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#1 ·
*Intro, info, challenge and materials*

Intro, info, challenge and materials
low budget, high pleasure

Intro:
Ok I made it! dovetails in my tooltote project, but learned my tools were not the best for this job.
First of all my Bahco 434-50 Bevel Edge Chisel are made for contractors (demanding carpentry, whatever that means), not for cabinet work, the backs are not completely flat, the sides are slightly rounded, the bevel sides are too high and the handles are too long for me to pare with, besides that they are really nice, and I will actually recommend them for construction site use since they are with split proof two component ergonomic grip, can take some nasty repeated hammer blows, will not rust, and take a excellent durable edge but for cabinet making and workshop use, I give them thumbs down.
(So yes I am on the lookout for the money to buy a nasty set now, and have my eyes on the Iles UK).

So this lead me to do some investigation on this subject, and I realized my pension was not a well match for a set of good dovetail chisels, so as we say in Denmark 'need learns the naked woman to spin', even I'm always dressed while in the work shop…

Info:



This was where it all started, I purchased a old toolbox full of tools from UK, amongst the tools was a old tool roll with chisels, most of them was not beveled and in a bad condition, so I put them aside for future use… (Now).

The challenge:
To make a set of chisels for dovetails out of those old English chisels.
Turn new handles.
Flatten the backs.
Make new profiles on the steel;
A fish tail chisel.
A left and a right 'dovetail' chisel set (sides at maximum 45 degree and almost to the back).
A left and right skew chisel set.

The materials:



Here they are the old crooks, all has served their first life well, and deserve with no doubt a new one in better clothes…



And here a old table leg found in the street years ago, hardwood of some kind…



Destinies are now determined.

I'll split the blog up here, so it does not become too long for a ISDN connection…

Press here for part two.

Hope this winged dovetail tour can be to inspiration,

Best thoughts,
MaFe
 
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#2 ·
My dad always said "some people can turn nothing into something and some people can only turn something into nothing". You sir are of that first category. I can't wait to see the rest of the blog.
 
#7 ·
I just recently made myself a cabinet skew chisel from an old rusted tool I found at a garage sale…..love those old tools (heavy duty metal and most of all CHEAP)....I have been making my own lathe tools from old ones (I find them at yard sales and swap meets) and you just cant beat having a custom tool that is made for the type of work at hand and the much cheaper price then buying them new - not to mention that even the more expensive new tools can be very cheaply made.

I am looking forward to watching your progress here….I have some cabinetry chisels I have collected over the years….but would be nice to put together a matching set.
 
#8 ·
Hi there,
reggiek, I have saved also some old chisels to make some special tools for the lathe in the future, will love to see yours.
Just follow the links, it's all there now.
Dennis, here some info
Explain:
http://chestofbooks.com/home-improvement/woodworking/Elements-of-Construction/20-Chisels.html
Where to buy:
http://www.oldtools.co.uk/new.tools/henry.taylor/f49-f54set.php
Herb, my GF are French…
Dan, ;-)
helluvawreck, happy if you do, I always enjoy when you are arround.
ShopTinker, that was a wonderful compliment thank you, it touched me. My daddy always just said 'you can do better'...
Best thoughts and a big smile,
Mads
 
#9 ·
*Chisel handles on the lathe *

Chisel handles on the lathe
no money, no pressure

Intro:
This first part will be how I made the handles.



Here the materials, a old table leg found in the street and cut into needed size, and a piece of aluminum tube for ferrules.
First step is to mark the centers.



Here the wood is set up in the lathe, and in the background you can see my sketch for the app. shape I wanted.



First turning the end for the ferule, I used a caliper to set the size.



The shoulder takes form.



Now I turned the wood around, so I could shape it all up with minimum waste.



Seems I did not found the center all well here… But she sure gets some nice hips.



And even a sweet butt too.



Then I lay down the first one on the table in front of me, and turned the rest freehand after this.
I was amazed to see that they looked almost the same…



Sanding while spinning.



