Thursday, September 4, 2014

Bookshelves - Part 2

Back panel glued on (I need more clamps!)

Fitting the face frame.  I am still figuring out how I want this to look so I haven't put the face-frame on yet.

All of the shelves are completed with a 1/4" thick piece of solid walnut glued to the front of each shelf.  The movable shelves were done with the Kreg Shelf Jig with only three holes per shelf.

Wednesday, September 3, 2014

Joiner's Mallet

I built this mallet based upon plans from Woodworkers Journal (Link) using Hard Maple and Walnut.  I had been saving a piece of Maple with some subtle quilting, which worked out great for the handle.  I finished the mallet with three coats of Danish Oil.





Tuesday, September 2, 2014

Stanley Bedrock #607

I was finally able to add a jointer plane to my collection, a Stanley Bedrock #607.  As near as I can tell, the plane was manufactured in 1922 and is in great condition.  The blade is about as sharp as a butter knife, but the sole appears to be flat, and with a little work I fully expect to have this beautiful piece of American craftsmanship tuned up like new.  Notice that the plane fits perfectly in my cabinet I built...this was intentional when I built the cabinet 5 years ago, I wanted to fit a #7 jointer plane on the bottom shelf!


Monday, September 1, 2014

Bookshelves - Part 1

I have put this project on hold, primarily because I knew that it would be a lot of work.  These bookcases will be 7' tall x 32" wide and will be made out of Walnut plywood and solid Walnut.  The case is joined together with 5mm domino's.
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Getting ready for the first cut on the 4x8 sheet of Walnut.  At $130/sheet, this was a little unnerving.

Shelves

Side Panels



Using the Festool Domino to cut mortises for the case.

Mortises


Using the Kreg Shelf-Pin Jig to drill holes for movable shelves.

Dry-fit

All glued up in the clamps.


Friday, May 9, 2014

Putter Display

I wanted to build something that challenged me from a design perspective, something that wasn't "square".  For years I have collected putters and I  had been wanting a way to display one of them so I started sketching out a floor display that would hold a single putter, but would also function as a "practice hole".   Overall I was happy with the shape that I drew, now to transfer that to some wood.  This project is made from 6/4 Walnut.

Sketches

Main pieces cut out.

The "trunk" balances nicely on the base.

First time using the Festool Domino...amazing machine!

Multiple coats of Danish Oil followed up by a coat of paste wax.

Completed.


Thursday, May 8, 2014

Dining Bench



8/4 Poplar being cross cut on the Kapex (see Miter-Saw Post)

Making the bevel cut on the table saw.

Dry-fit

Dry-fit
Completed

Sunday, April 20, 2014

Miter Saw

About 10 years ago I bought a number of Craftsman power tools from Sears, and while they have served me well over the years, I have been slowly upgrading as funds permitted.  The last Craftsman tool that I needed to upgrade was my 10" compound miter saw.  This saw has cut a ton of wood over the years, but I had been wanting to upgrade, primarily for more capacity as it could barely cut a 90° angle on a 2x6.

The saw that I was most excited about was the Festool Kapex.  I own a fair number of Festool tools and all have exceeded my expectations.  The ease of use, accuracy and dust-collection justify the extra expense in my mind.  In reading the glowing reviews of the Kapex I had no doubt that the Kapex would be the perfect saw, and worth the $1,400 price tag.  I purchased the Kapex from my local Woodcraft and two weeks later returned it!  Here are the reasons why:

1.  With every Festool power tool I own I have been blown away by the dust collection, and I think my expectations may have been too high with the Kapex.  The marketing materials state that it will collect 90% of dust, but I only found that to be true in some circumstances.  Cutting a 1x4, sure the dust collection is good, but when I was cutting an 8/4 x 12" piece of poplar, not so much.  While I firmly believe that the Kapex does a better job of dust collection than any other miter saw...I wasn't blown away, especially for a $1,400 saw.

2.  The Kapex was not square out of the box, not even close.  Both the bevel angle and the miter angle were out of square.  Again another expectation that may have been too high, but I spent about half an hour attempting to get the saw to cut square.  In my opinion, a $1,400 saw should be square out of the box.

3.  The table was not level with the wings.  This is a little hard to describe, and I should have taken a picture, but the inner-table that rotates with the saw was about 1/32" lower than the wings.  Evidently this is normal for the Kapex (according to some information I found on the internet), but I hadn't seen the "feature" on any other miter saw I have ever used.  This may or may not cause an issue with making cuts, but I believe that it should be perfectly level, especially for a $1,400 saw!

4.  The blade that came with the Kapex is awesome (see note #6 below).


Thankfully Festool offers a 30-day return opportunity, which I have never had to exercise until now, and I was able to easily return the saw to Woodcraft.

So I ended up purchasing a DeWalt 780 12" sliding miter saw.  Here are a few of my observations about the saw:

1.  The dust collection is ok (not as good as the Kapex), but for $600, I didn't expect great dust collection.

2.  The saw wasn't accurate out of the box and I spent about half an hour getting the saw to cut square (only the miter was out of square, the bevel angle was good), but for $600, I didn't expect it to be square out of the box.

3.  The saw table that rotates IS level with the wings...why isn't the Kapex?

4.  I got the DeWalt mobile cart, a $200 value for FREE when I purchased the saw from my local big-box store (no mail in rebate required)!

5.  The saw has plenty of power and capacity.

6.  As expected, the blade that came with the DeWalt was a few steps above garbage so I did purchase an 80-tooth Freud blade that is much better.


So for me the bottom line is that the Kapex is a very good saw, but not worth $1,400 in my opinion.  The DeWalt is a pretty good saw, and is worth $600, especially with the stand thrown in.  At the end of the day, I was able to get the DeWalt for $600, and now I have enough left over to get the Festool Domino I have been drooling over!