Archive for the ‘workbenches and work-holding’ category

Skottbenk equals sticking board – Big sticking board

February 28, 2014

This is a typical situation with a "skottbenk" used with at "skottokse" (the handplane) for shooting the edgde of a long board. Photo: Roald Renmælmo

Roald Renmælmo posted this photo today on Norsk Skottbenk Union, and graciously allowed me to re-use it.  Roald and his associates are doing great research into traditional work methods from Northern Europe, especially Norway.  His post describes the skottbenk as a Jointing Bench, Shooting Bench or Sticking Board.  Ah!  The light went off in my head – Sticking board!  That immediately explains it’s use to anyone coming from the English-American tradition.  It is one big sticking board.  I’m surprised that these benches were not commonly used in the U.S., especially in the Upper Midwest, in the large Scandinavian American Communities.  Maybe they were and there simply isn’t much about them in current woodworking literature.  If anyone can enlighten me, I’d appreciate it.

Roald and his associates also provide more general information about workholding methods at  I’m looking forward to following their research.  And I’ll try to get Roald to share more information about the specialized “two man” planes used in his part of the world.  Thanks for the Internet, so we can learn more about the past.  How ironic.

If you don’t know your hyvelbenk from a skottbenk – you should

February 26, 2014

Most handwork aficionados in the U.S. practice what might be referred to as “the English system”.  The style of our tools and workholding devices pretty much follow a pattern that has been developed over the last three hundred years or so, largely by practitioners who speak English (well maybe a few speak French).  But brothers (and sisters), there are a lot of other ways to skin that old cat.

If you’ve ever tried to dress and joint any heavy plank, you know that it can be a tough job, very tough indeed.  Well, in the Scandinavian countries, heavy plank construction has been widely used over the centuries and the Norsemen have developed planing benches specifically for the task, the skottbenk.

Skottbenken. Bilete skanna frå artikkelen til Arne Vennevik i Årbok for Namdalen 1981

The photo above was “borrowed” from the blog  Norsk Skottbenk Union.  If you’re interested in handwork, workbenches and woodworking history, you need to go to this website!  Now!  (As soon as read the rest of this post).

The planes that are used in this process are of particular interest, as, for the most part they are “two man” designs.  There are planes for jointing, tonguing and grooving.  These are the hyvels.  More on planes and workbenches is to be found at Hyvelbenk.

Both of these blogs are written by professional woodworkers and historians.  Both are packed with excellent photography.  The blogs are written in Norwegian, but it’s amazing how much information  you can pick up from photos.  Maybe, with a little encouragement, the writers will help us figure out a way to translate so we can all benefit from their research and the information they are presenting.


Building the “End All – Be All” Workbench

February 24, 2014

Let me just start by saying that there is no such thing as the “End All – Be All” workbench.  Workbenches come in all shapes and sizes.  The selection criteria is based on the ergonomic needs of the user and the type of work that will be accomplished on the bench.  Remember, the workbench is just a great big clamp.  And, various types of work require varying methods of work holding (clamping).

Many of you already know that I work several hours a week at the local Woodcraft Store.  We’re very fortunate to have a staff that is made up of experienced woodworkers.  Of course, experienced woodworkers are used to working in conditions of their own design.  Those of us who continue to do a great deal of hand work, have complained that our benches are simply not heavy enough for our uses.  So recently we all agreed that we would build a demonstration bench that would be well suited to all methods of hand work.  It fell to me to determine what would be the appropriate design.  So I began extensive research into the matter.

