Showing posts with label Woodworking in America. Show all posts
Showing posts with label Woodworking in America. Show all posts

Woodworking in America Conference II

Since I had such a great time at the Woodworking in America Conference last November in Berea, I'm happy to say I'm planning to go to the next one in St. Charles, Illinois (near Chicago) from August 14-16. The first WIAC conference focused almost exclusively on handtools and technique. On top of that, the marketplace between sessions (or during them if you skipped!), was a handtool free for all. It was great, but sometimes you have to stop focusing (or fixating) on thousands of an inch and step back a bit. If the first WIAC was left-brained, the next one is going to be right-brained.


Design is more about the qualitative than the quantitative. It's one thing to read about methods for cutting dovetails; it's quite another to read how to create something out of nothing. Where do you begin? Do you have a style in mind or are you making up your own? What are your client's requirements? What are your influences? What is your budget? What materials are available? The list goes on. Even if you are following a plan or making a reproduction, you still need to design it to some degree. You have to make decisions on dimensions, wood grain, joinery, finishes and everything else. I'm looking forward to hearing what some accomplished furniture makers have to say about their design process and how they answer some of these questions for themselves.

I'm going to do my level best to avoid visiting one of the golf courses at the meeting site but please keep in mind that I'm only human. I'll try to write as much as I can about the sessions and the general scene (here are my posts from the last one). You can find information about the conference at www.woodworkinginamerica.com. Please contact me if you're going to attend. I'm sure there are some beverages that will need to be consumed.

Woodworking in America: Berea Arts Council

If I haven't said it already, one of the great things about the Woodworking in America conference was the venue -- Berea, KY. The northeastern part of Kentucky is gorgeous, with rolling hills, horse farms and cool little towns. Berea is a college town, home of Berea College, which has its own interesting history.


In the downtown area, near the historic Boone Tavern and several galleries and restaurants, is the Berea Arts Council. During the weekend of the conference, they held an exhibit of furniture by Berea-area woodworkers. They had a chair by Brian Boggs (even though he moved away from Berea, they still claim him as their own), a table by Kelly Mehler and furniture, turnings and carvings from a couple dozen other artists.



The chair, above, was made by David Wright. The turning was by Jack Fifield. Both photos were by Gin Petty. One of the most interesting pieces was a reproduction tool chest by Don Weber. The original was discovered in Mästermyr on Gotland in 1936. It was preserved in a bogg and dates back to 1100 A.D. Weber recreated the chest and made the wrought iron hardware as well.


This was a great sampling of local woodworkers and shows the concentration of talent in this area. You can read more about the Berea Arts Council and their work at www.bereaartscouncil.org.

Medullary Rays -- Update

A couple of folks have mentioned Bruce Hoadley's book, Understanding Wood, as a great resource. Brian Boggs recommended it during his session, and I should have mentioned that. Interestingly, he said he wouldn't recommend Hoadley's other book, but that's neither here nor there.

Thanks for the suggestion!

Woodworking in America: Medullary Rays

One of my big take-aways from the conference was learning about the medullary rays in trees, a topic addressed in the session on wooden planes with Don McConnell and Larry Williams from Clark & Williams Planes and Roy Underhill. Brian Boggs also talked about medullary rays in his seminar on understanding wood for chairmaking.

The medullary rays are wood fibers that run perpendicular to the grain. They are what gives quartersawn white oak the flecks that are integral to the beauty of Arts & Crafts furniture. With the flecks, you are seeing end grain, which is darker in color than long grain and causes the contrast.

In a tree, the medullary rays help stabilize the structure and allow moisture and nutrients to flow back and forth, while the grain of the tree allows the moisture to flow up and down. Generally speaking, all trees have medullary rays, though they are more pronounced in some species than others. Medullary rays start in the center and run straight out like the hands of a clock.

They stabilize planes in the same way they stabilize trees. For planes, which are also often made of quartersawn lumber (Beech in the case of Clark & Williams planes), the medullary rays help distribute moisture from one side of the plane to the other. This effect helps keeps the wood stable as it counteracts the effect of the moisture running the length of the plane through the end grain.

Brian Boggs spoke about medullary rays in the context of finding parts of the tree that serve different functions as parts of a chair. My memory on which parts go where is a little sketchy here, so if anyone who attended that session can fill in the blanks, please comment. All that said, I'm going to dive in and do a bit more research to understand this stuff better.

Glen-Drake Toolworks

At the Glen-Drake Toolworks booth at the Woodworking in America conference, Kevin Drake was nice enough to give me a demonstration of two of his most innovative products: the Kerf-Starter and the two-handled Wild-West Joinery Saw. At the end of the video, check out the accuracy of the cut. I'll do a real post about their tools soon, but wanted to put up this video. Listen closely, there was a lot of ambient noise.



