Click here for the most recent Rough Cut Show video!

If you are like me, hungry for another great woodworking podcast, you have to check out Thomas J. MacDonald aka T-Mac aka T-Chisel aka T-Chizzz on The Rough Cut Show. The show covers the construction of a beautiful Bombe Secretary in a unabashed style. He is an absolute blast to watch and there are some great learning points in every episode. More importantly, The Rough Cut Show “Ask The Masters” Forum has started a groundbreaking project. Approximately ten forum members are participating in a unique internet woodworking classroom collectively building a Crazy Leg Federal Table. The sole purpose of the project is to explore Federal style legs and embellishments such as stringing, banding, fans and inlayed bellflowers. So check it out and perhaps join the forum group and build your own Crazy Leg Federal Table!

Tommy’s Official Website: Thomas J. MacDonald Fine Furniture

Enjoy!

I had a great New Years Day afternoon speaking with Todd Clippinger. I will apologize in advance for a long download but it should be worth the time. Todd shares some insight to his approach to woodworking, design and craftsmanship. I think you will be surprised what his favorite tool is!

Click for Hi-Resolution Video

Woodworkers throw away your roller stand once and for all!

My last Ezee-Feed video was a bit of a teaser as I unpacked and started the installation process. Well I finally got the Ezee-Feed system installed on my saw. What a sweet accessory! I have a very small shop. This system allows me to cut sheets of plywood without any help. As a side note, my saw guard was left off for clarity while shooting the video . . . something I would not do on a regular basis.

This video demo of the Ezee-Feed infeed and outfeed system for the table saw will show you a better and safer way to cut rough lumber, plywood, MDF, melamine & other sheet goods. Ezee-Feed is the perfect solution for both the large production shop and the small garage or basement shop. Reduce back strain and kickback. Increase shop production and efficiency. Order yours today from Ezee-Feed Manufacturing!

Made by our own Lee Jesberger!

Ezee-Feed Manufacturing

Lee Jesberger
856-875-8618
Made in USA

Click HERE for Hi-Resolution Version

This was posted this earlier on my blog The Folding Rule Show. The video highlights construction details of The Cooper House and some of Todd’s furniture.

I just had the distinct pleasure of a cyber visit with Todd Clippinger, a talented designer and craftsman. I met Todd through one of the woodworking forums . . . well, the best woodworking forum; Lumberjocks.com! A first for me last night, but typical of Todd’s many talents and character, he pushed my technical envelope because our visit was via iChat. We had a great conversation. He was exactly as I imagined from previous Lumberjocks interactions.

Stay tuned for a future installment on this interview series. Todd has agreed for me to stitch together a series of interviews. This will be done slowly as it is very memory intensive and I will need to be respectful of Todd’s time. I also do not plan on posting Episode #2 until I have completed a demo video for Ezee-Feed.

Todd’s website American Craftsman

Todd Clippinger Gallery

Click for Large Format Movie

I just posted this on my woodworking blog and felt it was something important to share with my fellow Lumberjocks. I am sure many of us can remember middle school and high school woodshop. It is a sad state of affairs that industrial arts are being dropped due to budget constraints. It is up to each of us to help pass on the joy and traditions of woodworking.

Those of you that have followed any of my entries on Lumberjocks.com, The Folding Rule Podcast or The Folding Rule Show Blog know that my son Matthew is a burgeoning woodworker. We have had a lot of fun in the shop. His first project was a birdhouse that we built 10 years ago in Paulsbo, Washington. That birdhouse hung with pride from the limb of a large pine tree in the front of our first home. More on Matt’s woodworking projects to be posted in the future . . .

Since that time Matt has continued to learn about woodworking while pursuing scouting. When he was a Cub Scout we built toolboxes as a den project. Later in Boy Scouts he completed his Woodworking Merit Badge when we hosted some scouts from Troop 728 in my shop. I posted the experiences of Matt and his fellow scouts as a blog series on Lumberjocks.com, as well as, an episode on The Folding Rule Podcast.

Matt is also a very serious history buff with a special interest in The Revolutionary War and The Civil War. I recently had the privilege to strike up an email conversation with Master Woodworker, Charles Neil. I complimented him on his Unplug The Kids YouTube episode where he hosted a number of kids for an afternoon of woodworking in his shop. I also shared our experiences with Matt and his fellow scouts in my shop. Getting young people into our shops and passing on the joy and traditions of woodworking is vital in these days where industrial arts have been dropped from many school curricula.