Some chips and dust for finish (a tip I got here on LJ).



This is the result, not so bad for a beginner! (I'm so modest).



Then I turned this pipe, just to please my fellow LJ's… (Ok that was not the truth, sorry).
- and it was really hard to smoke while spinning.



A not sharp image of applying the linseed oil.



Here with a thick layer so it can soak up really well.
(Wonderful to see the color now).



Finally a five nice handles, ready for the chisels.
I'm really pleased, they got a good grip in my hand, and the round butt is so sweet in the palm of my hand (Kelly I do not want any comments on his one).

I'll split the blog up here, so it does not become too long for a ISDN connection…

Press here for part three.

Hope this winged dovetail tour can be to inspiration,

Best thoughts,
MaFe
 
#19 ·
*Honing the chisel blades to new shapes *

Honing the chisel blades to new shapes
no cut, no pain

Intro:
This first part will be how to make the new bevels, and hone the blades.



Where we ended last, with the old chisels and five brand new home made handles.



One of the old blades, as you can see some of them needed a helping hand…



With a marker I draw my layout on the blade, this one for the fish tail.



Time for that Dremmel tool to get running again. I use this because they are quite fast, and do not produce too much heat (relatively).



I said relatively much heat, since I was nervous to lose the hardening of the steel, I dipped in water all the time, I held my hand on the iron, and when it was too hot to hold I dipped it (app. on million billion times I think…).



Almost done!



The edges after the Dremmel tool, were quite rough.



But a quick tour on the stone, and it was fine.



So time to run that water grinder, and my finger…



When you hold your finger long enough on the side of this you start to bleed, and when the edge of the chisel comes to life you should not touch it - I tried both, learning by doing, again and again (no cut, no pain)!



Separate the blades from the old handles (my chisels were forged tang models).
I used two methods; to saw it on the band saw, this might destroy the saw blade, so I stopped after the first.



Then I simply put the handles into my metal vice, and tighten it until it crushed the handle, this was quite effective, and I was able to take out the tangs, I even managed to save the brass ferrules for other projects (I love recycle).



Here we are; blade ready for next step, after a little cleanup of the tang.



Here the marking up for one of the skewed chisels.



And then Tour De Dremmel.



Back to the water grinder, now in skewed angel.

STUPIDITY
Ok, I admit to be so lazy I can do really stupid things…



This was an attempt to let the machine do the work for me since I have troubles with my arms, and cant to well do repetitive moves (due to neck operation).
So I build this crazy setup to let the grinder run without my help!
It did not work at all, not enough pressure.



But I did not give up…
So an elastic band and the machine could work alone while I was smoking my pipe.



Just one more for the laughs.

Back to reality MaFe!!!



Free handing the new low beveled sides of the dovetail chisels.



Here a good part of the way.
It takes quite some time, so I would recommend to find some beveled to start with, but it was possible.



Finally all the blades ready, it was a big work, and took several hours in total, but I have no doubt they will be worth the trouble for many years to come.



Here a update on the fishtail chisel, I grinded the sides also, so it can clean up the bottom of the dovetails, and get into all the little places.



Same.

I'll split the blog up here, so it does not become too long for a ISDN connection…

Press here for part four.

Hope this winged dovetail tour can be to inspiration,

Best thoughts,
MaFe
 
#29 ·
*Fitting handles on the chisels *

Fitting handles on the chisels
no fit, just hit!

Intro:
This first part will be how to mount the tang blades in the handles, and then a go go.



Where we ended last, with a set of reborn chisel blades.



The tube is cut up into smaller pieces, and these are grinded flat in the ends.



Handles and ferrules.
Next step was to drill holes in the handles, I forgot to photograph this one, but the this is how it's done.
First drill a small hole in the handle, this hole must have the deepness of the tangs length.
Then you drill two or three more holes, less and less deep, in this way you make a hole that fit the shape of the tang.


Mount the blade in the wise.


Fit the handle over.


No fit, just hit!