The Roubo bench has gained renewed popularity in recent years.  It is a heavy bench that lends itself well to a number of tasks.

roubo pg 12

While the Roubo is excellent for doing heavy work, there are other bench designs that are better suited to doing finer, lighter detail work.  The German and Swedish style “cabinet makers” benches are a case in point.

swedish workbench

This style bench, however, may fail to provide adequate work surface area and weight for many preparation and assembly tasks.  I wanted to find a bench that would, for example, allow us to joint long boards and “thickness” plane, as well as hold drawer sides for dovetailing.  It was obvious that some type of compromise had to be considered.  There are a great many contemporary designs.  But, more often than not, these designs have grown out of need for specialized work holding, so I found myself looking back to historic models.  There is good reason that there are several historic designs found all over Europe and the Americas.  They work!  So I went back to the books.

The design I kept coming back to was what is commonly called the “Nicholson”.  Of course Nicholson did not design this bench (and it’s ever so likely that A.J. Roubo did not design his namesake).  He simply illustrated, what had evolved to become known as the English Joiners bench in one of his books on trade skills in the mid nineteenth century.

english joiners

john hill carpenters shop 1813

The “Nicholson” has a broad work surface.  The bench is substantial.  And, it is a work holding “tour de force”.  Bench screw vises can be placed anywhere.  Planing stops can be placed “in length” or for cross planing.  The large aprons on both sides permit the use of holdfasts on the vertical as well as horizontal surfaces, allowing the user to secure workpieces like “six board” chest parts for dovetailing with ease.  A crook (or crochet, si vous preferez) can be mounted at the end of one of the aprons, making holding larger pieces for jointing a simple task.

Several years ago at WIA in Cincinnati, I saw a “Nicholson” derivative that had been built by Mike Siemsen’s School.  It was a great design.  It was built from construction lumber, keeping the cost low while providing the user with an excellent, all-around working bench.  It incorporated a split top with a stepped cross planing stop, a very useful device.  I must say that the one thing that stuck with me from the WIA show was that little workbench.

Siemsen's "Nicholson" bench

Siemsen’s “Nicholson” bench

My only major concern was that it still might be a little light for really heavy work.  And I would caution anyone using construction lumber to be attentive to it’s moisture content and make allowance for movement in service.

I went out to Sharples Domestic Hardwood and selected lumber for the new bench.  Top will be maple, aprons of ash and the frame from red oak.  A quick calculation would suggest a weight of 350 pounds (give or take).  Stability shouldn’t be an issue.  However, finding staff members young enough and strong enough to assemble and move the thing, might be.

We’ll start construction on March 1st.  The project will be completed over the course of five weeks.  You’ll be able to follow the progress here, or you can come to the store and see for yourself.  It should be fun and keep the old guys on their toes.



A Very Simple Jig for Boring Leg Holes in Windsor Chair Seats

July 3, 2013

Alright.  All the really good guys use sliding bevels, mirrors, try-squares and any number of other arcane methods to help them bore holes in a Windsor seat plank.  I’m a devotee of tradition.  However, I’m not a slave to it.  I’m working on a little Stick Windsor (practice chair) and decided that what was really important here was getting the thing put together with some semblance of accuracy.  So I used the little boring jig pictured below.  While I’d like to take credit for it, I cannot tell a lie.  The idea came from Thomas Moser’s book, “Windsor Chairmaking”.


I actually put the entire assembly (with jig) in the vise, in a vertical position.  This made boring the elm much easier.  That said, I did work up more than a few beads of perspiration.  Elm is tough.  Of course that’s why it’s great for seat planks.

I decided to use cylindrical tenons turned on the lathe, for this chair.  This means that I won’t need to do any taper reaming.  If I were going to use a tapered type undercarriage on a “one off” project, I probably would not go to the bother of building the jigs (one front, one back).  However, if I was doing multiples, the jigs would offer a significant advantage.  The guide blocks are simply screwed to the supporting 2×4, so the same jig could be used for varying seat widths.

