stevenbunn Wed, 08/05/2015 - 16:19

I received an email earlier today from Ned Dykes showing the hand-screw clamps he's made after reading my article on the subject published in American Woodworker Magazine. His photo and comments are published here with his permission.

 

 

- I just wanted to say thanks for your article on making these hand-screws. I had a great learning experience starting with repurposing the wood billets that the clamps are resting against (in the photo). These were supposedly used as foundation cribbing some 50+ years ago and I bought about 200 pieces at an estate sale. I think it might be ash? The dowels are purchased hard maple (no lathe yet!) and the handles are formed from pieces of 2-by leftover construction lumber from the shop build. Bottom line ... these work great and I plan to make more because they are so useful. So, thanks again for the great instructions and photos. And, I've enjoyed looking around your web site. Not up to making chairs yet, but I did repair an old one that is still "sitting" well!

 

Great job! Its always wonderful to hear from anyone who has read one of my articles, and its even better when they've been inspired to make their own interpretation of the published project.

 
stevenbunn Thu, 07/30/2015 - 07:15
The completed saw box, mounted on the wall next to the work bench
 
As usual one thing leads to another, and another, and on and on. All I started to do was build a simple case to store my hand-saws. These have wandered into the shop at various times over the years without me paying much attention. About ten years ago I picked up a box of saws at a yard sale for $25.00. I pulled the shiniest two saws, both Disston D23 pattern saws out to put in my new tool box. See the reconfigured box in earlier posts. The rest I frankly ignored. All of the saws had the name Mr. Fish blazoned on the handles. The box with the rest of the saws migrated to the lower shelf of one of my work benches. On another trip to a local flea market I found an antique tool box, with five sliding trays filled with tools for $150.00. Who could ignore such a deal. Cetainly not me. The tool chest weighed a ton and took the assistance of several bystanders to lift into the car. I hoped the tool box would hold a hand plane or two, but no luck. A full set of spur auger bits however came close to paying for the tool-box, which is what I really wanted. Everything inside was just gravy. That box too found a place in the shop and dropped off the radar.
 
Having completed the hanging saw box I started gathering together my existing saws, and as part of the effort, pulling the rest of Mr.Fish's saws out of his box. Then I remembered the old tool box beside the drill press and opened it up. The tool box alone contained six saws of various length and tooth count. Several were modern junk. Cheap hardware store saws from the eighties. But amoung the dross were a couple of beauties. The most unique was a small panel saw with an etched maker's mark identifying it as made by the Richardson Bros. Co of Newark, NJ. A little research on line showed that Richardson Bros. was in business between 1850 and 1875. Mr. Fish's neglected saws included a Disston #7 ship pattern saw, a Disston #8 with thumbhole in the handle, and another obvious Disston saw with a Warranted Superior medallion, rather than the stardard Disston medallion. Intriquingly there was a reinforcing metal plate screwed to the underside of the handle extending under the join where the lower portion of the blade seats into the handle. The small reinforcement plate, which I've seen on no other Disston saw had a patent date of __July 1883 stamped on it. I initially identified this saw as a pre-1900 #8 based on the shape of the blade. Finally, there was a skew backed blade with a loose cherry handle, but no saw-nuts or medallion. The carved wheat pattern on this handle failed to match any of the known carving patterns used by Disston over the years they were in business. I spent way to much time on line trying to trace down that pattern. Finally I found a photo of a Harvey Peace hand-saw with exactly the wheat carving as the one I held in my hand. The saw was a dead ringer for the one I had. The photos of the Peace made hand-saw clearly showed the reinforcing bar I had found earlier on the miss-identified #8. The handle whose pattern I was trying to match was cherry and had an identical screw hole from a now lost reinforcment plate. Researching Harvey Peace further I learned that he was in business between 1863 and 1890. He sold his business and a number of patents he held to the Disston company in 1890. Disston cntinued to make several Peace pattern saws, marketing these with their Warrented Superior medallions rather than the standard Disston & Sons pattern medalion. So now I had a skew backed saw with cherry handle identified as a Harvey Peace product dating somewhere between 1883 and 1890, and a second nearly identical saw with an apple handle, skew back blade, a Warranted Superior medallion, and the Peace patented nickel plated guard at the base of the handle. This one a Disston product dating between 1890 and WWI.
 
