Slab Top Coffee Table Project

I harvested this slab of elm from a tree that grew just three miles away. When it had to come down, I had two logs milled into boards. This is the last board from that tree. It measures 48" long x 19" wide x 1" thick and it has incredible natural character. I made the base from walnut scraps left over from a bathroom vanity that I built for a home in Park City, Utah. So it is a fine example of locally made, sustainably-sourced goods, and I hope that it manages to be inspirational or helpful in some way.

I used a jigsaw to trim the slab to length a create
a faux live edge.  Not a bad sta

I marked the locations for the legs- I didn't worry
about making a perfect rectangle, as this
piece was kind of organic in nature anyway.

I used an angle gauge to determine an angle that
looked right for the legs.  It ended up being 15 

I used an angled drilling guide, and I used the
angle gauge to set it to the right angle.

After testing the setup on scrap, I drilled holes
for the four legs.

The legs were milled from 1" x 1" walnut.

I used the bandsaw to cut tapers on the ends of
each leg so that the taper cutter fit.

This taper cutter isn't cheap but it's worth it, and it should last
a lifetime.

I cut a slot into each round tenon.  This one
wasn't lined up so well, so I made another.

I used  a belt sander to make wedges from
contrasting wood to fit the slots.  

I made the legs longer than necessary, because
I figured I'd need to level the table.  I shimmed
the legs up so that the top was level.

I then ripped a scrap of plywood to a width that
would create a finished height of 18".

The legs were all trimmed in different amounts,
but the results was a level table with no
perceivable wonkiness.

I cut the tenons off with a flush-cut saw.

Fitting the short stretchers was tricky business-
I used an angle finder to determine the angles.

I used slightly narrower stock for the stretchers
so that I created a nice reveal.

I secured the stretchers with Miller Dowe

The long stretcher went in just above the short
ones.  I set them into place so I could see where
to mark them.

I marked the vertical cuts directly from the legs,
and used a ruler to extend the angle of the leg
onto the horizontal surfaces.  This made for
compound cuts, which I approached cautiously
but nibbling away and readjusting until they fit

I used Miller Dowels again, although plugged
screws would've been a good choice, too.

The sanding was just business as usual

The walnut yielded a nice little bonus.

Thriving in a Small Shop

I’ve had a number of shops in the course of my almost twenty year career.  Seven, actually, and they’ve really run the gamut in terms of size, layout, and various other attributes.  One was located on the third floor of an old warehouse and was accessed by a clanky old freight elevator. With exposed brick walls and mountain views, it was high on the charm scale.  It was also huge- around 3,000 square feet- and this actually turned out to be too way big.  I basically just ended up camping out in little nooks and then moving around like a nomad to another spot when the mess became unmanageable.  My current shop is my smallest yet- around 400 square feet, or the size of a two car garage, but it is definitely my favorite.  For one thing, it is located at our home, so I just can’t beat the commute.  It allows me to walk our daughter to school in the morning and pick her up in the afternoon.  Logistically, it really works for our family.  There's also the fact that it allows me to run an extremely low overhead business: it feels very satisfying to be in a “whatever I make, I keep” mode for once.

While I love this shop, and figure that it will likely be my home for the next twenty years or more, it does take a certain attitude and a certain set of strategies to make it work.  I’m not sure I could’ve pulled it off at earlier stages of my career, but now it’s great.  Here’s a list, in no particular order, of a few considerations that keep me happy in my small shop:

-Put everything is on wheels.  This allows you to move things around to accommodate different kinds of jobs.

-Don't build any built-in storage units, workstations, or benches.  These things serve as anchors that prevent you from thinking creatively about the space and rearranging as needed.  When you have tons of space, this is less important, but in a small shop, the ability to move things around is critical.  Fixed structures feel, to me, like anchors that get in the way of flexibility.

-Don't hoard scraps or other unnecessary stuff.  It may be unrealistic to get to a “zero tolerance” for scraps, but less is more.  When I have scraps from a project, I try to use them right away.  Not someday. 

-Have a ready-use for scraps.  To this end, I make and sell cutting boards in random shapes, styles, and sizes.  Some times they’re really interesting, and sometimes they’re plain, but I make them as soon as possible and then list them on my online store.  I make a couple of thousand bucks a year doing this and it is a win-win.

-Donate extra scraps that you won’t use.  We have a Habitat for Humanity restore in our area that takes whatever I don't want, which minimizes what I throw away. 

-Reflect on what makes the space really speak to you.  For me, I need a big, bright, open area where I can feel expansive.  I’ve decide to divide my shop roughly in half so that all of my tools and storage are in half of the shop, or less, and this provides me with a nice, open space to work in.  This is a personal preference- I’m sure that someone else, with the same space and the same tools, would arrange it quite differently.