Two other thoughts in closing:  First, If I were going to use the jig in a production basis, I’d make the guide blocks from something harder than Douglas Fir, hard maple or even Elm would hold up much better.  (But the “DougFir” was here.)   If I decided to become a complete “sell-out”, this same set up could be used with a drill motor and long stem spade bits by simply putting an appropriately sized spacer underneath the jig, leaving adequate clearance for the spade.  Did I just say that?  This is supposed to be a blog about working wood by hand!  Well, I said it and I’m not going to take it back.  You’ll see what I mean when you start cranking that brace and the bit starts to bite into that elm!  Whew, is it tough!

The Menuisier’s Workbench

March 17, 2013

I haven’t been writing much as of late.  But I have used my spare time to do a little investigating into the realm of traditional French carpentry and joinery.  It seems like U.S. woodworkers are very much oriented to the woodworking traditions of England, Germany and (to some extent) Sweden.  But for some reason, most of us have seemed to overlook the French tradition.  During our Colonial period, we opted for styles that were more straightforward than their highly decorated European counterparts and the fact that French Settlement in North America happened in Canada may have decreased the opportunity for sharing “secrets du metier” between U.S. and French practitioners.  Whatever the reason, most of us have missed out on a substantial legacy of history and knowledge.

One notable exception is Roy Underhill.  He has demonstrated an interest in the French tradition for many years and most of us can thank Roy for introducing us to what has become known as the Roubo workbench.  It’s name derives from being featured in the work of Andre Jacob Roubo, an eighteenth century French furniture maker (Menuisier or Ebeniste) of renown.

roubo bench

I was somewhat surprised to find that this particular style has been the standard design for centuries in France and that it has continued in use to today.  It is a strong design, without frills or unnecessary ornament – a bench with effective work-holding devices.  In short, the traditional French menuisier’s bench is built for work.

While staying true to the design, the French bench can be seen in many sizes from the diminutive benches of the primary training schools in the early twentieth century to the very large benches seen in the work of French Encyclopedists, Diderot and D’Alembert.

The schoolboy's "Roubo"

The schoolboy’s “Roubo”

A menuisiere from Diderot and D'Alembert

A menuisiere from Diderot and D’Alembert

It’s with good reason that this French style workbench has been gaining popularity in the U.S.  It can built quickly, inexpensively and can be made to be very portable while providing a stable work platform.  You can’t ask for much more than that.

I’m going to continue with my exploration of the French woodworking tradition.  There’s a lot more there than good wine and pomme frites.

Happy St. Patrick’s Day

Walnut Pattern Makers Workbench Gallery

December 15, 2012

Raked leg Roubo workbench redux

December 14, 2012

Ya call that a workbench?

October 23, 2012

Wow, another big gap between posts.  But I’ve been busy.  Busy with official stuff and (I’ll admit it) busy with a few distractions.  The walnut slab bench is finished.  It’s over the top.  But it’s a heavy, working bench.  In the next few days, I’ll share some more detailed information about the bench and how building one like it can provide an opportunity to perfect both some very basic and some more advanced skills.  The lignum vitae vise handles aren’t just for show.  They add weight.  And, in this case, the heavier the better.

Note the admonition – In other words “Get busy and stop wasting time”

The beauty of the Emmert’s Vise

August 11, 2012

As they say, “a picture is worth a thousand words”.  Here’s the reason folks love the Emmert’s Patternmaker’s Vise:

Straight hold on a cabriole leg

Rotating the vise up to 360 degrees

“Tilting” the vise up to 90 degrees

Holding a taper (an auxiliary jaw allows vertical holding of even greater tapers)

Holding above the jaws with dogs

Reversing the dogs makes holding rounds and irregular shapes a simple task

This is why I went to all the trouble.  For anyone doing work that requires the ability to hold the workpiece in many different positions to facilitate hand work, the Emmert’s vise is a thing of rare beauty.

Just a few more details and the bench will be ready for service; tail vise, storage shelf, tool tray and rack.  This thing might weigh 450 before it’s all said and done….