If the blade not fit perfect, or you want a better grip, use epoxy, I did on the skewed, since I think they will be used also with mallet.
(The real way I heard, is to heat the tang and stick it in while red hot, but again I was afraid of the hardening on the blade).



Sizes: 6mm-1/4"low angel and side, 15mm-5/8"skev, 11mm-7/16"dovetailed.

Grease box, pipe and a set of self made dovetail chisels - what more can a man ask for?
CAROLINE!!!

It's the end of this blog (for now)…

Hope this winged dovetail tour could be to inspiration, perhaps bring some old chisels back to a new life,

Best thoughts,
MaFe
 
#56 ·
*Paring and a Exocto science (for beginners...)*

Paring and a Exacto science
ok perhaps not science… just minding the grip.

Intro:
When using the chisels I realized I still had to reach for my other set to pare, and for smaller cuts, key holes and cleaning out it would be fine with a delicate cutting tool.
Exacto knifes are not exactly science, but they are really easy to use, and you can sharpen and shape the blades as you wish fast on a grinder.
So it was time to make an update on the dovetail chisel set!



Excato knife, two wonderful old English cabinetmakers chisels and three fresh turned handles.



Beating up those handles with my new brass mallet , notice a little worm have had a life in the handle once (I start to like those little bastards (when they are gone)).



We are on a good road here I think.



Clean up the tangs , keep them rough, so they will bind better in the handle when set.



Cut the Exacto, exactly where you like it.



Find a drill that match the Exacto and drill a hole in the handle (this is the rocket part…).



Fit the ferrule, and cut it over.



Sand the end for beauty and comfort.



This is where we want to be now!



Now we take a detour to the chisels.
Mark the center.



Find two or three drill bits that graduate in size, from small to a little smaller than the with oh the tang top.
(Like a tall pyramid, if this makes any sense).



Start with the smallest drill and drill a little deeper than the lengths of the tang.
Then step up in size and drill less deep and so.



Clean out the hole.



Fit the tang, so it is sticking up a little (the hole is too small).



Like this!



Then fasten the iron to your wise and bang the handle on.
Three ways now:
1. the handle was too small and cracked so you need to go back to start.
2. the hole was too big so the tang falls out, go to the epoxy part.
3. the tang sits tight in the handle so you smile and continue this tutorial.



Perhaps it's me, but I have no doubt who is the ugly dugly here…



Exacto again.
Clean out if needed.



Epoxy! This is so exiting.



A ferrule that doesn't fit can be glued in place too.



And fill up the handle of the Exacto.



Hole in one.



Now we have several possibilities in one tool, all from keyhole, cutting, marking and chiseling with custom made blades like my little dovetail here. Cheap fast easy.



Here are the updated set in the tool roll.



And here ready to work.
Sweet is it not?
(Perhaps my water based self confidence survived the rain after all).

I was having a cold, so no smoking the pipe…

Hope this winged dovetail tour could be to inspiration, perhaps bring some old chisels back to a new life,

Best thoughts,
MaFe
 
#71 ·
Upgrade of the set

Upgrade of the set
Now ready for really fine work.

Why:
Well… Ahhhh… Hmmmmm…
Ok I admit it!!!
Just for my pleasure, I love making tools, now I said it!

So now my dovetail set is able to clean up really fine dovetails and also able to get in to half blinds and other for cleanup.



Once again some old chisels of a nice quality, now some really narrow for cleanup and a 6mm for making a small dovetailed chisel.
Separate the handles from the tang from the handle and then put on new handles (look in this blog series).



The narrow just need a sharpening.



Ohhh yes and a new handle for my little Razor saw to match the set.
I give it two lines like the old to make it stand out from the chisels once they are stored in the roll.
(Yes I'm an architect).



Then some fine shaping on the water stone grinder and a new dovetail chisel is born from the old 6mm.



Now I should be able to get into just about every little corner.



And here we are, the full set.

Hope this new dovetail upgrade could be to inspiration, perhaps bring some old chisels back to a new life,

Best thoughts,
MaFe
 
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