
Architectural furniture so decided not to fit them. I have also added Cherry is quite expensive compared to say
I can only try! The nice thing about a small more construction detail to the article as an oak or ash, which I feel are too coarse-grained
console or hall table like this is that it fits in encouragement for readers to attempt the for such a light table as this. It is twice the
well with the modern home, matching up well table yourselves. It is quite straightforward but price of oak or ash but as only about 1.5 cubic
with contemporary furniture. You can see needs attention to detail, especially when feet is needed for the table, the price was
aspects of Lloyd Wright’s style in the strong fitting the leg decorative rails and collars. reasonable.
rectilinear lines of my table; the comparatively The problem with using cherry is that much
large overhang of the table-top and the Timber choice of the sawn stock is good on one face only,
shallow roof pitch-line is echoed in the angled I chose American cherry as was suggested with a fair amount of sapwood on the reverse.
rails fitted between the rails of the frame. earlier because of its warm look, the colour It is worth spending some time going through

The big project
▲ Pic.4 Having planed the legs to size, clamp them together and mark the ▲ Pic.5 The positions for the mortises were clearly scribed out
positions for the joints with a mortise gauge
▲ Pic.6 Although the mortises are quite small, the bulk of the timber ▲ Pic.7 Cut the mortises to finished sizes using chisels. The mortises will
was removed with a drill break into each other as they are cut into adjacent faces on the legs
the stock and looking at each face to select the

best boards and minimise waste.
Having transported the timber home, the
first task I like to handle is passing the boards
through the planer/thicknesser, just enough to
clean the boards up. This allows me to see the
grain and any small defects and I can plan
where to cut the boards.
Draw the table full size on a piece of board
to produce the rod; this enables you to check
the overall dimensions of the piece and is a
valuable aid for setting out the positions of
the joints.
The table-top and shelf…

… were made first, mainly so that after
gluing-up it could be set aside while I worked
▲
The rails and

collars echo the on the table frame, allowing it to settle before
roof lines and finishing. Plane the boards, leaving them
cornices seen on slightly oversize to allow for planing after
Lloyd Wright’s gluing up, making sure the edges of the board
Prairie Houses are truly square to the faces. Lay the boards
American hall table
▲ Pic.8 Having cut the joints, glue the front and rear frames together, ▲ Pic.9 Join the front and back rails together with end rails. Use a cramp
being careful to ensure squareness across the diagonal to keep the frame square
▲ Pic.10 Carefully sand the infill rails to length and to the correct angles.
Make sure the table is set square to the sanding disc
I have added more Cramp the boards

together, making sure the
faces of the boards are
construction details to aligned. Alternate the
cramps above and below the
encourage readers to boards to equalise the
cramping force.
attempt the table When the glue is dry, set
aside and finish in stages. I
prefer to plane and scrape to
finished size over a period of days,
flat and arrange for best grain pattern, allowing the stresses in the board
remembering to keep the growth rings to stabilise, giving myself the best
alternating to minimise risk of cupping. chance of keeping the table-top
I jointed the boards with a simple rubbed perfectly flat.
joint, which means simply applying glue to one
edge of a board, then rubbing the edge of the Legs and rails
adjacent board against it to spread the glue. Next, it’s time to tackle the legs, which
You soon feel more resistance to the are just lengths of cherry finished to
movement as the glue is absorbed into the 32mm square by 740mm long. Mark out
wood, causing suction which then pulls the the vertical positions of the mortises from
boards together. the rod then scribe the mortises centrally

The big project
▲ Pic.11 The infill rails are inserted in pairs, and hold each other in place ▲ Pic.12 Prepare the segments around the legs on the disc sander using a
while the glue dries mitre fence to ensure the segments fit neatly together
on adjacent faces, the width of these being

8mm. Although the joints are quite small, I
find it easier to remove the bulk of the waste
using a pillar drill, cleaning up the joints with
chisels. As the mortises are meant to be cut
from adjacent faces, allow them to break into
each other.
Having cut the joints, I finished the legs by
tapering the inside faces of the lower legs,
which adds a little visual interest. It’s not a
feature I’ve seen on other Lloyd Wright
furniture, but our interpretation is flexible.
The main front and rear rails are all the
same length and section, with the side rails
also of the same section but obviously much
shorter.
Mark out for the tenons, the distance
between the shoulders on the front and back
rails being 634mm and those on the side rails
being 216mm. Mark out the 20mm-long
tenons centrally on the rails and carefully cut
to size with a fine-cut saw, finishing to size
with paring chisels. Simple surface, preventing the
Having cut the tenons, the ends need to be decoration Danish oil I use for finishing
mitred or the rails will foul each other on The decorative infill rails from penetrating the
assembly. With all the parts cut, assemble the are strips of cherry, planed timber. Also with the
frame dry, easing joints where necessary and to 18 x 10mm. Having lightly intersection of all the pieces it
cramping up to make sure all the joints pull up marked the mid position of the makes it very awkward to clean up
tight. Mark all the joints so the dismantled upper rails, I found the easiest and most if excess glue is allowed to dry.
joints can be reassembled in the right order. accurate way to form the double angles on The collars around the legs are small sections
Also mark the inside faces of all the top rails the ends was to offer the over-length rails of 10mm-square cherry, with the mitres formed
and the front and back lower rails as these against the frame, judging by eye where they on the sanding disc, but this time using a mitre
have small mortises cut in their inside faces for intersected with it and each other and guide. Glue these in place, applying the glue
the buttons which will attach the top panel marking them with a pencil. sparingly and ensuring they are perfectly level
and shelf. I trimmed the rails roughly to shape and and the mitres are closely butted. Again, be
The top front and back rails have three then carefully free-hand sanded the final shape careful to remove excess glue before it dries.
mortises each, the end top rails have one each, using a disc sander, repeatedly checking the fit
and the lower rails have two each. of the rails against all the mating surfaces, Assembly
With all the rails cut and sanded smooth, the until they were just long enough to spring into The buttons that attach the table-top and shelf
front and back frames can be glued, assembled place. This way they would hold each other in are the same size, being cut from 12mm-square
and cramped, ensuring all is square and true. place as the glue dried. stock, 30mm long. Saw to shape and drill a
Once they are quite dry, these can be Having glued the parts, be careful to countersunk hole through. To attach the table
assembled together with the side rails. Again remove any glue residue. I use PVA glue and if top, lay it face down on the bench, protecting it
you need to check that all is perfectly square. the excess glue is not removed, it seals the with a piece of thick cloth, place the upturned

American hall table
▲ Pic.13 The buttons to hold the table top were prepared from square ▲ Pic.14 Having cut the step, part the button from the stock. Then drill a
sections of timber. A small pull saw makes a neat job of removing the waste countersunk screw hole through
▲ Pic.15 The buttons fit into mortises cut into the inside faces of the rails. ▲ Pic.16 Attach the lower shelf using four buttons
Eight are used to hold the table top
frame on it and centralise it before inserting the

buttons in the mortises and fixing with screws.
Fixing the top by this method allows the top
to move against the frame, reducing the risk of
damage as the timber moves. The top could be
fixed with slotted metal brackets if preferred.
The shelf will need to be clamped in place
while the buttons are fitted.
With all the assembly complete, remove the
table-top and shelf and apply the finish. I used
three coats of Danish oil, denibbing between
each coat and finishing with a good-quality
wax polish such as Briwax.
Have a go yourself
If you pop along to getwoodworking.com
you’ll be able to access a free download of a
clear drawing of Martin’s table replete with
dimensions and a cutting list. The drawing
gives the main dimensions for a well-
proportioned table but these could easily be
adjusted for a wider table.
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Cottage door
B
ack in GW192:18, I made a stable
door for my woodworking friend,
Paul, who lives in a one-up one-
down former weaver’s cottage in a
small Derbyshire mill town. Ann, his wife, was
so delighted with the result that Paul was
encouraged to tackle the other external door
in their cottage, which gave me the chance to
try out a design that I’d had in mind for some
time. ‘Why not make a conventional full-height
door,’ I suggested to Paul, ‘that opens inwards
as normal, but which has an outward opening
window light set into the top?’ Now, I’m sure
this isn’t a new idea, but the only place that
I’ve ever seen anything similar was at a tiny
preserved railway station, which featured a
small counter and hatch set into the door of
the ticket office — and you can’t buy one of
these from your local timber merchant!
As with the stable door project, the
appearance of the finished door needed to be
in keeping with the period of the cottage,
which is set within a conservation area. The
door in question, however, is at the rear of the
building and not on public view, which usually
means that the rules applied to the
appearance of replacement joinery are slightly
less stringent. Paul and I decided, then, that
the door would have bead-and-butt boarding
in the bottom part, and four panes of glass in
the opening top part; this pattern of glazing,
we thought, would match the appearance of
the vertical sliding sash windows. The good
Window on
news was that the overall size and thickness
of the door proved to be close to normal
standard at 762 x 1981 x 44mm (30 x 78 x
1¾in).
Timber choice
the world
and preparation
I’m a fairly irregular user of softwoods, most of
my output being in English or European
hardwoods. However, when making anything
in softwood, I generally buy unsorted grade
Swedish pine. This is normally only available
from a proper timber merchant in rough-sawn
full lengths. I’m fortunate, however, in that my
merchant also has unsorted grade boards that
Mike Jordan’s ledged & braced version
are planed all round, 22mm-thick, and
available in a wide range of widths.
still has the look of a stable door
The 500 x 225mm boards that I selected
were from a particularly good consignment Marking out for the boards were also formed at this point,
with a high resin content, which also made it The positions of the mortises in a framed taking care that the stiles remained properly
weightier. You can see from the ’photos that ledged and braced door are dictated by the paired up. Wedge room was cut from the
there is plenty of colour in the material. I am thickness of the boarding to be used. The outside of the mortises by hand.
happy to pay a little more for the best available thickness of the boarding and that of the rails The tenons were cut on the rails using the
grade of softwood; it works much more easily at the bottom and centre of the door must add cross-cut saw for the shoulders and the
and has far fewer knots. up to the thickness of the stiles. Bare faced bandsaw for the cheeks; any final trimming of
Buying 225mm-wide boards also means that tenons are used on these rails, and the mortise the tenon cheeks is best done with a rebate or
I can rip them down to give two 100 x 50mm only needs to be set back from the face by the badger plane. The top and bottom rails must
sections for the stiles of the door, allowing me boarding thickness. In this instance, only the have the haunchings cut before each of the
to remove the centre 25mm of the board bottom rail has a bare faced tenon since it’s joints is individually fitted. The assembly
where shakes and splits tend to be found, even only half of a framed ledged and braced door. wedges are best cut from the waste parts of the
in the best quality material. After cutting to With the mortise positions marked on the tenons. Finally, the shoulder lengths on the top
length and width, the stock was surface- stiles and squared around, the mortises and and centre rails were cut to the same size before
planed on one face and edge before being haunchings were cut on the machine using a the diminished shoulders on the outside of the
thicknessed (see cutting list). 12mm chisel. The stopped rebate and groove centre rail were marked out and cut by hand.

