July 30, 2010

Cut…stone the saw…cut…

In my previous post I showed the beginning of my journey into hand-cut dovetails. Many of the comments I received addressed the heavy set on the teeth of the new dovetail saw:

Recommendations from experienced hand-tool users addressed one specific solution to reduce the saw set: Stone the saw. Doing this makes it easier to follow a line; and it will also clean up the kerf, and thus leave a much smoother cut.

I took everyone’s recommendations at heart, for I respect the advice of the people who commented and made the suggestion above. Once I got a little time in the shop I prepped some red oak cutoffs and made some test cuts. In between each numbered set of cuts I stoned the saw once on each side with a fine diamond stone, until the cuts were straighter and the kerf looked much cleaner – about dinner time:

Note: The earliest cuts, #1, is on the bottom left, and the most recent ones are at the top-right in the photo above.

For these practice cuts I switched from using dovetail-shaped lines, to straight lines following the grain direction. Based on my experience thus far, my admiration for the craftsmen who can do beautiful hand-cut dovetails has grown exponentially!

I think the dovetail saw needs a little more fine-tuning. As a result, I will have one more session of cut… stone the saw… cut…

In this context, I quote Kari, a.k.a The Village Carpenter, who in January 2008 wrote the following in her blog, addressing stoning the saw:

By stoning, I don’t mean that if your handsaw is misbehaving, you should go all biblical on it. Instead, I mean there is a way to gently persuade it back to the straight and narrow by using your sharpening stones.
– The Village Carpenter, Stoning your Saw, January, 2008

I chuckled about her opening statement… But at the time I did not realize the importance of this technique.

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Practice should make perfect: Hand-cut dovetails

The cat’s out of the bag: I have started practicing hand-cut dovetails.

I started my practice sessions with this gent’s saw; in retrospect, I should have practiced starting the cuts with a much lighter touch than I used, as I could see a curve in some of the kerfs as the cut went deeper:

I am certain ignorance on my part played a big role, but I just could not get comfortable with the grip on the gent’s saw. As a result, I ordered an E.T. Roberts & Lee Dorchester 8-inch, 21 ppi rip dovetail saw. As soon as the saw arrived I started practice sessions, cutting parallel lines marked on the end grain of the board:

Problem: At first I was unable to remove the protective coating from the steel – Grr! It turned out that this company uses lacquer on their steel, to minimize the risk of corrosion between manufacture and delivery; a few drops of lacquer thinner removed the coating completely, and made a huge difference in performance! My bad, of course. Isn’t ignorance bliss? I understand that most (?) American manufacturers use a wax coating, which is easily removed with mineral spirits.

As I started using the new saw, it seemed somewhat difficult to get the cut started. My intent was to make practice cuts, targetting 1) a pre-set depth, and 2) perfectly parallel cuts. I noticed, as my practice session got longer and longer, it became much easier to start the cuts. And toward the end of the session I was able to start a cut and finish it in seconds. I have read somewhere that this is normal behavior for this type of saw.

However, I will have to practice a lot more, for I noticed two serious problems:

  1. I have a tendency to overshoot the depth, and
  2. I can cut better parallel lines when the saw is tilting to the left, as in the last photo.

Next step: Cutting to a line.

I hope I can get better when cutting with the saw tilting to the right. Practice should make perfect – I hope!

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Learning woodworking by reading an old book

You can learn a lot about woodworking by exploring books that were published before you were born… A fantastic place to begin is George Ellis’s “Modern Practical Joinery”.
- Christopher Schwarz, “Finding Roubo via Canada“, Woodworking Magazine Weblog, December 2005

Make sure to read Chris’ short review of Ellis’ book by clicking on the link above. If you have never heard of this book, the review is must-read material, just like the book itself.

I recently ordered the book – before I knew about The Schwarz’ book review (next time I will do my homework a little better). As soon as the book arrived, I started reading. Boy, I am learning a lot by reading George Ellis’ Modern Practical Joinery. This is a 1987 reprint of the original, published in 1902. I was not familiar at all with much of the joinery shown in the book; and it reinforces much of what I have learned in woodworking through the years. It is a treasure trove of joinery.

I highly recommend this great reference book on joinery. Price range: $15 to $22 – a real bargain!




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