The website for Glen-Drake Toolworks is www.glen-drake.com.

Woodworking in America: The Shakes

No, not withdrawal from the overdose of the Woodworking in America conference. This is another kind of shakes.

During his session on understanding wood for chairmaking, Brian Boggs explained the concepts of wind shake and fell shake. Think of growth rings as layers (because they are). One of the things that holds the layers together is the wood fibers of the medullary rays. Wind shake, which is most common in cherry in my experience, is an internal separation between growth rings. The term "wind shake" is a bit of a misnomer, since the separation is not caused by wind moving and twisting the tree -- at least not directly. Wind shake occurs when a fungus enters the tree and attacks the growth rings. The fibers connecting the growth rings are compromised by the fungal attack. With these interstitial fibers weakened, movement from wind can be the culprit that separates the damaged growth rings. Wind shake manifests itself as checks (or cracks) inside a board. It should be avoided because it lacks structural integrity (sometimes, so do I). I'll post a picture later of some shakey cherry that I keep around just to have as an example.

Fell shake can occur when a tree is felled. The tree may crash against another tree or a log or fencepost or something that causes it to crack internally. It may also crack when it is felled because of its own weight or because it crashes onto pavement or frozen ground. Insect and/or fungal attacks can play a role in the integrity of a tree and can therefore contribute to the likelihood of fell shake.

It's important to note that these kinds of checking are different than the checks you almost always see at the ends of boards. These are caused by the fibers separating as the wood dries.

PS As always, I'm writing this, first, to learn about it myself and, second, to share what I've learned with anyone who's interested. If I'm off my rocker or write something that is just plain incorrect, please email me or comment. The last thing I want to do is misinform.

PSS Alternate title ideas for this post included Do you want some fries with that shake?, Shake me baby all night long, Shake it like a Polaroid picture, Shake it up (the Cars) and All Shook Up.

Clark & Williams Planes

While the Woodworking in America conference was winding down on Sunday morning, I was able to have more time to talk with Don McConnell of Clark & Williams Planes without having to deal with the throngs of people gathered around their booth. To use one of their planes is to appreciate how well a well-made traditional plane does its job. C&W makes a whole line of bench planes and molding planes that are the best traditional planes on the market. As part of the conference, Don McConnell and Larry Williams, along with Roy Underhill, gave a great seminar on using traditional planes to make molding. They also talked about the history and evolution of the planes and how they are used. Their knowledge of that history as well as their extensive experience in woodworking informs everything they do.



Molding planes are in the class of planes called escapement planes, which means the side of the plane is open and the angle of the blade is skewed a bit so that the wood shavings curl out of the side of the plane (see the opening on the plane in the photo below). During the seminar, Roy Underhill used a handheld camera with a light and an excellent zoom lens to follow along while Don ran a plane along a board. He was able to focus in on the cutting edge and show in great detail what has always been theoretical in my mind. I've only seen in drawings the action of the blade forming the shaving and the shaving lifting away from the wood and curling free. It was a great way to show the process up close.

Learning about this and trying out the Clark & Williams planes has inspired me to make my own coffin smoother. That will take lots of research and head-scratching, but I'll try to document the process (not the head-scratching). Along with the planes, the company offers DVDs on plane making and plane use. As with the other exhibitors, it's amazing to see a company's entire product line all in one place and set up to be used.

You can see more of the Clark & Williams line of planes at their website, www.planemaker.com. I highly recommend their section on why 18th Century British planes are the ones they chose to make.

Brian Boggs seminar

At the Woodworking in America conference, Brian Boggs lead a seminar called "Understanding Wood for Chairbuilding." Listening to Boggs talk about trees is like listening to the Car Talk guys talk about carburetors. He knows them inside and out. I think if Boggs hadn't become one of the leading chairmakers of his generation, he would have been a chemist or some other kind of scientist. I have to admit a lot of what he said went straight over my head. But I did come away having learned a few interesting things.


Boggs harvests his chair parts from specific parts of a log. He described it as being similar to the way you cut up a chicken. You don't take a whole chicken, cut it into slabs and cook it. If you did that, you'd get white meat, dark meat, bones and cartilage, organs and all the rest in each piece and it would be a mess. Instead, you cut off the wings, you cut off the legs, you cut out the breast and so on. It's similar with a tree. He gets the back legs, which he steam-bends into the shape that is the signature of a Boggs chair, from the lower part of the tree. He gets slat material from higher up in the log. He gets front legs from quartersawn sections of lumber.

Another fascinating topic was his discussion of end grain. I've always followed the gospel that end grain is not a glue surface. That's generally true except for when hide glue is used. Boggs gave an example of a contest he heard about in which woodworkers were challenged to join two pieces of wood at a right angle to produce the strongest joint. They could use any method they wanted. All the joints were tested for strength. The woodworkers had entered all kinds of complex mortise and tenon arrangements, dovetails, pinned joints, etc. Someone laminated the corner. But the entry that won, and won big, was a simple miter joint fastened with hide glue.