Relating my regret for not knowing Charles sooner, as we had recently made several trips to Virginia for “history vacations”, I shared Matt’s passion for history and The Civil War. Charles very kindly responded with an offer to send Matt some left over material from a recent commission. Some very special material as this was timber from a limb pruned from The Stonewall Jackson Prayer Tree! Well, Charles made the day for a 12 year-old boy that day. We will not travel through New Market, Virginia again with out taking the time to stop by to visit Charles and shake his hand.

Matt was quite excited about a package soon to arrive in the mail. Luckily we went away for the Thanksgiving holiday providing for some distraction. Upon arriving home we found a package on the doorstep from New Market, Virginia. Matt was very excited as he opened the box and pulled out two pieces of some very remarkable wood. What will become of this timber? For now it is safely tucked away. We anticipate taking advice from Charles and will likely turn a pen or two and hopefully a small presentation box.

The Stonewall Jackson Prayer Tree is estimated to be anywhere from 275 to 300 years old. It is considered one of 36 most historic trees in the United States, according to the US Forestry Department.

Please checkout Charles on YouTube at In The Workshop, as well as, his homepage The Workshop of Charles Neil - Maker of Fine Handcrafted Furniture.

Below is an excerpt from Charles’ November 2007 Newsletter.

I had the opportunity to do a historically significant piece too. A client who is on the Board of Directors for the Shenandoah Valley Battlefield Foundation asked me to make a gavel and a dovetail box from a limb pruned from the Stonewall Jackson Prayer Tree.

Legend has it that Jackson would ride to a nearby brick home (still standing today) every morning for breakfast, but would stop at this tree on the way, get off his horse, and pray. A small project, but a very meaningful one.

- Charles Neil, November 2007

CLICK FOR LARGE FORMAT

I am making a video series showing the Ezee-Feed Infeed and Outfeed Tables designed by Master Woodworker Lee Jesberger from Ezee-Feed Manufacturing. I just got the outfeed table assembled and securely mounted on my table saw.

Not one to wait around, I decided to shoot a small preview video which was originally posted on my website & blog. The Ezee-Feed system is going to make cutting large panels and sheet goods a breeze! This is the definitely the safety and efficiency answer for someone like me that works alone in a small basement or garage shop.

FYI – this video was shot with the video feature of a small inexpensive pocket digital camera becuase my digital video camera was included in the shot. So if you have a pocket digital camera, you can start posting woodworking video content!

If you are like me, when not in your shop its fun to watch woodworking videos and podcasts.

Did you take the Digital Lumberjock Quiz?

See if you can answer the following questions:

1. Wears a surgical scrub cap and has a passion for furniture design

2. Boston accent and an unabashed approach to period furniture

3. Warm friendly Southern accent with a straight forward approach to woodworking

4. Posts audio & video woodworking content featuring intro music by 3 F33T UP

5. Festool, Powematic, technology & too much energy

OK, if you know the answers than you need to get a life and get out into your shop!

If you don’t know the answers than you are missing out on some great woodworking content on the Internet.

Either way, consider adding some video woodworking content of your own. Lumberjocks is a great forum to share some video of your woodworking experiences. Perhaps document your newest project, a unique technique or special woodworking skill.

While doing a bit of research for this series, I contacted some of our favorite woodworking podcast producers. Neil Lamens was very generous with his time and offered the following advice during a series of email messages. “If I could make a suggestion, keep the editing software as simple as possible. Time becomes a major issue in getting podcasts posted. Especially when you have another job. Late nights are not unusual.” He also alluded to the need for good lighting stating, “you’ll be surprised how well the light bounces off the ceiling and the camera adjusts exposure.”

UPDATE (Thanks to Neil) – “To add to your plastic bag dust protector, if shooting when sanding, cut a hole in the plastic bag, extend just lens through and seal with rubber bands around the camera body.”

Matt Vanderlist responded with a well thought out discussion on making shop videos that I have included as a PDF document. This is a great source of inspiration and advice.

Marc Spagnuolo forwarded a link to his website that describes his equipment, as well as, a tutorial link he wrote for Lumberjocks detailing uploading video on BlipTV. He also shared that he does his editing on a Mac using Final Cut Express stating that “. . . As far as planning episodes go, I usually just wing it for the most part. I typically have a rough outline of what I want to do, and I go out there and just start running my lips. LOL”.