Is that a “Lamb’s Tongue” or Gene Simmons in the distance

July 27, 2012

The new workbench is going a little slower than I’d like.  And one of the reasons for the delay is my decision to include some absolutely useless decoration on the base.  The decorative effect I’ve chosen to use is an old, and very traditional, edge treatment known as a stopped chamfer with a “Lambs Tongue” terminus.  You don’t have to have a fantastic imagination to understand why the terminus picked up its common name.  And you would only need to see Gene Simmons and the “KISS” gang to understand why our younger brethern (and sistern) might identify it with something seen on the concert stage.

This was a very common edge treatment for posts, beams, balusters and other architectural details.  So in times past, carpenters and joiners, alike would have been very familiar with its use.  Upon closer inspection, it’s obvious that, viewed from the side, it is simply an ogee shape that has been rotated 45°.  Some folks go to a great deal of trouble, laying out small ogee patterns on both sides of the chamfer, then shape the “tongue” with rasps and files.   Believe me, if you were a carpenter or joiner on a job site with dozens of posts and beams to complete, or a joiner with hundreds of balusters to shape, you’d take a somewhat more pragmatic approach.  You would simply mark the length of the tongue, then, with its bevel down, you’d tap a bench chisel through the cove, then the bead.  That would be that.  Practical craftsmen simply didn’t “overthink” things like this.  They were busy, trying to make a living.

Turners also employed the “Lamb’s Tongue” on pommels that would lead to a full cylinder or simply an “eased edge” shape.  It’s a wonderful little “touch” that still “holds up” and all serious woodworkers should get familiar with it.

Big Walnut slab + Emmert’s style pattern makers vise = just one more distraction

July 22, 2012

The poor little lowboy is sitting there, dry-fit, in-the-white, just waiting to be finished.  It should be my priority.  Then again, I should be turning out some bowls or anything else for the marketplace.  But what am I doing?  I’m screwing around with yet another workbench!  But, this one is really going to be special.

Remember that big slab of walnut that Charlie dropped off a couple of weeks ago?  Well, I planed it up in a previous post and I believe  I mentioned that I had something very special in mind for it. 

It just so happens that I was lucky enough to buy one of the last of the Emmert’s style pattern makers vises that Woodcraft discontinued a few years ago.  I can only guess that the vise was just too expensive for most pocketbooks.  Lee Valley manufactured one called the “Tucker” vise, which was discontinued about the same time.  It’s a real shame that these vises didn’t get the attention they deserved.  Anyone who has used either of these vises, or one of the originals, knows what wonderful tools they are.  And, if you’re a woodworker who does any carving or shave work, these vises are really without peers.  Authentic Emmert’s can sell for $1500 +, so the several hundred dollar price tag on the Woodcraft or Lee Valley version was a real bargain. 

The WC version weighs in at 55 pounds.  So a heavy-duty bench is in order.  Also, I’m contemplating another antique, cast-iron vise for use as a tail vise.  So the combined weight of the vises and bench could (easily) be in the range of 250-300 lbs.  Ought to be good and steady.

Trestles are made from 3 1/2″ square Ash.  Stretchers are of 1 5’8″ x 5 3/4″ Ash and cut with a half dove-tail tenon.  The stretchers will be held in place with a wedge that will complete the dovetailed connection.

Lay-out is critical.  You’ll note any number of matchmarks and “surface messages” to myself.  (It wouldn’t be the first time that I’ve cut a mortise on the wrong surface.)  So tomorrow I’ll finish up the stretcher mortises in the legs and with any luck at all, the base should be ready for glue up and assembly by mid-day.

Planing big slabs

July 15, 2012

My friend Charlie just dropped off a couple nice big slabs of walnut.  The original intention was to cut them into heavy veneer and squares for legs.  But one of them was was just dead straight and I immediately knew that I had something else in mind for this particular piece.

Big slabs seem to pose problems for many woodworkers.  They’re hard to move around.  They’re usually too heavy or too large to run through planers and sanders.  But for the folks that understand how to “walk” a board and use handplanes, big slabs can be handled with relative ease.