Project
▲ Pic.1 Mike ripped down a 225mm-wide board ▲ Pic.2 The thickness of the boarding dictates ▲ Pic.3 ...which Mike cut on the mortiser using a
to make two 100 x 50mm sections for the stiles the positions of the mortises... 12mm chisel, saving his chisel and mallet...
Fig.1 Cottage door

Section through light Section through door
25
Top rail 55
(machined)
▲ Pic.4 ...to cut the wedge from the outside of ▲ Pic.5 The wedges themselves were cut from
the mortises by hand the waste material
18
21
Boarding
8
▲ Pic.6 The stopped rebates and grooves for the ▲ Pic.7 The diminshed shoulder on the outside
boards were also made at this point centre rail...
60
Bottom rail
(before machining)
38
▲ Pic.8 ...is marked out and cut by hand
CUTTING LIST Sizes shown are planed dimensions (mm) ▲ Pic.9 The frame is now glued up, assembled,
and the wedges are driven home
Component Number Req’d Size Length
The door The door was now ready to be glued,
Stiles 2 44 x 95 Door height + 50 assembled, cramped up, and the wedges
driven home, before being left to set
Top rail 1 44 x 95 Exact door width overnight. Once dry, the door was sanded prior
Centre rail 1 44 x 95 Exact door width to fitting the boards, where I found that
Bottom rail 1 22 x 175 Exact door width softwood with its high resin content clogs up
the sanding discs in record time!
Boarding 6 Ex 22 x 100 par 1100
The window light Bead and butt boarding
The bead and butt boarding was made,
Stiles and top rail 3 55 x 38
sanded, and fitted to the bottom part of the
Bottom rail 1 60 x 38
42 GW294
Glazing bars July 2015 www.getwoodworking.com
2 21 x 38
Cottage door
▲ Pic.10 The bead and butt boarding is secured ▲ Pic.11 After planing and moulding the stiles ▲ Pic.12 ...ready for mortising, a task that Mike
with 38mm oval nails and rails, the stiles are marked... carried out on, well...the mortising machine!
▲ Pic.13 More machinery, this time to cut the ▲ Pic.14 ...followed by the cheeks ▲ Pic.15 A simple mitre block is used to guide
tenon shoulders on the rails... the chisel...
▲ Pic.16 ...when cutting the ovolo profile on the ▲ Pic.17 The job is finished with a short scribing ▲ Pic.18 ...produces the correctly shaped rebate for
window rails cut, which... the moulding on the stiles
▲ Pic.19 The rails are offered up to the stiles, ▲ Pic.20 ...and the moulding cut to create... ▲ Pic.21 ...a flat area ready to receive the square
which are marked... shoulder of the rail
door using 38mm (1½in) oval nails punched that’s to say, it would overlap the opening by tenoned; the tenon shoulders were then
below the surface ready for filling. The boards, 8mm all round and stand 12mm proud of the finished square and level. With this done, it
which had been left slightly over-length, were face of the door. As a concession to the period was a simple task to mitre the end of the
then trimmed to size, and the horns on the top of the house, the mouldings on the light were moulding and use the cut shape to guide the
and bottom of the door were also cut away. I to be finished with an ovolo profile, and then gouge, cutting a short scribe. The portion of
was then able to measure the aperture in the jointed by scribing them by hand. This may be the moulding next to the mortise is then cut
top of the door and start the opening light. a rather old-fashioned method, but it’s a quick flat to take the square shoulder. The glazing
and simple one, once you’ve made a mitre bars, meanwhile, are joined using a halving
The opening light block to guide your chisel. joint, which obviously meant relieving the
I had already decided that the opening light To start, the stiles and rails were planed up upper bar to receive the profile of the
would be made like a storm-proof window — and moulded before being mortised and lower bar.

Project
After the glue had set on the light, it was
sanded off and rebated round to fit as shown,
(Fig.1). A pair of storm-proof hinges was used
to hang the light in the door.
The glass for the light is 6.4mm-thick
laminated glass, which provides both safety
and security. I also made weather moulding for
the top of the light and the bottom of the
door, as well as an oak threshold strip.
The fitting of the window stay and locking
fastener was left until after the door had been
▲ Pic.22 It may be an old-fashioned process, but ▲ Pic.23 The glazing bars are fitted using halving hung.
the completed joint goes together neatly joints, and the outer edges are moulded...
Fitting and fettling
Come the great day, the weather was bright
and sunny, and I set out with the new door
and my tool box in the back of the van. The
tools were just going for a refreshing day in the
country really; as before, my master plan was
to supervise while Paul hung the door. I didn’t
expect to use my tools, then, but it is nice to
show willing.
The door had been treated with a ‘flood’
coat of clear preservative as an alternative to
priming paint. This had been allowed to dry for
▲ Pic.24 ...to create the channel that prevents ▲ Pic.25 Fitting the light to the door — aren’t several days, but still managed to fill the van
the ingress of water cordless drills brilliant? with a powerful smell reminiscent of a hospital
ward. The need to keep the windows closed
Fitting and the heater on ensured that I arrived in high
spirits! The opening window, meanwhile, had
been removed to make the door a little lighter
to carry, and to allow the glazing to be
installed on site.
The original door was removed and the
hinges and handles set aside for reuse; the old
lock was replaced with a new five-lever sash
lock. Paul had treated himself to a new power
planer, which now emerged from its wrappings
for the first time. Suffice to say, we had the
door planed to fit in a matter of minutes, and
ready to be wedged in the opening while the
▲ Pic.1 Paul got to use his new ▲ Pic.2 Using a flat bit in the ▲ Pic.3 ...which was then hinge positions were transferred from the
power planer for the first cordless drill to cut the cleaned up with a chisel existing recesses in the frame.
time. How was it? Effortless! mortise... After the hinges had been recessed into the
door and the door hung in place, it was again
removed to make fitting the lock easier.
A battery drill fitted with a flat bit was used
to remove most of the waste from the lock
mortise before cleaning up with a sharp chisel.
After fitting the lock, the door was re-hung to
allow the lock keeper plate to be correctly sited
and cut into the frame. The mortise from the
original keeper plate will be filled and painted
over later.
The opening window was then reinstalled,
and its casement stay and locking fastener
were fitted. The weather moulding over the
top of it was fitted using screws that were
pelleted over, and the weather moulding and
threshold strip at the foot of the door were the
finishing touches.
I’m pleased to say that the finished result
has been well received. It allows welcome
natural light into a lobby area that previously
▲ Pic.4 Having fitted the glazing it’s time to ▲ Pic.5 ...and it the weather moulding with relied on artificial lighting, and it can also be
hang the door... screws that are hidden by pellets used to improve the ventilation when the
warm weather arrives.

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INVISIBLE STORE OF HAPPINESS

American maple & cherry, steam-bent frame & woven strips
Sculptor Laura Ellen Bacon and furniture designer/maker Sebastian Cox collaborated to create
an elaborate 3m-high installation out of American hardwood to stand in the archway in front
of the Museum of the Order of St John, London during Clerkenwell Design Week
“ The Invisible Store for me has become a

store of many things. It started out as a store “ As a sculptor, I have enjoyed the
refinement of form that has been possible “ Working with Sebastian Cox, one of the
UK’s foremost makers, challenges the way
of our shared passion of making, but as the with these woods; allowing the curves and wood works in a way nobody else does. And
project unfolded it became a store of much stability formed in the head to find their feet Laura Ellen Bacon, with her artistic sensibility
more: education, ambition, pride, late in the finished, grounded form. I know this to coupled with her wonderful sculptural work
nights, steam, experimentation, unknown be a true collaboration: both Sebastian and I in willow wood, is the perfect complement to
quantities, passion, cups of tea, swear words have merged our language of form and Sebastian’s approach. When we set this
and so on! The whole thing has been the function, like merging two colours to acquire project in motion we had no idea quite what
biggest thing we’ve ever undertaken, and we a new shade. For my part, I was hoping to we would end up with but we knew one
couldn’t have done it without Laura’s find a way to distill the act of making into a thing for sure, the result would be ambitious,
creativity, experience and calm nature.
Sebastian Cox, ” solid form of containment, perhaps a little
like blending a perfume and pouring it into a
vessel. With our use of scale, solidity and
perfectly executed and thought
provoking.
”
www.sebastiancox.co.uk David Venables,
precision, we have been able to use the wood American Hardwood Export Council
as the essence.
”
Laura Ellen Bacon,
www.lauraellenbacon.com