This blog entry shares how I make low-tech and low-cost woodworking focused video content in my shop. I have written this blog entry for the average Digital Lumberjock. Now, this is not meant to make you a Neil Lamens or a Matt Vanderlist, but rather expose you to a simple primer explaining how to post your own video using simple equipment you may already have available. Granted, videography takes time to set-up and produce. It might even slow you down a bit. The benefit is that this is a lot of fun and a great skill to add to your repertoire. It also gives you a chance to appreciate your work from a new perspective.

What’s my motive? More woodworking videos of course!

My tips are use a tripod for a steady shot and try for the best lighting possible. Have fun and start shooting!

DIGITAL VIDEO CAMERA

VIDEO CAMERA POWER SUPPLY

DIGITAL VIEDO CAMERA EXTRA BATTERY, REMOTE CONTROL, EXTRA DV TAPE

WIRELESS MICROPHONE

CAMERA CABLE, LENS BRUSH, VELCRO CABLE TIES

TRIPOD

SHOP LIGHTS

POWER CORD & MULTI-OUTLET

I have been a bit frustrated, as I can’t use my shop until the outside portion of our house reconstruction is complete which should be very soon. I have been using the down time to restore my Stanley bench plane. As soon as I get back in the shop, I have plans to make a video tool review so I am quite anxious to get going!

My Stanley Bench Plane restoration project is near completion. As a reminder, this is NOT a plane with intrinsic collector value. I am restoring this “user plane” to be used on my bench. Before using any of these processes make sure you do not de-value your plane if it has value as a “collector plane”.

All parts were cleaned of rust using the electrolytic rust removal process described in the prior blog entry. The plastic front knob and tote were polished with white Tripoli and carnauba wax. Rather than re-apply blue japanning to the plane body I kept the utilitarian look of raw cast iron by using a modified “Parkerizing” process followed by several coats of wax.

To “Parkerize” the plane body, I soaked it in KleanStrip Phosphoric which turned the cast iron an even mild gray color. Immediately after the acid bath, the plane body was doused liberally with WD40 to displace the acid and water. The plane body was then dried and gently heated to 150° in an oven followed by two coats of carnauba wax and buffing.

For comparison, this is how the plane body used to look

This is how the plane body looks after de-rusting, modified parkerizing and hot wax treatment

Next step is lapping the sole and sides. I am still deciding if I will spend the extra money on this humble plane to replace the plane iron and chipper with a heavier set from Hock Tools.

Reminder: Always use common sense and don’t do anything that feels unsafe. Wear gloves and safety goggles. Always add acid to water! (I did not mix any acid solutions during this process – just trying to be complete).

MSDS for KleanStrip Phosphoric

My Stanley Bench Plane restoration project is progressing well. All parts have been cleaned of rust using the electrolytic rust removal process described in the prior blog entry. I was really impressed with how clean the parts were after the electrolytic de-rusting process.

As a reminder, this is NOT a plane with intrinsic collector value. I am restoring this “user plane” to be used on my bench. Before using any of these processes make sure you do not de-value your plane if it has value as a “collector plane”. The plane body came out of the electrolytic bath sparkling clean.

I decided to remove the blue japanning for a couple of reasons. First, I really like the clean smooth look and feel of the cast iron. Second, as this is a user plane, I wanted to see how well I could clean the iron as a reference for any future projects. I had initially planned on reapplying the blue japanning, however, I am now considering keeping the utilitarian look of the raw cast iron. I will most likely “Parkerize” and wax the plane body for protection from rust.

The black plastic tote and front knob have been cleaned, waxed and lightly buffed.

Next step is lapping the sole and sides followed by replacing the plane iron and chipper with a heavier set from Hock Tools. Check out The Craftsman Studio for another source of great tools and Hock Blades!

I am also documenting this project on my blog The Folding Rule.

For comparison, this is how the plane looked before beginning restoration.

Plane body after electrolytic de-rusting and stripping blue japanning.

Close-up of plane mouth and front knob.

View of the plane sole after electrolytic de-rusting.

Close-up in front of the tote showing product numbering.