The first thing is to get one side in plane.  This becomes the datum, the surface from which all other dimensions are taken.  Using a set of winding sticks, the rough surface is checked for wind, cup or bow and imperfections in sawing.  Those areas are marked.


Rough planing is done with a long plane with substantial camber in the iron.  My favorite plane for this part of the process is a 20″ wooden foreplane.  Planing is usually done at about 45 degrees to the grain direction of the workpiece, although many times I find that I’m planing cross grain.  The heavy camber of the iron allows for large shavings to be taken without an irordinate amount of edge tearout.

After the datum surface is in plane, a smooth plane is used to remove the wide, shallow “scallops” left by the foreplane and render the datum dead flat.  Then the slab is flipped and the required thickness is measured and marked with a cutting or panel gauge.  Again the foreplane if used to produce a plane second surface, parallel to the datum.  If a large amount of material must be removed from certain areas, a scrub plane can be used.  The scrub plane has a narrower iron with greater camber than the foreplane.  This enables the plane to take very thick, narrow shavings and speeds the work of stock removal.  The foreplane can then be used to remove the deep grooves created by the scrub plane.

Trueness in length can be checked by a straightedge or the winding sticks can be laid flat at both ends of the slab and a line can be stretched across them. Any variance will be quickly determined by simply measuring at points along the line to the surface of the slab. And remember that the human eye is a very precise instrument.

Only time will tell what this slab will become.

Splayed leg Roubo nears the finish line

March 4, 2012

Well it’s really been a “slog”.  But, finally, it looks like I may finish the little Underhill style workbench before much more time passes.  The bench has a diminutive look to it.  But, in fact, it’s nearly seven feet long.  It’s thirty six inches high, which tends to make it look a little shorter than it really is.  Right at the moment the leg vise is just hanging by a thread, so to speak.

The end vise is massive.  This design could certainly be used as a front vise, as well.  However, I decided to use a leg vise in front and keep the location of the screw low.  This will allow me to join wide boards without having to stand on tiptoe.

There are still a lot of details to finish.  Then, of course there is “the finish” which will be BLO, Turpentine and Urethane.  It’ll be a while yet, but I’m getting there.

Ode to a Filletster and a Roubo bench update

February 26, 2012

Whether you call it a filletster,  fillester, rebate or rabbet, using a moving fillester plane is just “plane” fun.  Long pigtails of stock come shooting through the side escapement.  The wooden version of the plane absolutely “sings” as it works (some folks might call it more of a howl).  For me, the process of working with handtools is every bit as important as the end product.  So the tactility matters a lot.  But top that off with the auditory pleasure of heaing a well tuned handplane working and you’ve got a real winning combination.  Folks come into the shop and are surprised that I don’t have a radio or disc player (and I’ve been a musician all of my adult life).  I simply tell them that the tools make the music in this place.

L - Sargent 79 Duplex Rabbet, R - Sandusky Tool Moving Fillester

I broke the fillester out to rabbet (rebate for our readers in other parts of the English speaking world) the bottom of the tool tray on the Roubo bench.

Using a rabbert plane is pretty much foolproof, given, of course, that it is well honed and the depth stop and fence are correctly adjusted.  The one challenge is to insure that you keep the plane at right angles to the surface being planed.  There’s no real secret method here.  Just keep your fingers out of the way of the escapement so shaving don’t clog up the throat and concentrate on what you’re doing.  And, remember to move and use your body weight to your advantage.  This is when that extra ten pounds you put on during the holidays will really pay off.

So here’s where I’m at with the small Roubo (little splayed French) bench top.  The work surface is only 13″ wide, but the 8″ wide tool tray should more than make up for the top’s narrow width.  Hopefully, tools will find their way to the tray, not to the working surface (as they have for the last thirty-eight years on the current bench).