Invisible Store of Happiness
Laura Ellen Bacon and Sebastian Cox The weaving is intricate How Laura’s shoulders must have ached
Problems
& solutions Assembly posed many problems to be solved The build called for many mortise & tenons
The maple and cherry have been crafted

into an elliptical-shape frame with huge
arcs of steam-bent cherry, hand jointed
together in mostly glue-less draw-bore
mortise & tenon joints.
Through complex machinery the
components of this solid frame are
effectively shredded into strips and
made supple and weaveable from time
spent soaking in the River Thames
beside Sebastian’s Woolwich workshop.
These strips were manipulated by hand,
flowing and twisting into the space to
create a whirlpool of texture and shape
held within the external frame.
“The biggest challenge has been the
sheer number of unknowns, which we
broke down week by week using
collective thinking and design-grounded
problem solving. It was just relentless
unanswered questions because of the
nature of the piece,” says Sebastian Cox.
“Would the steam bending work? Yes,
after week three and some new metal
straps. Would the spindle moulder
survive the constant use? Yes, after
week two and a new circuit breaker.
Would the mortises tear out as we You need a very good eye, but how many more The completed structure in situ
mortised the arc? Resolved after week to go are there?
four and three jig prototypes. Would the
scarf joints be strong enough? Resolved
after week five.” www.getwoodworking.com July 2015 GW294 47
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Competing for success
Everyone’s a winner but, left to right,

Woody Harringman, Steve Pickton,
trainer Christian Notley and Sam Brister
still have an anxious 24 hours to wait
War of
the Worlds
How do you choose between three
of the best young furniture makers
in the UK? Andrea Hargreaves
witnessed the final nerve-wracking
selection battle for August’s
WorldSkills competition in Brazil A painter & decorator competes
for his place in Brazil

WorldSkills
Cleaning up the inlaid veneer panel of mahogany Sam fits one of the two gull-wing doors
and burr walnut
Under pressure, Steve checks the daunting list of …before fixing the Soss hinges on one of the
marking criteria… gull-wing doors
E
dward (Woody) Harringman, Sam the lateral slide of his drawer. In the final 60
Brister and Steve Pickton had been seconds Sam was checking and rechecking the
building a fiendishly complicated dimensions of his piece, prepared to shave off
cabinet on tapered legs, with sliding the tiniest tad if necessary, Woody was paying
drawer, for nearly 22 hours over 3½ days particular attention to the taper on the legs,
when their trainer, Christian Notley, began and then they were into the final 10-second
the countdown that would determine who countdown, still sanding with a mix of fury and
would go to Brazil to represent the UK and extreme care to achieve absolute perfection.
who would be left behind. The final whistle blew. To hand claps all
With 10 minutes to go Steve was cutting a round they wiped their sweaty faces with their
notch for a handle on the gull-winged top, with smart UK Squad shirts and rictus frowns of
four minutes to go he was fitting the handle, concentration broke into grins of relief. It was
while Sam was making minute adjustments to all over. After months and months of training

Sam just has time to clean up the internal

carcass end that also acts as a door stop Final checking of overall measurements; note the block stop
Tomorrow the world

Watching the closing stages of the final on
that tense Friday were George Callow, 23,
and Luke Griffiths, 27. George had just
celebrated his birthday with the best gift
ever, the presentation of the British Empire
Medal he won as a result of gaining Gold in
Leipzig. While this year’s finalists were
waiting to see who had won through to
represent the UK in Sao Paulo, Luke and
George were waiting to hear confirmation
from an investor that cash was being
The world awaits: WorldSkills veterans Luke
Griffiths and George Callow have a grand stumped up to enable them to hit the big
career plan time by setting up a company which will
concentrate on high-end contract joinery for
hotels and luxury houses.
They have both worked at Cimitree, near
Chichester College, and Luke taught George
at Chichester. Luke has also taught Woody
and Steve, who is employed by Grech &
Grech Interiors, Chichester.
Since winning WorldSkills George has
attended World Wood Week, having been
Hinge access is awkward but doable
invited by the International Woodcraft
Society, and worked in Perth, Australia doing
they’d done their best and had now only to
everything from shop fitting to demolition to
wait an agonising day for the results to be
fund a backpacking trip to the Far East.
totalled up. The only young men not
If this pair’s career path follows its current
applauding their achievement were the two
trajectory it is likely they will be going on
joiners sharing the huge workshop, Dominic
their own milk round. “We want to start with
Hicks and Dale Hodgins, whose own
a young workforce, first me and Luke then up
competition, making a very curvy frame and a
to, say, 20 people. It all depends on the
ladder fancy enough to merit the term
investment bid,” said this man who knew he
furniture, had another fraught hour to run.
wanted to do woodwork from the age of five,
always pleased to help his family fix up their
home and selling stuff to neighbours. “I’ve
Competition setup
The WorldSkills selection finals took place at
always known what I wanted. I’ve been to 34
Burton College’s modern construction
Could it involve any of the UK Squad 2015? countries now. Everyone always slates
academy at Swadlincote, Derbyshire alongside
Here, watched by its maker, Luke is England but you have such good
competitions for welders, stone masons,
scrutinising Woody’s build opportunities here.”
bricklayers, tilers and painters & decorators.

WorldSkills
As Woody is all too aware, all surfaces have to

be sanded to at least 240 grit
Other trades were judged at four other venues

around the country to find the one
representative from each discipline who will
have the responsibility of representing their
country in this remarkable competition, which
is held only once every two years, with the
winner up against the best from countries all
over the globe.
Our cabinetmakers and joiners each had a
workspace of 3 x 5m from which they had
access to machines, but so devious is this
competition that they had to calculate ahead
when they would want to use those machines;
any errors there would be precious time lost.
They knew to what the piece would
approximate a month beforehand – the
WorldSkills piece of two years ago – but were Final touches on the door pull Woody’s going for Gold…
thrown a googly right at the start: 30% of the
design and materials had been changed, with
different stock and dimensions, particularly
Crowd training
We pussyfooted around the finalists as they worked, scared to do anything that would put
awkward being the gull wing that required
them off, but Christian pooh-poohed our fears. “They’ve got to get used to people and
differing angles to be worked out and cut. As
cameras. This is nothing compared to what they’ll find in Brazil. This is all part of the training.
Christian pointed out: the competition had to
They’ve got to get used to it.” Indeed, I’m not sure even a fire alarm would have interrupted
get progressively harder to keep stretching the
the squad’s concentration as they beat the clock to finish.
candidates. This year the leg frame was
tapered on the inside, the mitre on top
meaning two different widths and angles of
48° and 47° required. To get within the
laid-down dimensions they had to be within
0.9mm. “They should all get it,” he said with
the confidence that comes from getting to
know these young men so well over the
training period leading up to regional heats,
final sessions and this contest.
Because of the tropical hardwood likely to be
used in Brazil sapele was chosen instead of oak.
Kit search for jigs

“They can use machines for anything they like
but the drawer dovetail must be 100% hand
cut. They have to make any jigs during the
competition and most made a jig for the dim
saw,” said Christian. Choices here came down
to time constraints, he observed, adding that
rather than the drug tests of sporting events,
WorldSkills contestants would have their
luggage and kit searched for jigs. And he The contestants were confined to a 3 x 5m space
wasn’t joking. A number of illicit jigs had been

Joinery winner found in the kit of non-European contestants Not so the furniture makers. “Cabinetmakers are
two years ago. not allowed any gap,” Christian pointed out.
Watching the final stages of the joinery
At each stage of the UK finals build the In São Paulo the winning joiner will be up
competition it seemed too close to call, but
contestants were marked subjectively and against 27 competitors, with the triumphant
when the marks were totalled Dale
objectively on very detailed marking sheets, cabinetmaker facing a field of 24 from nearly
Hodgins emerged the victor. He trained at
which afterwards were scrutinised by Christian all the European countries and fierce
what is now Banbury and Bicester College
who studied them over 1½ hours. The markers, competition from the Far East.
but was then known as Oxford & Cherwell
who included former squad trainer Peter Legg, Thus all the training: “We don’t set them up
Valley College (OCVC) and was sponsored
awarded points for every key part of the to fail,” said Andrew. “Tomorrow there will be a
by employers Oakleigh Joinery in Stroud,
construction process, from the start of the lot of tears. The WorldSkills final is paid for by
Gloucestershire. He won by a narrow
competition on the Tuesday to its completion UKplc so we have to please a lot of people.”
margin from Dominic Hicks who trained at
on the Friday. Total kit shipping costs for the whole UK
Pembrokeshire College and is employed by
“If I’m happy that they are fair and valid on contingent will be around £100,000 – the UK
Keating Joinery, Narbeth, Pembrokeshire.
Saturday they will be brought into the room furniture maker’s toolbox will tip the scales at
and someone on the other side of the room will 250-300kg alone.
tell them who’s it. It’s gruesome. I hate it. I know
them. They’re all nice guys and have put so It’s all over…
much effort into it. I’ll be in tears,” said Christian. So after the final whistle how did the
candidates, all aged 21, think they had done.
Fine record Said Woody, who has already set up his own
This man who heads up Chichester College’s Battle, East Sussex-based workshop and won
furniture-making department is only too familiar the national SkillBuild title: “I went to the
with this position, having previously trained the second. I didn’t want to go too fast. I was
squad from which George Callow emerged happy with the walnut over the oak. The two
triumphant at Leipzig in 2013. Not only did he doors were a little bit trickier but it didn’t make
teach George and, before that, Calgary (2011) it any more difficult.” And in the future: “I’ve
competitor Luke Griffiths, at Chichester, but two got my own business, set up two years ago
of this year’s contestants, Edward and Steve, when I couldn’t get an apprenticeship. I left
both went to that college too. college and got my own unit and now make
Joinery trainer Andrew Pengelly said that everything from wardrobes to freestanding
each internal joint was marked for fit and cut furniture.”
and for assembly and finish before the external Steve commented: “The drawer was quite
Dale Hodgins with his winning pieces joints were examined. hard to fit but overall I was quite happy with
“To get 100% they are allowed a 0.15mm gap.” what I had done.” And already the competition
has enhanced his career, with an interview
with top company Silverlining Furniture, lined
up. This is a reference to how the lead up to
WorldSkills is used as a milk round by top
makers in search of new talent.
Sam, who trained at South Moulton College,
is hoping that the Edward Barnsley Workshop
will offer him a second year and in the long run
wants to set up his own business.
And the winning cabinetmaker is, pause for
heart-stopping televisual 10 seconds… Woody
Harringman!
But let’s congratulate the losers too because
to have got this far signifies industry
recognition and the chance to take their
talents wherever they like. Meanwhile the
instigation of the competition itself not only
gives the trade crafts the boost in respect and
regard that they so richly deserve, but creates
an advancing benchmark for aspiration.
Phew! How did they

work so quickly?
Editor of The Woodworker, Mark Cass, was
gobsmacked at the speed of the squad. No
slouch at woodworking skills embracing
carpentry, joinery and furniture making,
and with a successful business of his own,
Mark confessed that he would probably
need a week to accomplish what these
young men achieved in only 22 hours.
Woody’s selection-winning piece

