Broken River Joinery

Shavehorse Nearly Done

I’ve just about wrapped up the shavehorse project-still need to build the seat and tack on the elastic cord to the ratchet pivot key. Looking forward to giving it a go this weekend.




Treadle Jaw

 Rounding off the corners on the upper jaw of the shavehorse mechanism.

Osage Orange

An interesting piece of Osage Orange destined to become a set of small boards.



A Life with Sincerity

There are other ways to live in this world.

Kanna vs Sandpaper

From the Tokunaga Furniture Company:



Plane on the right/Sandpaper on the left.

And just when I was thinking that maybe using a little sandpaper wasn’t so bad. Guess it’s back to the Kanna drawing board for me.

Working On a Shave Horse

In continuing my self-apprenticeship in woodworking (and taking a slight although not altogether unexpected detour from the current Shaker Bench), I’ve arrived by happenstance at the world of chair making, or more specifically, making things on which you can sit. When I first got interested in woodworking I remember coming across George Nakashima’s Conoid Chair,


which if so you’re so inclined can be had for $40,000 for a set of 4. Three things struck me about this chair, the first being the name, i.e. in my ignorance I had no idea what a Conoid was. Second, the fact that rather than have four legs, it had two bottom “rails” for feet (the better to slide across the carpet with my dear), and third-ly, the spindles. More specifically, how to make them, especially w/o a lathe. That was about 5 years ago.

In the intervening years I’ve tried all kinds of different projects, trying to build tables and desks and lots of frames and some kumiko work, and bookshelves, etc…all mostly flat, all mostly about a B or B+ (definitely a few D’s and F’s too), but I never tried many curves and I definitely didn’t try chairs. Chairs have always kind of been this far-off odd thing to me and yet over time it seems like every woodworker who ever made a name for themselves, built some kind of unique chair that was their standard, defining work. And so I’ve been through a lot of different projects and it seems only fitting that one of my last self-taught endeavors should be chairs. Which brings me back to lathes and curves, which brings me to the shave horse. Like how to make spindles and legs without a lathe. Turns out a shave horse is the way to go.

And what better shave horse to build than Brian Bogg’s designed horse? You can see the article in issue #139 of Fine Woodworking (members only…or borrowed from your local library). I had a nice piece of Ash lying around and was able to nearly lay out the entire shave horse on it. (8’x10″x2″).


I drew out the various pieces according to the article plans-everything is basically 2″ thick so it’s a fairly easy layout. Notice the blueish staining on the picture below…more on that later.



Due to the size/heft of the piece I used a combination of power and hand tools for the initial dimensioning. Here’s the first rail.IMG_4643 (1)


And the second, waiting to be cut to size.IMG_4645


You can barely make out the rear legs along with the various smaller parts; the ratchet riser, ratchet pivot key, rear block, etc.
IMG_4646Remember that discoloration from before? Surprise! It’s a nail.



After some severe encouragement, it decided to come out. Scrapbook.



Here’s the majority of parts, save the treadle mechanism. I didn’t have enough Ash for that, but do have some Cherry that’ll use once I get to that point.



I cut a 45 degree sawing jig to clear out the ratchet riser parts. Very handy.IMG_5001



And fitting the mostly hand carved ratchet pivot key to the ratchet riser. It kind of looks like a dove. Put a bird on it.



Here’s most of the parts clamped together to get a decent idea of the fit.



And now for clearing out the lap joints for the rear legs. I think the router plane is one of my favorite tools.



And Ash is a fun wood to cross-plane.IMG_5011



Fitting the rear leg to the rail. Nice solid fit. There’s a joy that comes with sliding a joint together, held only by the compression of the wood.



And here’s the saddle blank. I’m using a piece of White Oak that was a cut-off from when I built my workbench. I’ve never carved a seat before and I am very much looking forward to it, although using Oak for the first time should be super fun…and not hard at all.


There’s a lot of beards and suspenders at Handworks


Handworks 2015

Just in case you haven’t made plans yet for Handworks 2015, it’s only five days away. And there are still a few tickets for sale to see the Studley exhibit at the Scottish Rite Temple in Cedar Rapids.


Two years ago the first Handworks was a great experience and this time around will have even more to offer. I’m delighted that we have this fantastic event in my home state of Iowa and kudos go out to Benchcrafted for making this happen.

Hope to see you there!

May the Fourth Be With You

Thought it would be nice to share my favorite blogs on this most auspicious of day of days, since I don’t keep a running blogroll on my site. Many thanks to all below for much inspiration.


Shaker Bench

In choosing to begin fresh with a more direct intent, I wanted to try my hand at a basic Shaker Meetinghouse Bench. Christian Becksvoort has a nice how-to in Fine Woodworking 231 that I used for my first try. Eventually I’ll use Cherry for the later benches, but for this first attempt I used a single piece of Poplar. The final dimensions ended being approximately 18″ x 9″ x 7″. The most difficult step was fitting the corner braces accurately.

I started with the legs, cutting out the arch with a fret saw and smoothing it out with a rasp and then successive grits of sandpaper wrapped around a dowel. After that I cut out the two tenons that mate to the bench top.


IMG_4468Next was clearing out the 1/8″ dado and then chopping the mortises in the bench top to receive the tenons.



IMG_4484Moving along, the fit of the tenoned legs to the bench top was a bit tight and I ended up cracking the top but overall the fit wasn’t terrible and was a good reminder of why it’s a smart idea to build a mock-up first. It makes the mistakes that much easier to live with.




Fitting the braces was next and was the most challenging part of the process. My first brace was pretty awful but the second (after forcing myself to slow down) came out much better.





…and the second attempt…




IMG_4541The the dry-fit and finally glue-up and planing/sanding down. I didn’t apply a finish and this ended up making a nice gift for a friend’s son.







Get every new post delivered to your Inbox.

Join 127 other followers

%d bloggers like this: