2-Drawer File Cabinet Revisited

Hungarian Shelves Slot Height Revisited

Two recent sets of Hungarian Shelves ran thick and thin, i.e. in one case I made the slot height taller than my recommendation Slot Height for Hungarian Shelves and in the second case (the set above) shorter.  At first I thought the tighter the fit of the shelf in its slot, the better, but I have changed that thinking for several reasons.  First, wedges that taper to a knife edge are more likely to break upon insertion or removal.  Second, they offer too little wood for compression when driven into the slot.  Third, the thinner wedges lack rigidity and tend to fall away from the bottom of the shelf.  My revision is to make the slot height always a little more than 1/16" rather than less.  I found that even a 1/8" space works but that tends to be a little too much.

The uprights are African mahogany stained to match the accelerated darkened cherry, accomplished by some careful time in the sun.  As always the natural face of cherry is so lovely.  She requires no makeup.

Commercial furniture makers still think that cherry should look black.

Three Easy Pieces

One of my shopmates asked if I had reverted to high school shop, and that may well be true here.  Nonetheless, the beauty of a three-legged table, like its companion the three-legged stool, is that no matter how uneven the surface the table is stable.  This, of course, is canceled somewhat by its tendency to tip over when pressed between legs.  I thought the rock would enhance its stability, which would be the case if it were ten times heavier.

More Copper Collage Sculpture Slabs

"Theo Helii"

"Theo Helii'' - Detail

 

"Delphinus"

"Delphinus" - Detail

Copper Collage Sculpture Slabs

"Casement Vision"

The “Copper Collage Sculpture Slab” series of works represented one of my few forays into the world of art furniture.  Mostly tables and trivets they were shown at galleries in Sedona and Flagstaff as well as my favorite venue the Coconino Center for the Arts.  Thin 1/4" slabs of float copper, often containing large flecks of native copper, were arranged on a bed of actual mining tailings in collages, sometimes suggestive of particular forms.  Durable bisphenol epoxy resin was then poured over the entire system to lock it in place.  The slabs were provided to me by prospector extraordinaire, the late John Sikorsky, who also provided the inspiration for this line of work.

The epoxy pours were nightmarish affairs, first requiring a day’s cleaning to render a woodworking shop dust-free, no mean feat.  Then the mixing ratio needed to be near perfect, a quart or more of epoxy having to be stirred in very short order.  The thousands of bubbles thus induced had to be popped before the epoxy hardened, using the rather dangerous technique of blowtorch heat which could ignite the whole affair.  Special covers had to be designed that did not attract dust like a capacitor while the casting hardened over the course of many hours. 

One of the pieces entitled “Ore, Timber and Rail” actually won first prize for sculpture at “Vision Southwest,” a show for artists residing in the states of the Four Corners.  This particular coffee table contained elements suggestive of an ore car riding on tracks.  Remarkably it not only provided a cash prize to the maker but also sold from the show.  That was an exception as most of the pieces were eventually purchased by existing customers.

2-Drawer File Cabinet

Kitchen "Spacer" Wine Rack

When this kitchen installation required a 3" spacer it seemed a waste of space to place it at the face frame. Always looking for a new tunnel for the wine cellar, it occurred to me that the width was perfect for a bottle of wine though insufficient for a wine rack with sides and shelves.

The idea of supporting wine bottles with just a bored hole was provided by my cooperative shop partner Tony Furhrman (Summit Woodworking).  Thus the spacer was moved back, thickened, set slightly away from the back wall, screwed to the side of the adjacent cabinet and now provides storage for 8 bottles of wine.  The lip of each bottle locks it in place so it can't slip out.  Tony points out that though the bottles slant down from the neck, corks are still fully submerged.  A similar "spacer wine rack" provides storage for 8 more bottles at the base cabinet level.  A little clever rotation of the bottles  allows the labels to be read without removal.  I like the fact the bottles share the same cantilever support mechanics as Hungarian shelves, less the wedges.  Though very secure they are easily inserted or removed.

Yet More Hungarian Shelves

Finally realized upon installing this set of shelves that knocking in the wedges with an oversized block that extends beyond the front edge of the shelf not only allows placement of the wedge perfectly square to the shelf but also prevents marring of the bottom of the shelf with the hammer.

King Bed Platform

King Bed Platform Side View

Full Extension Drawer Detail

The Ship's Carpenter

Flying Circus Studios was in business for more than 35 years in Flagstaff, and with this move to Tucson I am sure that there are those who feel disappointed, perhaps even betrayed, that I have jumped ship.  And I am afraid that that is true, for though I did do fine woodworking in Flagstaff I was perhaps not so much a fine woodworker as I was a ship's carpenter, and, at that, for dozens of vessels over those years.