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Woodworker’s journal
Man
of
letters
Edward Hopkins
I
blame David. He pushed me into the deep plans, drew up a cutting list and took the
end more than once. “They can because timber to David Oldfield, a master maker who,
carves his they think they can,” is his motto. If you

believe it, it will be so. When, in the late
with unbending kindness, followed my intricate
directions and unpacked from the baulk a
1970s, I hauled him over from Suffolk to puzzle of components until I had everything I
philosophy on Somerset to inspect my first tentative house
purchase, he gaily announced that it would take
needed and nothing, but nothing, more.
William slept soundly in his cradle. Moons
a cradle and me six months and £500 to put the building
right. He was wrong on both counts by a factor
waxed and waned, leaves formed and fell; and
now, as if by magic, he is a man about to marry.
writes large of 15, but nevertheless, he gave me the
confidence to get going. I’m eternally grateful.
We’re going to his wedding party under the
pear tree that always was old, and the sprigs of
I’d been restoring antiques for a couple of yew that now are more like a garden wall.
years when he told me that Caroline was
expecting a baby and that I was going to make Love conquers all
a cradle. He brought along a baulk of field oak I want to give Will and Lucy a present;
and promised me a barrel of beer. I found some something pertinent and personal. I was 16

Hopkins’ home truths
when Lennon and McCartney proclaimed ‘All
you need is love’ and it rang in me like a bell.
Around the same time, Chaucer’s Nun told me
Amor vincit omnia (Love conquers all). I
believed her then and still do now. Either of
these would have worked, but not worked well
enough, for their associations, their origins, are
too strong and distracting. Besides, I thought
with indomitable arrogance, I can do better
than that. Simplicity and brevity are the
hallmarks not just of design, but of wisdom.
Less is more. And so, as the briefest
encapsulation of everything that William and
Lucy will need to know and perhaps be
reminded of gently, passively, tacitly over the
years to come, I arrived at the words ‘LOVE IS
ALL’. Love is all we need and, on a deeper level,
Love is everything; it is all there is.
I would carve these words in oak, but not in
any oak. William is William Holmes, and so
holm oak is the obvious candidate. It would be
difficult to find holm oak in a yard, seasoned or
not, but luckily I bought a small load probably
20 years ago. Some of it, I kid you not, is sitting
The cradle was my first major piece of furniture and the only reproduction piece I have made. I think life
is too short for copies, but David and Caroline live in a Tudor farmhouse that they have restored, so this
was most appropriate. I’m not sure what those pawns are doing as finials – they might be acorns
be careful as the hardness of different fibres the grooves would intersect, but by keeping
varies and the lines can go awry. I did think, their sides to 45°, they sorted themselves out.
years ago, that a V-shaped gouge (a veining The horizontal lines were too thin to cut with
chisel?) would cut the strokes in one swoop, a gouge. I had to go straight in with a chisel,
but however I’ve ground it and honed it, I just almost on the final line. In the finished piece,
cannot get on with it. depending on the light, they are hardly visible.
I aimed for a 45° cut on all lines. Any steeper The serifs punctuate the lines and maintain
and the gouge would mark the opposing slope. readability. This delicacy adds refinement to
There are one or two places (like the top of the the lettering.
A) where it wasn’t immediately apparent how I fancy carving some more lettering but
Lettering is easier
now. Half the job
used to be
draughtsmanship
and setting out.
Now computers
Repro it may be, but with no intent to deceive offer dozens of fonts
in any size you like. I
in my hallway right now. It is heavy, dense and chose Perpetua
beautifully marked. It should be good. Titling MT, printed
I must say at the outset that I am no great the words on three
carver. I’ve dabbled with it from time to time sheets of paper,
but I don’t pretend to be an expert. This, I hope then folded, cut and
you’ll find encouraging. If I can make a fist of it, taped them
anyone can. together
The carving process

I didn’t need many tools. A small gouge and
two chisels did most of the work. A pointed
chisel was good for scraping but I didn’t want
to do too much of that. I imagine that a
professional carver would not scrape at all but
leave the crisp cuts straight from the chisel. I
found an amount of scraping useful but had to

Woodworker’s journal
I laid double-sided tape on the back of the lettering and pressed it down
firmly. The tape gripped well and, at the end of play, could be peeled away
Spacing and positioning is important. Nothing should snag the eye leaving no residue
A gouge, not a chisel, is used to begin the

straight cuts because the curve of the blade
severs the fibres on either side and produces a
clean cut. The first touches are a little timid as a
central channel is established Edward started with the broad verticals, stopping short of the serifs at either end
A chisel is necessary for the inside of the O. You might imagine that the O is
the hardest letter to carve, but not so. Go round and round, inside and out,
maintaining 45° and restraint, and the letter develops by itself. A light
touch is needed with the chisel lest it mark the valley. Edward used a Gouging from either side, not worrying too much about the valley bottom.
wider, flatter gouge to help clean the outer cut Edging back to the lines but keeping clear of the serifs

Hopkins’ home truths
Establishing the 45° slope of the serif. Moving backwards with the chisel,
achieving the correct angle Establishing the point where the three slopes intersect
these letters are about as small as I’m going

to go. Some of the serifs involve tiny chisel
cuts as light as a feather, but a greater
limitation was my eyesight.
Gouges and chisels must be razor sharp. I
spent some time rootling in my box of assorted
tools, and attempted to clean off the rust of
neglect. Then I ground them on a little wheel
– not ideal – following this with a coarse
diamond block so that the hollow was
removed. I then revived an old fine water
stone, polished the back and sides and then
honed the bevel. The bevels on the gouges
were accomplished with the tool held sideways
and rocked with a twist of the wrist. The inside
of the gouges had to be deburred with a small
slipstone. It might seem extravagant to pay for
something you use so little, but when you
need it, nothing else will do. Turning the corner
Making mistakes marks away. And that’s my third mistake: I

The serifs on the size of lettering I chose were had trouble.
tiny. It is a long time since I’ve cut letters so I I might expect trouble. How can I hope to
had to re-teach myself. By the time I’d worked spring from a standing start and create
it out, I’d finished. I found it quite interesting exhibition-standard calligraphy, even if only
though, so I thought I’d carve a bigger letter one letter? This is a more dangerous sort of
so as to show the process more clearly. I chose arrogance, not because it harms anyone else
the letter ‘I’ partly because it is the easiest, but because it harms me. It’s OK to aim high
but also because, if the result is any good, I but I mustn’t be disappointed every time I fall
might give it to Imogen. I chose an offcut of short. I mustn’t take myself too seriously.
holm oak that tapered off to the bark like Neither, of course, must Will and Lucy. I have
some mythical mountain. But by this stage, I a little more cleaning up to do on their piece,
had already made two major mistakes. but I can’t make it very much better. I might
I said I’d made two serious mistakes. I lied: I not have done it at all. I could have had it cut
made three. The first is that I used such damn near perfectly by a computer-controlled
decorative wood. The flecked grain pattern is router. In that case they’d have had ‘printed
so startling that unless it is under oblique matter’ in wood. This way they have the
light, the lines of the carving, and therefore human experience – my human experience –
the carving itself disappear. The second of hoping, aiming, learning... and accepting
mistake was to use such hard wood. limitations. Such is life. They’ll have their fair
Something plain and relatively soft like lime share of it too, but over and above everything,
would have been better. Evergreen oak is the words, the wisdom, ‘LOVE IS ALL’ will, I
much harder than deciduous oak, and as you hope, stay with them. I wish them a long and
might see I had trouble cleaning the tool happy life together. Edward gets his giant I in

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Profile
Mahesh Jangid with one of his intricate carvings
Carving without
bounds
Using minuscule tools called
ulis, the Jangid family from
Rajasthan is carving incredibly
intricate miniatures that
celebrate deities and animals
Mohit Janjid with one of his super-miniatures