February 23, 2012

So okay!  I know!  I’ve been screwin’ around with this project for a year or more.  But I just got into other things….  You know how it is.   Right?  Well, anyway, I’m back at the Roubo bench project and it is the priority project of the season.  So, stick around, we’ll finish this darned thing together, so to speak.

So here’s what’s going on with the right end vise (really not a tail vise, now is it?).  Just about complete and being dry fit to to the to the top;

You can see the “sacrificial chop” squeezed between the front chop and the bench top.  It will be trimmed to height when everything is finally assembled.

The next step is to set up the tool tray.  This will require a “plough” that will accept the “floor” of the tool tray.  I could do this with a router.  But I’m still trying to loose that ten pounds that I put on during the holidays.  (I still don’t know how it happened.)  So, I gonna make this plough with a Stanley 45.  This is a plane that you can definitely develop a love/hate relationship with.

The one bit of advice that I can give you about using any plough (plow) plane is, to start “at the end”.  Work your way back from the terminus.  Trust me, it’s better that way.  Plough’s are remarkably rewarding in their simplicity and efficacy.  Just enjoy them and don’t worry about the time that it will take you to make that plough.  Remember, for hand woodworkers it’s about the process.  Right?  I mean, come on, it is all about the process, right?

I’ll explain that loose tenon hanging out of the end of the bench next time.  But for right now, let’s just let it be a mystery.

Wooden screws can become a vise

September 29, 2011

I’m getting closer to the completion of the portable Roubo (Underhill)  bench.  I decided that it should have a tail vise.  I wanted to do something a little different.  There are a lot of ways to create a tail (end) vise.  You can go traditional European, or use something like a “wagon” vise or some other type of “running block and pawl” apparatus.  I decided to build a vise that would use one of the many 2 1/2″ wooden screws laying in different corners of the shop and could use the entire width of the bench (except the tool tray) as an inner chop.  What I’ve constructed is, essentially,  a wooden version of the iron woodworking vise familiar to us all, like those made for years by Jorgenson, Record and so on.  The screw is in the middle and two stabilizing “rods” slide through two “saddles” to eliminate excessive lateral movement.   The nut is simply left loose.  The outer chop is 2″x7″x13″.  It’s thick enough that I can drill it out for a round dog or inlet a square sliding dog into the front surface.  Time will tell about that.  Ultimately, I’ll cut the rods to length and mount a simple stop device, so the screw can’t be inadvertently loosened from the nut.  The whole affair will then be lag screwed to the bottom of the bench.

top view (dry fit)

bottom view (dry fit)

  The front vise is a simple, heavy-duty, leg vise with a “cheese-board”.  However, I intend to have a secondary front vise that will allow me to hold large carcass parts for operations like dovetailing, ripping, etc.  This will be a single screw/single rod type vise.  I’ll be using one of my Lake Erie Toolworks nuts for this job.  A great example of this type of vise can be seen in use at the Anthony Hay Cabinet shop at Williamsburg.  (Also, check out their excellent blog,

Here’s a variant on the design from the “Manual of Traditional Wood Carving” by Paul N. Hasluck:

back viewFront viewfront viewfront view

And, “The Workbench Book” by Scott Landis has an extraordinarily good chapter on shop-built vises.  It’s well worth perusing.  There’s a lot of books out there about building workbenchs.  But, in my opinion, Landis’ book is clearly in a league of it’s own.

Making Wooden Screws – Lessons Learned

August 5, 2011

Well, just a few minutes ago my big wood tap screw went KABLOOIE!!  It was made out of cherry, so I didn’t expect it to have an extremely long life.  I’ll have to make another one, maybe.

If you’ve been reading the blog over the past few weeks you know that I became completely enchanted by the big wood screw making process.  Now I can share with you the wisdom I have acquired as a result of this process.