The trick is that you apply a thin coat of hide glue to all surfaces of the mortise and tenon and let that dry. The end grain pulls in some of the glue and bonds with it. Then you coat all surfaces again and assemble the joint. The new layer of glue re-activates the surface (and just the surface) of the old coat. The action of hide glue is to pull things together. Boggs said that if you dribble hide glue onto glass, it will chip out pieces of the glass as it dries. I had no idea it had that kind of strength. Pure protein, as Boggs described it.

Boggs went into all the other kinds of glue that he uses and lots more about steaming and chairmaking, but it's far too much for me to go into here. Suffice it to say that it was great to hear from someone so knowledgeable about his craft. And it's all the more inspiring when you know that Boggs started with the book Make a Chair Out of a Tree and about $50 worth of tools and built his business from there.

You can see his catalog at www.brianboggschairs.com. You can see one of my posts on Boggs here.

The Marketplace at the Woodworking in America Conference

Lie-Nielsen Tools had one of the largest booths at the Woodworking in America conference.  Here's a quick view of their display.


The Conference

I've been so impressed by how well the Woodworking in America conference has been run.  It's quite a feat to deal with 500 woodworkers, multiple sessions going on at once and a marketplace area all in the span of a couple of days.  The Popular Woodworking staff has been tremendous. 

It's been great fun to meet several other bloggers, including Matt Vanderlist from Matt's Basement Workshop, Kari Hultman of The Village Carpenter and Al Navas of Sandal Woods.  There are a few other bloggers that I hope to meet soon.  Everyone has been nice and fun and you can tell how much they love woodworking.  

You'll probably see footage of this on the Interblogs somewhere, but the keynote speaker at dinner tonight was woodworking legend Roy Underhill from the PBS series The Woodwright's Shop.  Suffice it to say, this guy might just be the most enthusiastic person on the planet!  (I got to have a beer with him last night.  How cool is that?!?  Nerd Alert!)  Anyway, he gave an incredible speech that ranged from Odysseus, to the Jamestown Settlement, to the Ice Age, to Abraham Lincoln and Thomas Jefferson and beyond -- all directly related to woodworking.  He was tripping on woodworking acid.  He brought down the house with a good-natured ribbing of Norm by saying that the only thing in his shop without electricity is his personality.  Snap!  

Geez, I'm tired.  I'll post more tomorrow.  I'll be making many more posts in the days and weeks to come with photos and video from the conference.  I'll also be writing Tools I Love posts about some of the great stuff I got to see here.  Two more sessions tomorrow and then I'm driving home to Nashville.  Goodnight!

Trying my hand with a trying plane

This is me at the Woodworking in America conference in the Marketplace area.  I'm at the booth for Japanesetools.com.  The board I'm planing is eight feet long and about an inch wide.  I did a practice run, then fellow blogger Keri Hultman from The Village Carpenter did the excellent video of the real thing.  The shaving that came out was translucent and was the full width of the board.  An amazing plane.  Believe me, the plane did the work on this -- not me.  Thanks, Keri!

Tool porn

Just a quick sampling of the wares on display:







Much more to come.

Holtey Handplanes

One of the great things about this conference is that there is an incredible array of tools from all kinds of makers.  I just had the great experience of being able to try out a plane made by Karl Holtey.  It was one of his smoothing planes.  I'm not sure how much it was worth, but I think it was somewhere in the $3,500 range.  There are planes and then there are Holtey Planes.  This is the woodworking equivalent of driving a Masserati.  It was perfect in every way.  The shavings on curly maple were translucent and wide and the mass of the plane seemed to coast along the board, taking little effort to push it along.  As you can probably tell, I was really thrilled.  What a treat to be in the same room as one of these.  Check out the website at www.holteyplanes.com to see the best planes ever made, and possibly the best that ever will be made.

Another taste of Pleasant Hill Shaker Village

I was able to go up to the attic of one of the buildings in Pleasant Hill Shaker Village and see the incredible timber-frame construction of the roof.  I'll post more pictures later, but even the floor was amazing to see.  Some of the boards were probably 30" wide, something almost unheard of today.  I guess the light happened to be at just the right angle to allow me to see this. This board has the original toolmarks of the scrub plane a Shaker used to make it the right thickness for the job.  And it shows the 45 degree angle that he used as he went along the board.  This board is a time capsule.  It comes straight from the Shaker who worked it.  It has dried out quite a lot over the last almost 200 years, but it is as if it comes straight from his workbench.  It's truly an honor to be able to see it.