Suddenly I've found myself with an interesting collection of antique saws which have been sitting in plain sight in the shop. And another collecting interest when all I started out to do was neaten up how I stored my saws.
 
Thank you for dropping by.
stevenbunn Thu, 07/30/2015 - 07:08
An interior view of the saw box
 
 
stevenbunn Sat, 07/18/2015 - 09:02
A view of the exterior construction of my tool box
 
My tool box was inspired by one of Roy Underhill's articles that appeared a number of years ago in Popular Woodworking Magazine. Up to the time I built this tool box I had been carring my tools around in an old canvas army cargo pack. It worked, looked like a pregnant sow, and wasn't elegant. My big tool box was way too big to take to fairs. Roy's tool box project fit the bill. The only problem was that constructing the box as drawn in the article required cutting something like 44 dovetails to construct the box. With the Common Ground Country Fair only weeks away, I needed something quicker to make. I built my version of Underhill's toolbox using mortised and tenoned frames with raised panels. The assembled panals were then rabbeted and glued together at the corners.
stevenbunn Sat, 07/18/2015 - 08:43
A view of the tool box's  revised storage arrangements
 
And there is still unused space on the inside of the lid! I considered purchasing a frame saw to hang on the lid, just for looks. But,they seem to have gone out of fashion. None of the major catalogs carry them these days. When I worked at a small tool store in Portland, Fox Maple Joiners Supply, over thirty years ago, frame saws were all the rage. The few I can find online today are too expensive for my taste.
stevenbunn Sat, 07/18/2015 - 08:28
Multiple drawers provide lots of storage
 
Once started it was hard to stop. With the saws stowed to my satisfaction, I considered how my remaining tools fit in the space remaining. As originally built, the box had two drawers and a shallow tray fitted in one of the two drawers. Chisels and cutting tools like spokeshaves were carried in tool rolls. Rummaging thru a drawer while demonstrating chair-making at a fair could be frustrating and I had to beware of pokies. I shied away from installing drawer dividers for my tools initially because I just didn't think the effort to make them was worth it. I rationalized this with the thought that building a drawer with, say, five perfectly fitted compartments, suddenly put  you at a disadvantage when you needed to find space for a sixth tool. But experience with the tool box proved that everything worked better if tools could reliably be found when required. 
stevenbunn Fri, 07/17/2015 - 20:45
The new saw till and slotted hangers for compass and drawknife
 
As I mentioned in my last post on this blog, I had a pent-up list of projects that I couldn't begin to work through until my church commission was completed. The most insistant need that cried out to be addressed first was to re-configure the mounting arrangements in my traveling tool box for the saws and framing square. I had initially hung the saws and square on the inside face of the lid. However, I found that the tool box bounced around while on the way to shows, causing the tools to shift, and sometimes come loose. So I had been looking at other woodworker's chests, books and articles, anything for some inspiration. Then a month or two ago, Chris Schwarz featured a simple notched braket on his Popular Woodworking blog that, when screwed to the bottom of a toolbox, provided secure storage for up to three saws. Equally important, the 3-1/2 inch x 5 inch brackets were both simple in plan and elegant. Just the thing I needed. With my saws now stored in the bottom of my toolbox, the now empty inside face of the lid suddenly offered a bonanza of new real estate for hanging my other tools. As always, one thing immediately led to another, and I found myself feverishly obsessed with a mad rubics cube like project. Rearranging tools on my bench top and the reshuffling them again, trying to fit things together as neatly as possble.
 