A ship’s carpenter should be able to, and did, make any piece of furniture or furnishing for stateroom or cabin, sometimes even the cabin itself.  His work largely derives from needs and is directed by query.  Besides the furnishings, a ship’s carpenter might be called upon to connect decks with stairs, be they spiral or straight, or construct the deck itself, or replace a porthole.  He might even be found wielding a paint bucket in hold or on hull.  A ship’s carpenter might find himself more often renovating the galley than displaying his artistry on the gallery.  There is also nothing he might not be called upon to fix, from the finest captain’s chair to a problem head. 

Truth be told the captain came to depend on the carpenter, and they built up a relationship over the years, and then again became good and fast friends.  This aspect does not end when the high desert separates.   I think of you and your vessels more often than you know. 

It is said that Shackleton’s carpenter could look at a space, go back to the shop, cut the piece, and it would fit perfectly.  This ship carpenter, however, could use a tape measure and still find the piece exactly one inch too short.  Nonetheless the analogy is growing on me, feeling almost comfortable; yes, a career of relationships rather than objects.  I have, I think, misunderstood the true nature of my portfolio.

Happy Thanksgiving

The morning paseo begins here

Forgive the fall hiatus in tips and portfolio photos for much remains to be done in moving Flying Circus Studios from Flagstaff to Tucson.  Relocation is chiefly the work of Sisyphus, redoing an endless string of the details of daily living, but advantages accrue too in reassessment, reflection, and, of course, sifting with a finer sieve.  Throughout this process I remain thankful for my family, friends and the new acquaintances of our Tucson life.

15 Tool Tips

1800's Level

Tool Tip#15 -- Hose through a Door -- a decorative and permanent way to route hoses or wires through closed doors

Tool Tip #14 -- New Grit for Sanding Sponges -- reviving the grit on a sanding sponge after its own grit is worn away

Tool Tip #13 -- Miter Gauge Tightening -- using transparent tape to quickly tighten a miter gauge sloppy in its track

Tool Tip #12 -- Grabbing for Arrows -- improving a pencil's handle to unsheath it more easily, not to mention removing more errors

Tool Tip #11 -- Sharpening a Hammer -- using a disc sander to prevent rubber mallets from marring work or skidding

Tool Tip #10 -- The Hulk's Bench Scraper -- plate glass to smooth and flatten bench tops as well as standard glass for use as a wood scraper

Tool Tip #9 -- Securing an Old Favorite -- draw tight latches improve the traditional door slab over sawhorse workbench

Tool Tip #8 -- Easy Fill for Portable Tank -- a double male coupling allows fast filling of a portable air tank through its outlet

Tool Tip #7 -- Sleeves to Shoulders -- using a shelf pin sleeve to reinforce frequently used 1/4" holes in pegboard

Tool Tip #6 -- Replacement Power Cord  -- the appropriate gauge extension cord makes an inexpensive and easily available replacement power cord

Tool Tip #5 -- Magnets in Molded Plastic Cases -- glue in magnets to keep bits, blades, wrenches or whatever handy in your plastic tool cases

Tool Tip #4 -- Extension Cord Hair Band  -- a giant inner tube rubber band nicely cinches an extension cord roll

Tool Tip #3 -- Power from Above -- just because you're working in front of a garage door doesn't mean you can't have a place to plug in a tool

Tool Tip #2 -- Nuts over Tangs -- protecting your hands from the sharp end of a file or rasp with a common electrical item

Tool Tip #1 -- Block Tenderizing -- if it's hard to bend that sanding block to receive sandpaper it may be time for block tenderizing

More Hungarian Shelves

Hungarian Shelf Wedge Detail

Small Hassock

Zen Bench

"Before"  (black walnut courtesy of Shawn Skabelund)

"After"

Lean Thinking Tip# 9: The Jig Is Up

Jigs are wonderful aids in the fabrication process.  Not only do they increase efficiency but they also improve precision.  Furthermore, more craftsman joy often derives from creating a clever jig than making the product itself.  Nonetheless most jigs are one time affairs.  I sometimes revisit these and wonder how in the world do you use it?  I have not left myself "operating instructions."  As these jigs accumulate they only add to shop clutter, and often the best place for them is as shown on the left.  "The jig is up."

Glassware Display Shelf Unit

Tool Tip #15: Hose through a Door

Over the years I've pinched and cut enough hoses and wires in my shop door because it was required to keep the door shut for heating, cooling, dust, vapors, etc.  The simple solution as shown is to install two cable hole grommets on either side of the door.  These serve to permit passage through the door, prevent chafing of the hose or wire and allow easy closure of the hole with the grommet's snap-in cover (lying on the sill).  My custom office systems have always included numerous cable hole grommets, though, with the advent of so much wireless equipment, the market for these will likely decline...a warning to investors in cable hole grommet manufacturers.