-Set things up to accomplish multiple purposes.  For example, my workbench (made by Kreg) is on casters and is set to the same height as my tablesaw, so it can quickly be scooted around to act as an outfeed for my tablesaw when needed.

-Buy materials on an as-needed basis.  I used to occasionally buy materials in advance because they were a good deal, and I’d used them later on when a project came up.  I don’t do this anymore.  For one thing, I’ve learned that there’s always a deal to be had if you’re resourceful, so there’s no reason to overextend myself in terms of money or space.  I have a few boards on hand that are really lovely, and I haven’t gotten around to using them yet, but they’re the exception rather than the rule.  By and large, I can get everything I need at the drop of a hat- I’m 9 minutes away from my favorite supplier- so I don’t need to turn my space into a warehouse.

-Plan your workflow accordingly.  When I had larger shops, I used to take on at least fifteen jobs at a time, and because I had the space, I’d always have a number of projects in various states of completion cluttering up the place.  Now I take on one or two jobs and work efficiently at starting and finishing them in short order.  “Get ‘em in, get ‘em out” is my motto these days, and it is not only the best use of my small amount of space, but it’s easier to manage, too.

For me, openness is a priority.  I sort of like squeezing
stuff in as needed to create a big "sanctuary" space
where I can really move around.

I keep it flexible.  The shop changes from week to week.

Even my storage- the wire rack in the background- is on wheels.

Mobile work supports help.

Mobile bases are essential.

I move my bench around as lighting conditions
shift throughout the day.  Thank god for casters.

Winter’s Coming- Time to Protect those Tools from Rust

(This post was sponsored by 3-IN-ONE Oil; the content, however, is entirely mine)

For many of us, winter time brings lots of changes in the workshop in terms of heating and cooling cycles.  While many woodworkers live in places with mild climates, many others need to rely on some kind of heating system to make our time in the shop more pleasant.  And the range of heating systems, of course, is pretty broad- I know folks who heat with wood, and others utilize natural gas, propane, or other fuels to get the job done. 

While heating a shop isn’t quite the topic of this post, it definitely has consequences for our beloved tools, so it is worth taking a second to consider.  When choosing a method for heating one's shop, I’ve often found that there are three factors that come into play: price, convenience, and environmental impact.  The best setup would cost nothing, require no work, and have no environmental impact.  In the real world, though, we’re all trying to minimize these three things, and so we all end up making a choice that represents our best option.  A key strategy that usually emerges is the fact that shops aren’t heated evenly at all times.  While some woodworkers do focus on keeping a constant temperature in their shop, I know many- including myself- who don’t.  This solves a few problems (it lowers my heating bills and minimizes the amount of fossil fuels that I utilize) but it introduces a new problem.  Big changes in the temperature inside your shop can cause the humidity levels to change.  And while the changes may not create effects that are directly observable overnight, they can cause problems over time: even small amounts of water vapor can condense on tools, which can create rust.  So, since I have a conservation-oriented mindset when it comes to heating my shop, this means that it is in my best interest to spend a little time protecting my tools.  It doesn’t take long, and it’s worth it.

You can apply oil directly to a tool's surface or
to a paper towel- whatever works best.

My favorite all-purpose solution involves using a light oil product because it’s quick and easy.  It also is versatile; whether we’re talking about hand tools that are stored in tool chests, or on pegboards or shelves, it works great.  I bring this up because some companies produce desiccants that you can put inside a toolbox or other enclosed space, and they work well there to help eliminate moisture from the surrounding air, but they don’t work so well in open areas- their effects are pretty much negated, in my experience.  My preference is 3-IN-ONE Oil.  It is available all over the place, and it is pretty inexpensive.

This old handplane isn't fancy, but it came
from my dad, so it is rather dear to me
nonetheless.   It's worth a little TLC now
and then!

How do I apply it?  That depends, but it’s not rocket science.  If I’m oiling small tools- a handplane, for example- I just use a paper towel or rag that I’ve dampened with oil to rub down the tool and make sure it’s free of dust.  That’s it.  For hard-to-reach places- like the trunnions and other moving parts inside my tablesaw- I’ll used canned air to clean things out, then I apply a light coat of oil.  As I said earlier, it doesn’t take long, and it’s definitely one of those cases where an ounce of prevention is worth a pound of cure.

Yep, this is what happens when you don't take
care of business.  Now I've got to put in a bunch
of elbow grease just to get back to square one.

 3-IN-ONE Oil is available at many retailers.  I’ve purchased it at Lowe’s and Home Depot, and I’ve seen it at our local Ace Hardware, too.