Indian carving
Now his sons, both in their 20s, are following shows the beauty of the Rajasthani lady with
in the family tradition. Mohit says: “I prefer our traditional jewellery.
miniature work because I have seen this from “I feel so proud of both my sons. They are so
my childhood and miniature work is the most dedicated to this work, they are always
important thing on our work because it makes thinking about doing something new in this
our items more attractive. We can make all carving work to make it more attractive and
kinds of woodcarving products but miniature beautiful. So I think they will both do much
carving is my favourite.” better in their life. They have already made this
Although he is a graduate he chose to quit carving more miniature.”
his studies in favour of woodcarving. “I’m so So how do they do this? Rohit explains: “First
addicted to my work that I think I can do best of all wood is cut into the desired shape and then
at it and if I do any other job then it will have very fine tools are used to carve out fine details
limits, limited salary, limited time, limited of the design, giving immaculate attention to the
work, all days the same things so I will minutest details. The fragrant wood is profusely
continue this work all of my life. This work has carved with scenes from epics, nature and the
Rohit Janjid needs a keen eye for ultra-fine work no limits, it’s all up to us, always new things, craftsmen’s own creative imagination.
new designs, more miniature work etc. “Woodcarving is not only an ancient but a
I
n the beautiful city of Jaipur a father and Rohit adds: “I like miniature work in my art, very famous craft in Rajasthan. Different kinds of
two sons are carving a living for and we are the only ones who make these kind wood are used for carving depending upon the
themselves in walnut, rosewood, ebony, of carving products with scenes in flipped lids. size and shape of the final product. First of all
teak and sandalwood, working these All scenes have their own story. And I like it the wood is cut into regular sizes and a freehand
woods into miniatures drawn from history, when people are surprised when I show them drawing is made with a pencil on the wood
religion, wildlife and day-to-day living and my work and then I open lids for scenes surface, then the outline of the designs is made
using traditional craft techniques. because they don’t expect this. with the help of a chisel, and fine carving is done
For Mahesh Jangid and his sons Mohit and “We work at home so definitely I will teach with minute tools called ulis. This minute
Rohit it is what they were born to do, to follow this work to my future children, and then if carving involves engraving of the wood on the
the family’s woodcarving heritage. Mahesh they want to go with any other profession then contours of the design with the utmost care.”
was learning to woodcarve at his grandfather’s I will support them. Because I also had these And if even the uli is unsuitable for a
side at the age of seven and by the time he was choices but I picked this carving work for my particular task? Then the trio makes their own
24 had been awarded a national carving prize life. Because according to me if we force tools, using small iron sticks. It’s ingenious
for a hand fan. He also created what is claimed anyone to do any work he can’t be the best in solutions like this that not only keep ancient
to be the smallest jointless chain from a solid that work, so it’s better that I will teach them crafts alive but build upon them.
piece of sandalwood. The chain is 10ft long, and then they can continue this work, but if
has 496 links and weighs 12g. they want otherwise then I will always will be Contact information
His work is celebrated throughout India and there for them.” For more information go to:
has also been seen at exhibitions in Europe, the And what does Mahesh say? “I always enjoy www.mrhandicrafts.com,
Middle East and the Far East. all my carving work but the carving on the call Rohit on +918769599896
Rajasthani doll is my most favourite, because or write to:
These deities were carved from Kadam wood, this we are Rajasthani and this piece shows the E -216 Ram Nager, near water tank,
tree featuring in Indian mythology and religion story of Rajasthani freedom fighters. And it also Sodala, Jaipur, Rajasthan, India , 302019.
www.getwoodworking.com September 2011 GW244 67

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Profile
A
fter Graham Carter has greeted me,
Noah is delighted by his father’s and his wife Alice has gone to the
Puss in Boots puppet kitchen to put the kettle on, he
ushers me into the sitting room of his
East Sussex home and introduces me to their
son Noah. As you might expect with a 3-year-old
in the house, there are toys on the floor, but not
the usual garish plastic variety: Noah is playing
with wooden bricks, from which the faces of
imaginatively painted animals can be built. It’s
not that the Carters are in any way precious;
it’s just, says Graham, that he prefers the
organic material to the manmade.
Originally from Gloucestershire, he now has a
studio in Hove and has been earning his living
from art for the past 20 years, in that time
developing several different styles since training
at Cheltenham, Brighton and St Martin’s. He
left the London college after two years of the
course because he realised that he knew what
he wanted to do and wanted to start hitting the
world with it. So, with some friends from
Brighton who wanted to do the same thing,
they set up an illustration collective; although
they were working from home at the time they
shared expenses like the cost of exhibitions. “I
was doing temping jobs to pay the bills,” he
recalls. “I started to get a good reaction from
things. I’d been in London for two or three years
when I got a commission from Saatchi &
Adventures
Saatchi. I had been in the right place at the
right time – my flatmate’s girlfriend was
working there.” They liked his cartoon-style
presentation, which had to be whipped up in a
day or two, and as a result he won
in Toyland
advertisement work and got himself an agent.
But, he agrees, he was following his head rather
than his heart. “We were warned about that at
uni, but you have pound signs before your eyes,
then after three years you say ‘is that what I
want to do?’ So I left London after four years.
The group was still going well but I left because
Graham Carter’s work, though never I wanted to do my own thing. I moved back to
Gloucester where I met Alice. I’d lived in
conventional, was two-dimensional Brighton before so we upped sticks. Alice is a
creative person who pushed me to do things.”
until he discovered the joys of wood. Turning point
Andrea Hargreaves meets him He learnt how to screenprint and the turning
point came in 2007 when they showed his
Detail from Arctic Fox, one of the first of his 3D pieces to sell at his
Graham got into laser-cut designs with pieces like New Yokyo Airbug successsful Brighton Festival show

Graham Carter
The Wood Baboon musing on the constant need for change in

celebrates joyous the race to offer something different.
colour “Technology advances and there are more
people doing what you’re doing.” For
instance, going back to the screenprinting, he
was one of the first people to realise you
experimental work and found that it sold well last year, seaside characters heavy petting in a could buy your own giclée printer at a
and was picked up by Art Republic. At the same saucy postcard look which really lent itself to reasonable price…
time his commissioned work dried up “so I took hand cutting for a cruder look. I paint the pieces Now he fancies taking his 3D work a stage
it as a sign and ran with it,” developing his and sand them back, then paint again. I might further by learning to carve wood in the
radical 3D multi-layered work using laser-cut do some more of those. round. “Because my work is eclectic it would
wood. “I was gobsmacked with a friend’s laser “For laser cutting you have to trace all the suit the old-fashioned toy look on a bigger
etchings,” he says. “That opened my eyes to lines onto a Vector format. The shape has to be scale,” he says, referring to a suggestion by a
what you can do [with the process].” traced in Illustrator and I send the Vector files blogger to make a puppet on a fairytales and
Graham starts off by using PhotoShop and to the laser guy.” folklore theme. Loosely based on Puss in
Illustrator to design in multi-layers and then When I visited Graham he was in the middle Boots, Graham’s sports a bionic arm for a
translates this into actual 3D pictures. “Wood of a successful month-long show at Brighton’s modern twist, and eyebrows that can be
lends itself to this very well.” He likes to give Ink_d gallery as part of Brighton Festival, and moved multi-directionally for the amusement
the flavor of old-fashioned wooden toys that the 3D work at £1000+ a pop, on his favourite factor. On cue, Noah, who has been eating
can be screen-printed for an aged look. quirky animal theme, was selling well along his supper in the kitchen, runs in, seizes the
“I design a piece on PhotoShop, separate it with his more affordable screen prints. “I puppet with delight, happily removes its
then gauge the distance in the real world. I experimented with different varnishes to get a head and wiggles its expressive eyebrows.
made a few mistakes getting the distances and penny arcade look to it. I find it fun to play with Who needs plastic when wooden toys are so
thicknesses right. I normally work in 3-4mm modern ideas but set it in a vintage setting.” much more delightful?
plywood and MDF that is made specially for
laser cutting by Hindley and by Hobarts. I go to More in wood Contacts
a company called Heritage Inlay in Brighton and And for the future? It’ll be a-changing. “I’m Graham Carter, www.graham-carter.co.uk
he has a CNC machine the size of a photocopier. hoping to get involved in marquetry with Heritage Inlay, www.heritageinlay.com
There are some hand-sawn parts using a jigsaw furniture makers. I would be interested to see Hindleys, www.hindleys.com
and a Dremel. I was doing a piece for a show how we can work together,” he says, before Hobarts, https://hobarts.com
Bee Revival depicts the lifecycle of the honey bee Detail from Bug Lady

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Jordan’s frame ls
l Build: Mike
lettering chise
gets out his lery
rd Hopkins his wife’s jewel
l Carve: Edwa es a stand for
09:09
12/06/2015
l Turn: Les
Thorne creat
5.indd 1
01 GW294ah
Men in their Shed

The Ash, near Aldershot, Shed provides warmth, woodworking facilities
and company for men, mostly retired, who like to make things. Many of
our projects are communal, designed for sale in the local pet shop or
supermarket, where generous managers have offered us display space.
The bird tables are hot items, and someone is likely to be producing
parts, or assembling one of them at any given time. The hedgehog
‘retreats’ are being prepared for next autumn, with
dimensions supplied by the Hedgehog Protection
Society website; production models will probably
feature pitched roofs to match those of our bird LETTER
tables. A sort of ‘house style’, you might say.
OF THE
Donated tools
Some of the materials and tools have been donated
MONTH
by local supporters, and the remainder are bought by
John Fairs, the coordinator of and expert tutor to the
Shed. John, also retired, had a career working in joinery and
colleges, and used to be in charge of the Joinery section at Guildford
College; now he is employed on a part-time basis by Age UK to supervise
and encourage up to six men in each of four sessions per week. His
profound knowledge and woodworking skills are essential to the men,
but his patient, caring nature is just as important.
The group offers repair work, an offer that has been taken up on
behalf of community garden furniture, and the damaged council sign
for a local park. Reclamation, reuse and restoration feature strongly
– maybe that’s true of the men too!
The small machines, neatly established down one side of the ’shop,
are very important when modifying and repairing – working to
non-standard dimensions. They are noisy, as is the dust extractor, but
our work is unpressured, and those who do not want to don ear
protectors can usually go outside for a few minutes with a mug of to pay for.
tea. At 20p per mug, tea is about the only thing that members need A comprehensive collection of electric drills, saws and routers, and a
generous arsenal of hand tools are neatly stored around the benches
and in the cupboards. The drill stand, heat gun and chopsaw all live in
their allocated homes, two of them with specially made jigs to make
them fit the bench and be safe.
The whole ’shop, including the benches, was designed and converted
by John Fairs and his friend Bill, ingeniously converting a former minibus
garage into a purpose-built workshop.
Wood storage is provided below the benches, and on shelves high on
the walls with captive ladder; beside the benches are several small but
key machines – saws and planer-thicknesser, which can be rolled out
when needed, and the dust extractor. Age UK, Surrey arranged with the
local council for running water, heating and electricity to be installed.
And, since the ’shop is in the grounds of the Shawfield Day Centre, Ash,
this provides facilities such as parking, toilets, café, even computers. I
wonder how long before one of us boots up a SketchUp design
programme on one of those?
John worked on the project for most of a year, drawing it all out on
AutoCad initially, and always struggling to fit everything into a rather
small space. The only external ‘extra’ is some space for wood storage in
a neighbouring garage.