Tool Tip #14: New Grit for Sanding Sponges

The aluminum oxide abrasive used on sanding sponges typically wears off quite fast, but those sponges make excellent blocks for other sandpaper.  In fact, the grit provides a flaccid velcro to hold sheet sandpaper (same width as your block sander) or a used disc from an orbital sander.  You'd be surprised how effective even a used disc can be for contour sanding.  Note also the crutch tip on the vise's release lever...to prevent power cords drawn across the vise from pinching and getting stuck.  Am I the only woodworker to whom that's happened?

Media Cabinet

Tip published in Fine Woodworking

Woodworking Tip #12 from the Flying Circus Studios blog, "Presquare" Large Glue-ups, was just published in the August 2012 (No. 227) issue of Fine Woodworking magazine in their "methods of work" column, page 16.  I don't think you can see this column online, but if you are not a subscriber to Fine Woodworking, you can receive a 14-day free trial membership to their online edition and services by clicking on their website FineWoodworking.com.  Their hand drawn sketches of the tips are a pleasant alternative to photographs.  I began my own subscription to Fine Woodworking about a year after it commenced publishing in winter 1975, bought the few back issues that I had missed and now have the complete set, which makes a superb woodworking reference resource.  The Taunton Press has done a very fine job with this magazine through the years and keeps it nicely up-to-date with the latest developments.

See also our shop at:  www.etsy.com/shop/FlyingCircusStudios

Stand for Military Memorial Plaque

The cherry fins not only symbolize the airfoils of the three axes of flight but also represent the vanes of the jet engine thrust reverser invented by George R. Urquhart.

Desks - Coconino County Board of Supervisors Meeting Room

Lean Thinking Tip #9: Hand Tools Backstage

I've already shown the upper story of my workbench in Second Story Office, and so now take a look at the basement level.  Some 8-10 electric hand tools are stored on a lower shelf almost as big as the generous 4' x 8' top.  Each is permanently plugged into his or her own receptacle.  Each power cord has a loop secured with a zip tie to hang on a hook, thus keeping the power cord off the floor.  Each sits on a pad of foam that lets me drop the tool back under safely.  Each has it's own parting in the curtain, which keeps them all clean and out of sight.  The plate joiner is purposely pulled out a bit to show how this works, and the five inch orbital sander actually mounts outside on the bench's apron.  Thus all the most commonly used tools are backstage each awaiting the cue to make their appearance instantly on stage.

Flying Hint #7: A Lesson in Every Flight

Piloting an aircraft is an extraordinarily rich learning opportunity..  Flying requires not only motor, mental, verbal and psychological skills in a 3-dimensional environment, but also knowledge of aerodynamics, aircraft systems, meteorology, navigation, the airspace system, communications and more.  Over the years I've found it the rare flight, indeed, that does not contains some lesson, big or small, some observation, some item for improvement.  I've recorded these in "aviation notebooks," the style of the first dating my flying career, which also include tips gleaned from the experiences of others, from reading, from Wings Seminars, BFR's, etc. A periodic review helps in retention, and they make good memories too. 

Side Table -- Through-Leg Detail

Craftsman Style Side Table

 

 See companion piece: Craftsman Style Coffee Table

See replica piece: Pierced Side Table 

Five-Drawer Bureau

Small Dovetailed Desk

Fir Wall System

Overview showing disguising of architectural columns

Detail showing pull out desk and sliding closet door

Woodworking Tip # 17: TOPCOTE for Hand Planes

Your hand planes will really take off if you spray the bottom with a layer of TOPCOTE by Bostik.   I had used this product for years to clean, seal and reduce friction on the beds of my table saw, jointer, planer, etc., but then one day I sprayed it on the bottom of my jointer plane pictured to the left.  The results were scary, as if the plane now had some propulsion of its own!  Try it, and you will be a believer.  I have concluded that most of the resistance in pushing a hand plane is the dynamic friction of the sole and not the cutting done by the knife.  Polish the sole thoroughly after application.  Other woodworkers have certainly discovered this too, though Bostik does not include the suggestion on their TOPCOTE can.   It is certainly a very effective use of this excellent product.

Tool Tip #13: Miter Gauge Tightening

The miter gauge that comes with many stationary tools typically fits loosely enough to induce errors.  Unless the miter gauge guide bar is fitted with adjusters, you can still make it snug in its slot by just adding a layer of transparent tape.  In the photo I add a single layer of "Scotch" tape to one side of my table saw miter gauge bar and trim the excess with a razor blade.  The tape's thickness of .001" is all that it takes to eliminate any play, and the surprise is that this quick fix lasts several years.  A layer could be added to the other side as well if the play were really bad.