For even more information, check out www.3inone.com

Sharp Tools- in the Workshop and in the Office

Small businesses are funny things.  And I don't mean in a humorous sense, although there can definitely be some of that now and then.  I mostly mean that there's an iceberg of activity below the surface of most small businesses that isn't always readily apparent when viewed from the outside.  Take the restaurant game, for example: I think it is fair to say that a lot takes place that doesn't just involve the putting food in front of customers.  Menu planning, recipe testing, and even boring tasks like carpet cleaning probably take a lot more time than you'd ever imagine, just to ensure that the table can even be set to begin with.

In my case, I've been doing custom woodworking for almost twenty years (where has the time gone?) and in an average week, I have to do plenty of stuff before I can even set foot in the shop.  It usually isn't very glamorous, but it is critical.  For example, I have to type up estimates and proposals, research design ideas, sketch plans for upcoming projects, invoice clients, network and promote myself on social media, update my website, and lots more.  Chores like these are hardly the reason that I got into woodworking, but in the end, they're what keep the lights on.  Most of these activities are sped up somewhat thanks to technology, but still, it's a lot to do.  And that's why it is so important to keep on top of the tools in the office in addition to the ones in my workshop.  I just got a new computer (what a game changer- should've done it sooner!) and I've been looking at new internet service providers, too.  Time is money, so a fast, reliable internet connection at a good price is essential.

Having looked at a few of the companies in our area, I've found that CenturyLink stands out.  Here are a few of the things I learned:

They're 100 years old.  Who knew?  Anyway it is nice to see that they're not a flash-in-the-pan, here-today-gone-tomorrow company.  In fact, they're investing in infrastructure to provide the fastest internet service in Salt Lake City- this makes life in the digital age a lot easier, more satisfying, and more reliable.  My daughter will love playing games online, I'll get my work done faster, and my whole family will love video chatting with folks all over the country.  To put the speeds into context, with 100 Mbps, you can download a high definition movie in less than 7 minutes.  Nice.

It looks like CenturyLink is really dedicated to serving the community for years to come.  They're supporting education through their STEM program in partnership with Utah Jazz, which recognizes outstanding students in science and tech by making a $10k donation to the students presented at a Utah Jazz home game.  In addition, their Teachers and Technology program offers yearly grants to teachers that exemplify technology excellence in the classroom – this year, we donated $55k to this program in Salt Lake City alone.

For more information on how CenturyLink supports your quality of life at school, at home, and at work, check out:

www.centurylink.com

This is a sponsored conversation written by me on behalf of CenturyLink . The opinions and text are all mine.

Block Plane Rehab

                                                           

Although I really only need one block plane, I've managed to collect a few more along the way.  I'm probably up to four or five by now, never having paid more than a few bucks each at antique store and yard sales.  That's a good thing, since they one's I've stumbled across aren't particularly high-end tools.  But, with a little bit of love, there's no reason they can't perform just fine at the kind of things that block planes do best- rounding over an edge, cutting a chamfer, and evening out endgrain.  This blog post will illustrate the process I recently used to tune up a plane- your own experience may differ, depending on the tool's condition, but I imagine that this might be a good starting point.

In this case, the plane was complete and there was no real damage to any of the parts- it was mostly dirty and in need of a tuneup!

Before I could get any farther, I had to loosen up the threads underneath the cap so that I
could get the plane apart.  I used 3-In-One oil- and it was nice to have the one with the extender
spout to get into the nooks and crannies.

Ta da!

Part of the tune-up just involved simple cleaning- I used steel wool, paper towels,
an old toothbrush, and some household cleanser.

The blade had been abused and was pretty dinged up.  Fortunately I have a way to bring it back to life quickly and easily.

Using your sharpening method of choice, you'll want to start by flattening the back of the blade.

With the back flattened, you can  work on the bevel- and after that, the microbevel.
I love my Worksharp because it is fast and doesn't demand that you learn a whole new
skill set- just follow a few simple steps and you're in business.

The body of this plane wasn't cast iron, and it was formed from a single piece of  bent
steel- pretty typical on cheap old planes.  The rust wasn't too bad, at least.

Flattening the bottom of the plane is an important step.  You'll want to make sure
the plane is assembled with a normal amount of tension in it.  This will ensure that
the tool is in its regular shape and isn't distorted.  In other words, if you flatten it without
the blade in it, it is possible that you could put in the blade and tighten it, and then end
up with a sole that isn't flat anymore.  I use 120 grit paper.

A flattened sole should show a uniform pattern of sanding scratches with no hollows or crowns.

One last thing- I recommend lubricating the threads to keep the plane's adjustments
easy to use.

I also lightly sanded the sides of the plane.  A coat of paste wax will help to protect the bare metal from corroding.