The picture posted above gives you a view of the notched brackets in the saw till. I found that two  narrow, flat tools, the scribe compass and draw-knife, which couldn't be fitted on the lid because of handle diameter, and a protruding locking nut, perfectly filled the void between the box's inside front face and the saws. In this shot you see the two tools housed in slotted hangers screwed to the front inner face. The tools hang below the ledger strip that supports the upper drawers. The drawers in turn will, when set on the ledger strips, sit over the tools holding them in place.  Neat.
stevenbunn Wed, 07/08/2015 - 18:56

The baptismal font is almost finished, just a few more coats of finish on the removable lid and I am done. I will deliver the font Sunday. I plan on posting photos of the font after it's dedication on the 19th of July. After the shop is cleaned up, I have a number of projects in the works. I have been working on a design for a hanging saw-box to store my hand-saws. I have looked at a number of other woodworker's designs on U-tube and the web. While many are nice, I am shying away from an open box with no top and an saws hanging exposed without any cover. I have found that anything exposed just becomes a dust catcher. Building a hanging cabinet with a glass-paned door will give me a chance to bone up on my sash-making skills, something I haven't done in a while. I have two smaller prototype children's Windsors for which I want to make new bows with different profiles than what are on the chairs now. It is a pain to cut stuff off and throw it away, but the design process sometimes requires it. I am happy with everything else about these two designs, but the existing bows suck. Either the curve of the bow is wonky or the size is too big for the rest of the chair. Proportion and smoothness of a bow's curve are important, and sometimes the first effort doesn't cut it. Then there is a Christopher Schwartz style saw till that needs to be retro-fitted in my traveling tool box. Not really something that I have to do, but the current mounting arrangement with saws mounted on the inside of the top hasn't kept the saws from working loose when the tool box is banging around in the back of the trailer. I am always looking for a better idea. It is a bummer to open the chest and find the saws and framing square jumbled together on top of everything else. And finally, I need to get back to working on a batch of hand planes. As you can see I have quite a bit of work a head of me, and this doesn't count the large settee I started last year, or my wife's list. This stuff has been accumulating while I have concentrated on the paying work. Trying to decide what to do first is going to be the big problem.

stevenbunn Thu, 06/25/2015 - 16:26
The assembled Saw-clamp
 
A quick shot of the assembled clamp using a shop turned wooden screw
 
This has been a quick and easy project. As usual I never follow directions or plans exactly. A personal curse since elementry school. Readers of Popular Woodworking looking at the published plans accompanying the article will note that the socket head screws holding the two jaws together at the hinge appear to be missing. In fact they are mounted on the 'back' side of the clamp and don't show in this photograph. An error in laying out the project, but not something that is of real importance. I can still easily adjust the socket-head screws with an allen wrench. At this point the clamp is usable. I haven't yet glued on leather strips to the inside faces of the jaws, as described in the text. I used my block plane to taper the mating faces of the jaws. Even without the leather the jaws grab a saw firmly with out slipping. I am holding off gluing on the leather until I am sure that I don't want to plane a little more meat off the jaws to increase the spring action. So far so good.
 
Another slight got-cha from the article, the plans show a second half-round cut out on the very ends of both jaws. This cut out doesn't appear in any of the photographs that illustrate the article. I went back and forth over whether to add these notches now or wait. Clamping four of my hand-saws in the clamp for comparision, I found only one of the four had a handle that would need a further cut out. But even in the case of this one saw, only the last 3/4 inch of the saw blade was left hanging in the breeze, because the handle obstructed positioning the saw-blade along it's full length. The clamp holds the blade firmly even with this little bit of unsupported exposure. So I am going to use the clamp for a while before making any additional changes to it's profile.
 
Well that was fun. Now it's back to the paying work. Have a good day.
 
 
stevenbunn Wed, 06/24/2015 - 08:23

 

Wooden screw and handle for the new saw-clamp
 

Another issue of Popular Woodworking, and another 'must-do' project I didn't know was on my list. Life was getting a little boring. The Communion table was delivered to the Phippsburg UCC church last Friday. Saturday and Sunday, back in the shop I was final sanding the octagonal top which sits on the font. A boring but necessary task. Last Thursday, the latest issue of Popular Woodworking arrived in the mail box, and in it was an article by Jason Thigpen on making a saw clamp to aid in sharpening hand-saws. Despite owning an antique metal pivoting saw clamp, the pictures sold me me on making one of my own. Before I knew it I was combing my scrap pile looking for material suitable for the project. I settled on mahogony for the clamping jaws and hard maple for the rest. While Thigpin recommends welding up a handle to tighten the bolt that compresses the clamp's jaws, or purchasing one from MacMaster-Carr, this project gave me another opportunity to make a wooden screw. I will post a few more photos of the project over the next few days. Thank you for stopping by.

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