Click here for large format version

More information available on my woodworking blog & podcast The Folding Rule Show

Step #1 – Cleaning & Rust Removal

I have been inspired by a number of resources to start using my hand planes and start on the slippery slope of a hand plane collection. Not the least of whom has been Wayne, our own Lumberjocks plane guru. Of course I have also explored a number of websites including our good friend Phil on the other side of the pond and Matt from Matt’s Basement Workshop.

Another great resource is Patrick's Blood and Gore

Most importantly I have come to realize I need these planes to achieve a higher degree of fit and finish. Plus I like the quite sounds of hand tools and the feel of a thin shaving of wood peeling out of the plane mouth. So the focus of this entry will be an old, but not so valuable, Stanley bench plane that has lived in my carpenter’s box for perhaps 25 years. I used and abused this plane for coarse fitting work on decks and fences. I also used it to hand plane a bunch of clear vertical grain construction redwood for a bed that I made for my wife and I almost 25 years ago.

I am hoping I can revive this fellow to take a place on my bench for future work building furniture and cabinets. Along with my small Stanley block plane, these will be the nucleus of my plane collection.

Today I disassembled the plane and started to experiment with electrolytic rust removal on the plane iron and chip breaker. I plan on replacing these with a Hock set in the near future. The reason I am spending time cleaning these is because I am going to use them in a multi-sized dowel-cutting jig. Also, I want to see how well this process works before dunking my plane body in the bucket!

UPDATE: Thanks to Wayne here is a great link to check out for HOCK BLADES

UPDATE: Thanks to Scopemonkey for noticing I got the polarity reversed on the first posting. Below is an updated diagram with the correct polarity. Thanks Scopemonkey!

The cool thing about this project is that I already had everything in the shop!

Use a brass brush and a 3M grey abrasive pad for final cleaning.

Some residual stubborn stains were removed with a bath in glycolic acid. I used Kaboom Shower, Tub & Tile Cleaner. After the acid bath I rinsed the parts in fresh water and ran them in the electrolytic solution for 15 minutes to neutralize the acid followed by a second rinse in plain water.

After completing the de-rusting and cleaning process all parts were treated immediately with BoeShield T-9 which is available at the Lumberjock Store. WD-40 would be a good alternative to BoeShield T-9.

Plane iron & chipper free of rust after electrolytic cleaning

Cap screw before cleaning

Cap screw after cleaning

UDATE: Thanks to Wayne, our own Lumberjocks plane guru, make sure you will not alter the intrinsic value of your plane or other tools by this type of cleaning process, i.e. some planes have igh collector vaule and should be left as is with age patina.

MATERIALS LIST

• 5 gal plastic bucket

• rebar pins for anode grid

• copper wire

• wire nuts

• alligator clips

• Arm & Hammer Washing Soda (sodium carbonate)

• 6/12 volt battery charger

• Kaboom Tile, Tub & Shower Cleaner

• brass brush

• 3M grey abrasive pad

• WD-40

• BoeShield T-9

BUCKET PREPARATION

• Drill holes near edge for twisted wire loops

• Secure rebar with twisted wire

• Connect rebar anode grid with copper wire & wire nuts

POLARITY IS CRITICAL!
The BLACK (negative) lead is connected to the part being cleaned
The RED (positive) lead is connected to the rebar anode grid

ONLINE RESOURCES

Instrucables – Rust Removal

Electrolytic DeRusting

Barry’s Woodworking – Rust Removal

Electrolysis Rust Removal

Electrolytic Rust Removal

Rust Removal on YouTube

Geoff’s Science Garage on YouTube

SAFETY CONSIDERATIONS

Before starting, review the Material Data Safety Sheets (MSDS) for the recommended products

Use common sense – if it doesn’t feel right don’t do it

The gases generated are oxygen & hydrogen

Do this process in a well-ventilated area away from sparks or open flame

Wear gloves and safety goggles / glasses

The electrolyte solution is mildly alkaline and could irritate your skin and eyes

Wash any splayed solution off your skin with plenty of fresh water

Despite some recommendations, DO NOT use stainless steel for the electrodes as the results produce a toxic solution containing hexavalent chromate. Hexavalent chromate is a poisonous and hazardous material that requires special handling and disposal.

Click here for a good discussion of why NOT to use stainless steel

MATERIAL SAFETY DATA SHEETS

Washing Soda MSDS

Glycolic Acid MSDS

Kaboom MSDS