WRITE & WIN!
We always love hearing about your projects, ideas, hints and tips,
and/or like to receive feedback about GW’s features, so do drop
us a line – you never know, you might win our great Letter of the
Month prize, currently a Trend Snappy Colour Ring bit set. Write
to the address on the left for a chance to enhance your marking
capability with this versatile workshop aid.
The Shed concept was first realised in this for Living Well and Ageing Well in Surrey, 2014.
country by Age Concern, Cheshire in 2009. Now Not bad for their first year of operation, and a real
there are over 80 Sheds open in the UK, with recognition for the founders, their foresight and
many others planned. While many of them are meticulous preparation.
focused on woodworking, the specific task is
selected by the men involved. We are all finding In the community
ways of working alongside others towards a An important function of the current year’s
chosen purpose – helping, co-operating, sharing, activities is to participate at the Community Rural
discussing and offering additional materials. For Activities Day. The exact nature of our participation
some it could be a 3-hour tea break, while others has yet to be finalised – democracy in action! – but
feel a need to create something in a well-designed last year the members prepared components for
facility. We’ve got the space and equipment to do youngsters to assemble into models which they
things most men can’t do in their homes. And could take home. A possible introduction to
usually, a man working in his shed is all alone, and woodworking as a hobby or career? Who knows,
even family members tend to leave them to it, but it is certainly helpful in triggering local support,
reluctant to disturb the creative process or scared materials to be recycled, or tools ready for re-use
of the tools and machinery they might encounter. after their owner lost interest in using them.
The movement began in Australia when men The organisers are keen to expand activities,
realised they could come together around and perhaps to include young men, veterans and/
practical tasks on a regular basis, if they had a or unemployed, who could gain skills, experience
designated place where tools and work-in-process and self-confidence. The movement has much
could be stored. Its success indicates what can be potential.
done to alleviate much of the feeling of social Peter Benson, by email
isolation which can occur later in life, as one loses
a working role, status, workmates and long-time How great it would be to have this project rolled
partner. Research by Age UK shows social isolation out all over the UK, so there is a Shed where men
can affect health and quality of life, with drinking – and women – can go to enjoy woodwork in the
problems, smoking and over-eating all connected company of others, and with shared machines.
to them. Peter refers readers to www.bettershedthandead
Making their own contribution, the Ash Shed and remarks that the first half is excellent.
last year saw them receive a well-deserved Award Andrea Hargreaves
MDF tests to follow

I must comment on the reader’s letter from Geoffrey empirical tests soon
Laycock concerning my homemade Dust Deputy. using MDF dust to see
Geoffrey mentions the ratio of the cone to the how much gets
pipes are wrong but I took the measurement trapped in the
details from Oneida's website and followed them container and how
almost exactly. The details are freely published on much gets through to
many websites. the extractor.
I take his point on the inlet pipe not being The extractor is
tangential but on the inside there is a right angle one of Ted’s homemade Dust Deputy is
joint pointing down and at an angle to create a Numatics’ working well
spinning cyclone effect. I just found it easier to professional
follow the contour of the cone and deal with range, twin motor with double filtration so I
fixing the problem on the inside. cannot see any airborne dust problem, but as the
Oneida name their Dust Deputy as a cyclone system is very new I will keep an eye on it.
and are one of the leading dust extraction Ted Hughes, by email
manufacturers.
I hope this clears up any confusion and the unit Thanks for the clarification, Ted. This
is now fitted to my new dust extraction system correspondence is now closed.
and working really well. I Intend to do some Andrea Hargreaves

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House andINGarden
ASSOCIATION WITH
I’d almost forgotten Q&A

just how efficient a Biscuits or pocket screws?
Tormek wetstone
grinder can be, Q When making a framed door for a
cupboard from softwood or hardwood
with a plywood panel in the middle, how do
The top rail and stiles should be the same
width, while visually it’s better if the bottom
rail is wider. In both softwood and hardwood
with no risk of you decide how wide to make the rails and rails and stiles usually finish about 20mm thick
overheating any stiles? Is there a formula that you can use to (from 25mm sawn timber), though you may
calculate these dimensions, such as a want to reduce this thickness on a small
edge tool in contact with the percentage of the width or length of the cabinet. Assuming the panel is about 6mm
wheel. Less intimidating than a door? For example, if I’m making
a door 500mm long x 300mm
fast dry bench grinder, too. A wide, what should the width of
rails and stiles be?
need to restore the bevels on a K Nairn, London
couple of chisels the other day
resulted in a mammoth
sharpening session. With the
A It’s always best to make a
scale drawing before cutting
any timber, no matter how simple
the design. That way you can get a
grinder set up on a Workmate pretty good idea if rails and stiles
outdoors, the weather was too will look too heavy, too narrow or
generally out of proportion.
good to be indoors. What There’s no hard and fast rule,
could be better than fettling a though when using softwood for
joinery work it’s traditional to use
few tools outside in the stock sizes, planed timber (PAR)
sunshine? Apart from walking you can buy off the shelf. For a
cupboard door I’d suggest 75mm
the South West coastal path in or 50mm timber would be
suitable. These sizes are nominal
glorious weather, that is… and are dimensions before
planing. So, 75 x 25mm sawn
timber actually finishes at about
70 x 20mm after machining, while
50mm softwood finishes at about
45mm. With this in mind, try
drawing rails and stiles at 70mm
Phil Davy, Consultant Editor or 45mm to gauge the overall
effect. You may find a compromise
(say 60mm) looks better.
If using hardwood then stock sizes are less thick it will take up about one third the timber
relevant, as here it’s only board thickness depth if using 20mm material.
which is standard. That said, stick to nominal You also need to consider the type of hinges
softwood sizes and you won’t go too far used to hang the door. If using concealed
wrong. If you have access to a planer/ cabinet hinges (eg Blum), these require
thicknesser, life becomes easier as you can 35mm-diameter holes, which can affect stile
prepare material to whatever size you like. Of width. If using butt hinges stile width is not an
course, you can still plane up components by issue as you only need to think about timber
hand. thickness.

House and Garden
Summer project
Takes: one weekend OAK GARDEN TRAY
Toolsed
you’ll ne, sander,
Router, jigsaw
drillstand
Going potty
Phil Davy’s tray is made from recycled
During a major clear out last year I
unearthed an old plans chest that had
oak which will now have a new life in definitely seen better days. Although
made from oak, it had been exposed to the
his garden elements and most of it had rotted away.

Fortunately, I was able to salvage a few drawer
fronts and sides, the timber displaying some
lovely figure. It was limited in dimensions, and
I wondered how best to use this attractive oak.
The answer was this garden tray, compact
enough not to take up too much space but with

House and Garden
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Fig 1: Garden tray
sufficient capacity for transferring plants to diameter plastic pot in each compartment. snug fit it’s best to rout the housings first,
the garden or holding a few small tools. If you don’t enjoy cutting dovetails this then thickness the divider material so this is a
Slats for the base mean drainage from damp project is ideal for finger jointing the corners. A sliding fit. That way you’re thicknessing to
plants or soil should not be a problem, though dedicated finger-jointing router jig makes the match the router bit diameter exactly.
these could be fitted closer together to make a technique straightforward, though if you have Stop the housings 5mm below the top
multi-purpose tray. Great for the home office a decent router table, a sliding fence and edges of the tray. The handle and dividers are
or kitchen, though you may want to reduce sacrificial board will still make it feasible. cross-halved so they slot together. Use brass
overall size for indoor use, or adjust the divider Dividers and handle fit into housings a third or copper pins to secure them to the tray
spacings. As it is, you can just fit a 76mm- the thickness of the outer tray timber. To get a sides, though pre-drill holes first.
1 When recycling timber always remove 2 Inspect all surfaces closely for defects 3 True up face edge of side and end pieces
old screws or nails first. If rusted, plan saw cuts and cut off damaged ends. Thickness clean with bench plane and shooting board. Check
to avoid defect timber to 10mm with straightedge
4 Trim ends square on shooting board. 5 Mark each tray component for width 6 Saw sides and ends 2mm over-length for
Cramp pieces together, face edge down, and and cramp together. Place on flat surface and trimming joints later. Scribe shoulder lines for
plane to width plane to width dovetails with marking knife