More on Frank Klausz

As I said earlier, it was amazing to be able to watch Frank Klausz work and hear what he had to say about his life as a woodworker growing up in the Hungarian trade school system and his views on the craft. I saw him in two sessions today, the first was on the age-old Pins first vs. Tails first argument with another woodworking icon, Roy Underhill. Klausz is a pins first guy. Before he came to America, he had never heard of anyone cutting the tails first. That's the European tradition. He was describing his very simple method for cutting dovetails, which involves no measuring at all, no bevel guages, no try squares. He cuts the pins first and he cuts them where they need to be. Fretting over measurements and symmetry is a waste of time -- time that could be spent doing work. He has a simple way of spacing dovetails on a board. He cuts a half-pin on each side, then roughly judges where to cut the internal full pins just by where they seem to belong.

Someone in the audience asked about what formula he uses to space dovetails, and, somewhat incredulously, Klausz responded that they just go where they need to go. In fact, he emphasized, they shouldn't be spaced perfectly evenly. He said, "Handwork has character." He described the coffin made for Pope John Paul II, saying that the Vatican cabinetmaker had decided on three large dovetails for each corner -- each three inches wide. He said that they looked beautiful, but he would have made them differently. He said it is up to the maker. That is an essential part of the character he was describing. Dovetails, in almost every configuration, are strong and will do their job. It's up to the individual maker to decide how to make them.

In the next session, Klausz demonstrated open dovetails, half-lapped dovetails and mitered (hidden) dovetails (which he said he had made maybe 12 times in his whole life). At the end he was asking for general questions from the crowd. They ran the gamut of technical considerations. I raised my hand and asked, "What gives handmade work its character?"

He seemed to think a moment, and then he said that sloppiness isn't character. Obvious mistakes aren't character. Different sizes of dovetails and different tail angles are character. Decisions made by judgment and not measurements are character. He said he taught his son (who has a degree from Harvard and an MBA from Wharton) how to make dovetails and that his son uses a different angle. He said, whatever angle you want, "take your angle and cut it." "Make it to the top of your knowledge."

He went on to describe what he thinks is a fine piece of furniture. It must have the right design. It must be made of the best materials possible. It must have appropriate and well-executed joinery. It must have a proper finish. There must be no visible machine marks. Tool marks inside the piece, however, are character. For the top of a table, there should be no machine marks. Underneath the top, tool marks -- even those from a scrub plane -- are not only acceptable, but add character. If you use plywood for backs and drawer bottoms, you are making a beast -- not a future antique. He often mentioned that he makes furniture for his children and grandchildren and that it must last. He said his favorite piece of furniture to make is the Queen Ann Lowboy.

After all this, someone from the audience actually asked if Klausz thought it was ok to use plywood for the back of a lowboy. His response may seem a little harsh (though the person asked just after Klausz was talking about why not to cut corners, so the guy sort of had it coming).  This is a paraphrase, but he basically said:

"If you use plywood, it's junk. Number one pine costs only $30 bucks more than plywood. $30 bucks. It is not worth your time to make it. You couldn't pay me to have it in my house. You may as well not make it. You may as well make a bird house. No, not even a birdhouse because a bird won't roost in it. Think about that. A bluebird won't roost in a house made of plywood. Is a bluebird smarter than you?"

Dovetail session with Frank Klausz and Roy Underhill

If I get any mustard on the blog, it's because I'm frantically trying to eat lunch and write this post at the same time.

This conference is packed!  I think there are about 500 people here, which bodes well for this becoming an annual event.
I just got out of a session on cutting dovetails with Frank Klausz and Roy Underhill.  To my surprise, they were like a comedy duo up there!  I've always heard about how Klausz cuts dovetails without any marking, so it was a treat to see him do it in person.  More later on this.  But he said he cuts dovetails more often than he signs his name, so he's gotten pretty good at it after 40 years.  He was very casual about the whole thing.  When people would get a little nit-picky, asking questions like, "What is the bevel angle on your chisel?" Klausz would reply, "The angle is sharp -- whatever angle makes it sharp is the angle I use."  Here's a photo of the set of dovetails he cut.  Amazing stuff.  




He tapped them gently together with his mallet. He passed it around and I got to feel the ends -- perfectly flush, as if they'd been sanded. When asked about whether to leave the tails proud 1/32 of an inch, he asked, "Why would you not want them to be flush?"



Now I'm off to another dovetail session with Klausz.  I could listen to him talk about this stuff forever.

Pleasant Hill Shaker Village

I'll have much more to say about this later, but I just visited the Pleasant Hill Shaker Village in Harrodsburg, KY. The village itself is great beyond explanation. I'll write a real post about it, with some photos, in the near future. Here's a taste:
One of the two spiral staircases in the Meeting House:


The grounds:


These photos were taken by Chris Vesper of Vesper Tools. Thanks, Chris! You should definitely check out his incredible work. And thanks, Ground Effects Coffee House, for the free wifi!

Stay tuned.