I recently finished working on a cutting algorithm app for the iPad and iPhone called Smart Cutter, and wanted to share the app with every one hoping get some feedback from carpenters and wood workers. Smart Cutter finds the maximum number of small pieces cut from a larger sheet of paper with minimum scrap. It employs a state of the art algorithm to generate the maximum number of small pieces cut from a larger sheet of paper, wood, cloth or any other material, with minimum waste. Whether y...
You ain’t ever gonna keep me down. Lyric spotters please feel free to comment. I left you, last night, as I was hacking at the pattern board with a chisel. No, I’m not mad. I’ve done all the tests. It worked. I repaired the pattern. I re-placed the mask and all looks good. Re-taped the pattern I scored a knife line into the pattern,along the outside edge of the outer tape. In combination with a strip of Polycarbonate, which has a line scored on...
In my last blog, I created the tray bottom. In this blog, I will cut the grooves for the tray bottom, rout finger holds and put the tray together. First step is to cut grooves in the tail section. I use the MCLS 13/64” plywood bit (because 1/4” plywood is smaller than it’s nominal size). As a rule of thumb, I like to cut the groove 2x the groove width (so 1/2” in this case) from the bottom in order to leave enough material for a strong assembly. I mark t...
I’ve decided to make this one with wood from from my scrap bin and my ‘Ebony Bits Box’ - I won’t bore you with the details but after a lot of cutting and sticking, using Viscose CA, I had made the pattern (with a few little modifications). This was glued onto a backing of 1.5mm Birch Aeroply, using PVA, and thickness sanded to 5mm. Hand sanded down to 600 grit and a couple of coats of spray acrylic (satin finish) later this is the result. I have sto...
After finishing restoring the blade, it was time for a new handle. A lot of friendly lumberjocks suggested that I try to make the old handle fit better before I went all out and made a new one from scratch, so I thought I’d try that. Then I saw this beautiful hunk of Padauk at the store, and it was just begging me to be made into a new handle. I couldn’t resist. Maybe next time I’ll try the handle refitting, but this time I was moved to the dark side. To start off, ...
In my last post, I finished cutting the double dovetails … sorry for the passive aggressive parting line. It was late and I was tired. Now I will put the finishing details on the tray. The only 1/4” plywood that I have in the shop is a piece 13”x72”. My tray is 14 1/4” wide. So this is an opportunity to create a composite panel as a tray bottom. It will look like this: First I cut the center panel on the table saw. Then I cut the outer...
In the last blog, I completed the tails for the project (after a few mistakes). The next steps are a lot faster and less error prone. Line up to the A cuts and then first step in cutting the tails is to set the stop block so it just barely misses the bit. Making sure to keep you fence mark side aligned against fence (easy to forget for this step), cut one full set of pins, advancing to each A cut. Then check the fit. As you can see, I am shallow by 1/16”. So I ne...
At the end of the last blog, I had glued up the trim to the tail sections of the R/L pieces: I used my oscillating belt sander to sand the ends flush Flush ends give me a flat surface for the next step In my previous blog, I mentioned that you need a zero clearance insert to avoid having the bit pull the workpiece down. I forgot to mention the need to ensure that you hold the workpiece against the fence, particularly when you pull the sled back thru the bit (the climb cu...
First step of a double dovetail is to cut a through dovetail on each side piece and then attach a trim piece. This blog entry will cover that process. So starting with the end pieces and a 6” piece of trim stock (same width as the side piece, thickness doesn’t matter). Install the two template strips into the positioning system (1 dovetail strip and 1 double dovetail strip). The dovetail strip consists of an A side which lets you cut pins at 7/8” intervals and ...
I have gotten a few questions (actually 3) from folk about to how create the Incra Double Dovetails Joints such as the one in this project: I will not be making a box in this blog. But a really good friend saw this box and asked if I could make a 14” x 19” serving tray in the same style. Maureen has been a huge help to my wife and I so I was happy to get a chance to make something for her. Obviously, first place to start is to get an Incra Jig System. I have the old 1...
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