House and Garden
Summer project
Takes: one weekend OAK GARDEN TRAY
7 Space dovetails to allow for 5mm rebate 8 Mark out tails with sliding bevel set at 9 Set gauge to 5mm and mark rebate for
at lower edge. Cramp boards together and 1:8 angle (for hardwood). Alternatively, use bottom slats. Pencil in waste to be removed
square lines across dovetail marker gauge between tails
10 Secure both tail boards tightly in 11 Remove waste between tails with 12 Cramp square timber block along
vice at an angle. Cut down sides of tails coping saw, keeping blade teeth clear of shoulder line to keep chisel upright when paring
with dovetail saw shoulder line back between tails
13 Cramp pin board in vice and lay tail 14 Pencil in waste between pins. Saw 15 Remove waste with coping saw as
piece across horizontally. Carefully mark out down sides of pins to form sockets, keeping the before. Pare back to shoulder line with
pins from cut tails blade level bevel-edge chisel
16 Holding chisel at correct angle, trim 17 Create 5mm-deep rebate along bottom 18 Cramp parts together and cut 3mm-
sides of pins (sockets) as necessary. Check joints edges for slats. Cut this on router table for deep housings for dividers. Run router against
fit, and adjust accuracy guide batten

House and Garden
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19 Housings are stopped 5mm below top 20 Clean up inner surfaces and check for fit. 21 Once glue has dried, trim protruding
edges. Square rounded ends neatly with chisel Glue and cramp up tray, checking for square dovetails flush with finely set block plane
22 If required, glue boards together to 23 Draw handle cutout with flexible curve 24 Mark hole centres and cramp board to
achieve sufficient width for carrying handle. or arched steel rule. Allow enough width for backing material. Bore ends of cutout with
Thickness when dry sanding drum 25mm flat bit
25 Remove remaining waste between 26 Clean up cutout with 25mm sanding 27 Handle and dividers are slotted
holes with jigsaw. Use this for sawing tapered drum or rasp and file. Smooth edges with together. Mark out halving joints and carefully
edges of handle abrasives cut away waste
28 Thickness slats to 24 x 5mm and saw 29 Rout small decorative chamfer along 30 Brush on two coats of finishing oil,
to length. These can be pinned or screwed edges of tray and dividers. Sand with 180grit wiping off after a few minutes. Alternatively,
into rebates abrasive add wax if for indoor use

House and Garden
Useful kit: Skil Fox 2 in 1 sander
Foxy fixed
Its 18V…
speeds There seems to be a growing number

of budget 240V multi-purpose
sanders available these days. Hardly
surprising when consumer brands compete to
tempt the user who may only want to buy one
sanding tool for occasional work. For finishing
a variety of surfaces this can make such tools
an attractive option, although whether they
will perform as well as dedicated single-format
sanders is perhaps open to question.
Unlike the Ryobi model we tested in
GW291, the Skil Fox combines a disc sander Bases are speedily swapped via a hex key The delta base can be swivelled in any direction
format with a delta pattern. This time you only
need remove one retaining screw to swap the
bases, though. A hex key is provided for this
and it takes no time at all. The delta base is
unusual in that you can swivel it to any
position, even pointing backwards. Like many
sanders the front triangular pad is attached by
Velcro and can be removed fast and rotated as
the tip wears. All pads feature hook & loop
fixing and a reasonable number of abrasive
discs and sheets is supplied.
Electronic braking The pads are secured with hook & loop fixings… …and several discs and sheets are supplied
Instead of variable speed, the Skil has two
fixed speeds (9500 and 13,000opm), activated
by the 3-way power slider button. This works
well and I found it more effective than relying
on a speed dial, which invariably gets left set
at maximum. You can instantly switch
between speeds, which arguably is all you
need. Electronic braking means the tool
comes to a standstill quickly. With the
125mm- diameter pad fitted you have a fairly
efficient sander for those larger flat surfaces.
Although this is not a true random orbit
mechanism – there are inevitable swirls left on The fixed speeds are activated by a 3-way The 125mm pad copes with larger flat surfaces
the surface – it’s still pretty effective. slider button
Motor rating is 250W, while cable length is
2.8m. Weighing 1.3kg, this is a fairly tip out the contents. No adaptor is provided certainly an advantage. Don’t forget that the
lightweight tool, so not too tiring for vertical for hooking up a vacuum extractor, though Fox is not a professional power tool, so it can’t
or overhead work. There’s plenty of soft-grip this is an extra accessory. be expected to work for extended periods
rubber where it’s needed, adding to the Fox’s without overheating.
ergonomic credentials.
Dust collection is via a rigid plastic box Conclusion
which is a push-fit at the back of the tool. Sanding performance was better than Typical price: £69.99
Inside appears to be a fabric filter, though you expected and it’s a comfortable tool to Made in: China
can’t access this. Once the box is full you just operate. Having the disc sander option is Web: www.skileurope.com

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Turning
Gem of a design
When Les Thorne
was asked to turn
a necklace stand
he knew it would
have to hold other
items too…
Y
ou must all think that ‘management’s’
dressing table would be full by now,
being home to all sorts of handy
wooden turned items of treen, but
no, the request for a necklace stand came in
after seeing one made from wire at a shop.
I don’t often have to design things from
scratch because I can normally find something
similar in books or on the net, but I struggled
to find something that I liked. A couple of
issues needed to be overcome while designing
the piece. It needed to be of a height that
allows longer items of jewellery to be hung;
this means the base would have to be heavy
enough and wide enough to stop it toppling
over even when there was too much hung on
one side.
The other thing that I was requested was
somewhere from which to hang bracelets. This
meant that another pair of arms was needed
lower down. The idea of making the base into a
bowl was mine, allowing rings, earrings and
brooches to be placed into it.
I think that it’s really important to make this
type of work stylish and elegant because too
chunky a design would look terrible on a
dressing table, and I hope I have got the
balance of this piece just right. Feel free to copy
it and do let me see your finished pieces.

Jewellery stand
▲ Pic.1 A great piece of wood, this yew plank ▲ Pic.2 Instead of cutting the blank for the base ▲ Pic.3 One of the problems with yew is the
had been hanging around for a long time. There round he has cut the piece into a octagon on the appearance of faults like this. Silver shake
are some defects in it but Les should be able to bandsaw. This saves wearing the set on your appears naturally in the timber and is very
work round them bandsaw blade unevenly difficult to fix, so is best turned away
▲ Pic.4 The shallow base means that Les has to ▲ Pic.5 True up the base with the bowl gouge. ▲ Pic.6 Make the bottom flat or slightly
use a spacer block to shorten the screw chuck. Keep the bevel pointing in the direction of the concaved. A pull cut with the gouge or a light
He could also have glued it onto a wooden cut and keep the flute pointing at 10 o’clock to cut with a scraper is perfect, sliding your hand
faceplate achieve the best finish along the toolrest to guide the tool
▲ Pic.7 Les is marking the diameter of the ▲ Pic.8 The recess depth is 3mm, allowing the ▲ Pic.9 Shape the base with a pull cut with the
chucking recess on the bottom. The left-hand hole to be plugged with hardboard before the gouge, this being the quickest way to remove
point makes a scratch that will line up with the baize is applied. The chuck’s sharp dovetail jaws timber. If the flute of the tool is too shut you will
mark on the right when correctly aligned will grip the shallow hole blunt the tool quickly

Turning
▲ Pic.10 Any detailing such as this small fillet is ▲ Pic.11 The edge bead is rolled over using the ▲ Pic.12 Before doing the shaping on the top,
cut with a skew used in scraping mode. The tool wing of the gouge. The beads on a cross-grain drill a 30mm stem hole with a saw-tooth bit.
is flat on the rest and gently pushed into the piece like this are turned the opposite way to Slow the lathe down to about 400rpm when
wood spindle work doing this
▲ Pic.13 Work the gouge in from the centre and ▲ Pic.14 He has swapped to the small Signature ▲ Pic.15 The finish left by this tool is perfect.
then down from the edge. This is because Les gouge because the bevel of this tool will fit When turning yew you really have to be careful
decided to make a small bowl on the base perfectly in the tight curve on the edge of about rubbing too much bevel as you can end up
the base with ridges on the wood
▲ Pic.16 When sanding the shape don’t round ▲ Pic.17 The stem is mounted between centres ▲ Pic.18 Les has now marked on the fixed areas,
over the edges. The main benefit of hand turning using a small Stebcentre. The spigot on the like the overall length and where the small
is that you can achieve really crisp edges that bottom has to be a really tight fit so use Verniers lower arms come out
cannot be done on most automatic lathes to gauge the right diameter

Jewellery stand
▲ Pic.19 The 10mm skew is used for all the V ▲ Pic.20 The small gouge is used for cutting the ▲ Pic.21 When you have a large cove like this
cuts as it achieves really sharp deep grooves. Be coves. The small bevel will only put a small you can break it up with a bead in the middle. As
careful about thinning the work down too much amount of pressure onto the timber. A long stem the piece gets thin you can support the spindle
too quickly can be built up with a series of these shapes with your finger as you are turning
▲ Pic.22 When turning coves keep the tool ▲ Pic.23 Les really likes these tight little details. ▲ Pic.24 The flat left in the shaft is for the arms
handle tucked into your body. As you cut this Turning such narrow coves you will have to be to come out of. I thought about putting a cove
shape make your body go through to the right as careful not to catch the right-hand side when here and in hindsight I should have – Mark II will
you slide the tool through the cut cutting the left and vice versa have one
▲ Pic.25 Les is using the indexing on his lathe ▲ Pic.26 He is turning the top spigot down to ▲ Pic.27 The small gouge is used to blend a cove
as well as a purpose-made drilling jig. He could 10mm to fit into the top cross member. It can be into the spigot. This tends to hide the hole when
have done it carefully freehand or using the worth taking a little tailstock pressure off at this it’s all glued together. Don’t be afraid of getting
banjo instead of the toolrest point to prevent splitting right up next to the centre