George R. Urquhart

IN MEMORY OF GEORGE R. URQUHART

Not even a year has passed that I have had to interrupt this little stream of works and tips to recognize the death of a dear friend, as well as my wife's uncle, George R. Urquhart, affectionately known as Uncle Bud.  The appellation is especially appropriate because, with little ado, he became everyone's uncle, exuding a rare warmth and interest in all whom he encountered.  Uncle Bud was inquisitive and would ask you questions, not a common trait at all.  He was an aeronautical engineer by profession, but in his retirement years became quite an avid and skilled woodworker.  Thus we shared two life interests:  aviation and woodworking, and enjoyed many a good conversation about both.  It was not even a year or so back we were discussing table saw practices.  Uncle Bud lived a full and rich 91 years, even publishing a book recently, entitled Reasons to Believe.  He will be sorely missed by all who know him.  More can be learned about Uncle Bud in the excellent obituary in the Kansas City Star:  George R. Urquhart.

Tool Tip #12: Grabbing for Arrows

I've never been a fan of carpenter's pencils, finding them imprecise, awkward and a hassle to sharpen.  What is it...a million hours of construction labor lost each year to sharpening them?  I do, however, like the better grip they provide when grabbing them from a tool belt or shop apron.  To provide that same grip on a typical pencil I glue on an arrowhead eraser.  In fact a pencil without one now feels quite naked to me.  I always have a pair handy in all the locations I need them:  a #2 for writing and a #3H for lines.  (See also Plague of Cheap Tools)  Furthermore, should you ever make that rare marking mistake you have a nice fat eraser to take care of it.

Six-Tray Pantry

Full Extension Pantry Tray Pull Out

Tool Tip #11: Sharpening a Hammer

Deadblow hammers are useful woodworking tools for both disassembly and assembly, though one hardly wants the imprint of a hammer face on either an antique slated for repair or a new piece of furniture.  The indentations, roughness and dirt on the face of the hammer shown in the picture are easily removed by a few seconds in contact with a disc sander.  The bed of the disc sander is especially useful in keeping the face of the hammer exactly parallel to the disc.  I usually bring the hammer face to the disc with the sander just turned off and winding down, since the disc at full speed tends to melt the hammer face rather than "sharpen" it.  By the way, sharpened hammers have much less tendency to slip or skid, like a student pilot.  If you've created too sharp a hammer head, relieve the corners slightly. You may even find that the disc is ever so slightly cleaner than when you started, i.e. like the work boot used to clean a belt sander in Old Sole Eraser.

Woodworking Tip #16: Slot Height for Hungarian Shelves

Judging from continuing traffic, lots of folks have viewed my method for fabricated the wedges for Hungarian shelves, and I thought it would be helpful to include a post about the appropriate slot height to use for these 2 degree wedges.  Make the slot about 1/16" bigger than the thickness of the shelf.  In this case the shelf was just over 3/4" with finish, and the slot height is a smidge more than 13/16."   Most hardwood is planed to 25/32," and so use a slot height of 27/32."  Pine is typically 3/4," slot height 13/16."  I recommend a slot depth of 1" to 1 1/4" to insure plenty of purchase for the wedges.  Hungarian shelves are definitely one of the niftiest shelving systems.  Happy New Year!

Top Corbel Rotunda Shelves

Artisan at the Holidays #2

     May the holiday season bring you the joy of gathering with friends and family as well as a deeper appreciation for the important people in our lives.
     For those of my readers who are artists and craft people this is also an excellent time of year to show appreciation to our patrons.
     For those of you who are instead, or additionally, my own patrons I myself offer now heartfelt appreciation, and I hope my works have provided some added joy to your everyday lives.
     You may even find, embedded in each piece, a unique gift, not just for the holidays, but deriving from the attentions proferred.  Open and enjoy it every day...and thank you for your patronage!
                         

Flying Hint #6: Flight Bag & Seat Slippage

The tendency of the front seats in single-engine Cessna aircraft to come unlocked and slip backwards on their rails has been addressed and likely fixed by Airworthiness Directives.  But I say, "What the heck?"  I put my venerable and indestructible Sporty's flight bag behind the pilot's seat, and just in case I find myself suddenly traveling aft, I won't go very far.  The bag is unlocked, and I can actually reach around and grab things if needed (the arrangement of the contents is well memorized).  This is hardly a problem for the back seat passenger as the density altitude at Flagstaff's 7000' elevation often transforms this 4-place Cessna Skyhawk into a 3-place aircraft.  Of course, if I take the advice I gave to my flight students and keep a gentle touch on the yoke, any surprise seat slippage would result in loosing one's grip rather than having the nose point skyward.