Turning
▲ Pic.28 The small arms are mounted between ▲ Pic.29 The bead is turned next to the drive ▲ Pic.30 Les is happy with both of them. A good
centres and roughed round to about 20mm. Turn centre. The 10mm skew is used, this tool match has been achieved by marking out and
the spigot on one end and take the waste down allowing a good finish and only a little of the top measuring. The little gun barrel design on the
at the headstock end to be finished by hand right of the bead is particularly pleasing
▲ Pic.31 The top cross member is mounted up ▲ Pic.32 Cut a series of coves along the length, ▲ Pic.33 He decided to finish the ends in a
last. The dark area in the centre will be where working from the tailstock end towards the mushroom-top shape. You can take down the
the hole will be drilled. He marked out a series headstock. Not only do they look decorative but shape just leaving a few millimetres of timber
of coves by eye they will also stop the jewellery falling off remaining
▲ Pic.34 Once it’s all glued together you can put ▲ Pic.35 For a glossy finish Les omits sanding
baize on the bottom. This is Les’s new circle sealer on this dense timber, and applies lacquer
cutter, the benefit of which is that it doesn’t followed by burnishing cream when the lacquer
make a hole in the middle is dry

WEB DIRECTORY
TOOL RESTORING & SPECIALIST EQUIPMENT
July 2015 GW294 85

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86 GW294 July 2015
TIMBER SUPPLIES, COURSES & SPECIALIST TOOLS
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DESIGN MAKE TEACH
SHORT COURSES
IN WOODWORK & FURNITURE MAKING
Yorkshire based Chris Tribe has been

teaching and making fine furniture since
1990. He offers half to six day courses from
basic skills to veneering and laminating and
dovetailing and drawer fitting.
Individual tuition also available.
christribefurniturecourses.com
The Cornmill, Railway Road, Ilkley LS29 8HT
Workshop: 01943 602836 Mob: 07817 456241
Email: chris@christribe.co.uk
July 2015 GW294 87

SHOP & WEB GUIDES
LEEDS
D.B. KEIGHLEY
MACHINERY LTD
Vickers Pleace, Stanningley,
Leeds, LS28 6LZ
Tel: (0113) 257 4736
Fax: (0113) 257 4293
www.dbkeighley.co.uk
P. A. CS. BC. MO.
LDEN TOO Router cutters

EA
Spindle tooling
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CO Bandsaw, jigsaw &
£3.25 MPAN Y
circular sawblades
FREE P&P
The Modelmakers Yearbook 320 PAGES Online catalogue & ordering
ANNUAL 2015 • ISSUE NO.45 • www.hobby.uk.com
NEW RC
www.wealdentool.com
DOLLS
MODELS HOUSE
REVELL SPECIALISTS
MODEL KITS
MATCHITECTURE
BUILDINGS
DREMEL
RANGE OF TOOLS
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NEW ARTICLES ...to advertise
NEW FRETWORK
MARQUETRY KITS here please
FREE PL ANatchstick
Working Mher Clock
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call David on:
Hobby’s (Dept GW), Knight’s Hill Square, London SE27 0HH
020 8761 4244 mail@hobby.uk.com www.hobby.uk.com
Available at WH Smith & leading newsagents or direct
01689 869 867
Musical Instrument Makers’ & Repairers’ Supplies
Largest selection of tonewoods, tools & parts in the country.

Visit our website or order our catalogue. Callers welcome
Touchstone Tonewoods, Albert Road North, Reigate, RH2 9EZ
Tel: 01737 221064 Fax: 01737 242748
www.touchstonetonewoods.co.uk
88 GW294 July 2015

WIN!
NEXT
MONTH
GW295 on sale 24 JULY

WIN TOOL CHEST & COURSE
Now here’s a competition every aspiring
furniture maker would like to win! Esteemed
maker and course provider David Savage is
offering a tool chest and a one-week course
at Rowden, his North Devon workshop, to the
“best and most deserving young maker in
the UK.”
MEET SCRUFFY DOG

Here we are slap bang in the middle of the
festival season. Glasto’s in full swing but
there are lots more to enjoy this summer,
and it’s more than likely that an enterprising
company called Scruffy Dog may well have
had something to do with their set designs.
Dave Roberts investigates
LAPPED DOVETAILS
In this latest instalment of his foundation
course Michael Huntley pulls out all the stops
– pardon the pun – to show you how to make
lapped dovetails, the kind that are usually
found on drawers, and details their setting
out and cutting
PLUS...
Dave Roberts offers his unique take on wood-
working problems and solutions, Andy King
scrutinises the latest tools, Phil Davy has a
weekend Around the House make and Les
Thorne lets his lathe do the work
Finishing Touch
Origin
of Michael Huntley’s
locks history of locks
Two early 18th-century steel locks; the one on the left has a link plate
A George IV lock with cover plate removed to A bureau lock and a small box lock A tumbler lock similar to a Bramah lock
show levers and spring
The earliest locks were pin tumbler locks,

sometimes known as Egyptian locks, and date
In 1818 Jeremiah Chubb made locks with a
mechanism that detected interference with the
Resources
from about 2000BC. They consist of a bar and levers by anyone trying to pick the lock. The lock Suppliers of locks for furniture,
some pins; the pins drop to lock the bar and are then seized and couldn’t be opened unless you www.j-shiner.co.uk
pushed up with the ‘key’ to unlock. Roman locks had the correct key. From Chubb’s improvements Forum about studying locks,
were much more like modern locks. They had furniture locks remained very similar until the www.antique-locks.com/
‘wards’, little metal strips around the post that mid 20th century except for Bramah locks, which Supplier and authority on locks and keys,
had to match the slots cut in the ‘bit’ of the key. are a special type of tubular pin tumbler lock that http://emorlands.com/
From Roman times until 1778 locks had more is almost impossible to pick. The Handyman’s Book,
and more complex wards, German One or two specialist locks are worth PN Hasluck, Cassell & Co.
metalworkers being very well known for their mentioning. A bureau with a sloping front will
intricate locks on strong-boxes designed to hold require a lock with the fore edge sloping and a The Complete Book of Locks and
money and jewels. special keep that matches the slope. A box or Locksmithing,
In 1778 Robert Baron invented a system using chest lock will have a link plate that has hooks CA Roper, Blue Ridge Summit, Pennsylvania:
levers held against a spring, that had to be lifted fitted to it, the lock itself having a specially Tab Books, 1991.
a precise amount and in unison. These were designed bolt to secure the little hooks. Lock and Key,
much harder but not impossible to pick. The Encyclopaedia of Locks by Joshiah Parkes Stephen Tchudi, New York: Scribner’s, 1993.
In the 18th century many locks were made in listed 120 specialist locks in 1958.
small-scale enterprises around the Midlands Well-known manufacturer’s names are
which sold to travellers who then sold on to Chubb, Goodwin, Parkes, Marshall, Showell,
retailers. Vaughan.

Unit 2, Sovereign Business Park, Joplin Court, Crownhill, MK8 0JP MILTON KEYNES
Tel: 01908 635 000, info@ukfelder.co.uk, www.ukhammer.co.uk Combination machine
C3 31 Comfort
COMBINATION
MACHINE +
STARTER-SET
• 4.0 HP (3.0 kW) motor
• Format sliding table 2000 mm
• 1100 mm outrigger table
• Precision mitre index system
• 1300 mm crosscut fence for outrigger table
• Planer fence tilts from 90° to 45°
• Surface planer table length 1400 mm
• Planing width 310 mm
• Remarkably user friendly
• Allows rapid retooling
6.718,05
5.390,00
Save up to 1.328,05 £ excl. VAT
Universal saw blade Cutterhead set

Ø 315 mm, Z 48 Universal cutter head
(steel made)
+ + AF 12 dust extraction extractor

with dust bag quick change system
Introducing the Brand New Range of
Woodturning Chucks and Jaws
We are extremely proud to introduce the brand new range of Record Power woodturning chucks and jaws.
This exclusive new range has been developed using Record Power’s extensive experience and knowledge of
woodturning in conjunction with a group of highly experienced professional and hobby woodturners, to bring
you the ultimate in quality, versatility and value.
Precision Engineered Gears Jaw Fixing System Heavy Duty Jaw Slides Sealed Backing Plate with
Super Geared True-Lock™ technology The SC3 and SC4 feature a jaw The improved and enlarged jaw slides Full Indexing
ensures high levels of accuracy to fixing which will not only fit give unsurpassed holding power and The SC4 features a strong backing
provide smooth and solid operation. the Record Power series of Jaws but load bearing ability. They are made plate to protect the gear mechanism
is also fully compatible with Nova and from high tensile steel, reinforced with from dust and 72-point indexing
Robert Sorby brand jaws. nickel and copper and heat-treated to around the full circumference.
ensure superior strength.
Brand New
Exclusive
Jaw Range SC3 Geared Scroll SC4 Professional
ble
Fully compatiand Chuck Package Geared Scroll Chuck
with Nova br £119.95 Package
chucks
£149.95
Prices valid until 31.8.2015 See online for full details
Incorporating some of the most famous brands

in woodworking, Record Power have been
manufacturing fine tools & machinery for over
100 years. Built to last we provide support for
thousands of machines well over 50 years old,
which are still in daily use. Testimony to the
www.recordpower.co.uk Tel: 01246 571 020 sound engineering principles and service support
that comes with a Record Power product.

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What are some well-known manufacturers of locks mentioned?

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MADE IN ITALY

Issue 294 £4.25

When you buy 6+ PACK

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CALL 0808 168 28 28 Solid Drawn Hinge

0808 168 28 28 IronmongeryDirect.com FIND US ON

© MyTimeMedia Ltd. 2015

www.getwoodworking.com July 2015 GW294 3

Tools Projects Techniques Advice

The No.1 magazine for aspiring designer

l Carve: Edward Hopkins gets

Intricacy in India 62 Italian job 20 7 Piece Screwdriver &

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Felder opens new

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Students at Peter Sefton’s Furniture School learn on Felder’s Hammer

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original facing was glued rather than pinned power: the

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ÄUPZOPUN[V\JO[V High quality, bespoke dovetailed drawers