Three wooden bench screws in ash (it’s tough and it’s what I had on hand)

If you’re willing to put in the time (and a little money), making the screws is pretty simple stuff.  The nuts, on the other hand, are difficult to make, at best.  They’re not that challenging in a technical sense.  It’s just extraordinarily laborious work.  Using the type of traditional tapping machine that Underhill shows (shown in previous articles in this blog), the nutmaking process requires hours of manufacturing time and a significant amount of elbow grease.  Fitting is required and though serviceable, the internal threads show an appreciable amount of  damage, created when the scraping cutter traverses the “against the grain” quadrant of the “face grain” presented block.

The nuts are the HARD part!

 The long and short of it is this:  I’m glad I did it.  And since I’ve built the fixturing, I may well make more screws in the future, a few for working, a few as gag gifts.  But my STRONG suggestion is this – BUY THEM.  Wooden bench screws are great for any bench application.  For hundreds of years they were the standard.  They’re still great!  But do yourself a favor, buy your bench screws from a reputable supplier; someone like Lake Erie Tool Works .  If you want to make your own screw, so be it.  But save yourself a lot of headaches and buy the nuts.  You’ll be glad you did.

A Simple Machine to make large diameter wooden screws – cont’d

July 10, 2011

So here’s a pic of the lunettes in place:

The “lead” (or master screw) and the workpiece are connected with a socket and stub joint that is locked with a  screw.  The stub should be the same diameter as the socket, close to the shoulder, but should be a little tapered away from the shoulder.  This will allow for some very probable misalignment.  Remember, we’re dealing with wood here and my shop is 90 degrees with a fair amount of humidity.

Set the router to depth (several passes are probably, but experiment), turn ‘er on and start twisting the lead screw.

Forty odd hours later, $50 lighter in your wallet, here’s what you end up with:

Wooden screws, these will be seated into hubs - but blanks with integrated hubs will work just the same

Have fun.  You’ll need to experiment a little.  But I think you’ll find that it’s very worthwhile.

A Simple Machine for making large (2 1/2″) diameter wooden screws

July 10, 2011

Alright!  I should have been cleaning up this hell hole that I call a shop.  I should’a just bought the damned things.  But wait a minute…

walnut "machine screw"

After forty hours or so of scratching my head and puttering around in the shop, I’ve managed to build two simple machines that will allow me to manufacture all of the big wood screws I want, in short order.  So if I figure my time at $35/hour, I’ll be in the black after I’ve made a dozen or so.  So, guess what everyone’s getting for Christmas this year.

Well okay.  If you only need a couple of big wooden screws, buy ’em.  However, it seems that a number of wooden screw manufacturers have come and gone in recent times.  So, it might be a valuable skill to have in your “toolkit”.

Here’s what did:

First, I laid out my spiral on the cylinder that would ultimately become the “lead screw”.  Then I sawed down to the root depth.

Note the "depth stop" held in place with a couple of small clamps

Then I built a “box beam” and eight (or so) “stantions” that will be used during the screw making process. 

some stantions are held fast, others are loose so they can moved during the process

Followers of this blog will immediately note that there is a router involved.  I’m sorry!!  But the machine is built in such a way that a manual cutter could be used.  But, you know, I’m getting older, I don’t know how much time I have left, I’m not as strong as I used to be….  So live with it!!  I used a router!!

router simply secured to the stantions by a couple of drywall screws

Then I used one of the stantions to mount two “lunettes”.  The lunettes are actually made from a .025″ x 12″ feeler gauge.  See Roy Underhill’s book, “The Woodwrights Workbook” for an excellent explanation of how this will work and remember that the lunettes must be offset by half of the pitch (you’ll figure it out immediately).  The “ramps” are set at an average angle of the pitch taken from the minor and major diameters.

Well, I’ll finish this up tomorrow.  It’s been a full day and, alas, it’s time to retire.


Making Wooden Screws – The Saga Continues

July 1, 2011

There’s a pretty good chance that if I would have charged myself $10/hour for my time, I could have paid for the two screws from Lake Erie Toolworks by now (maybe more).  But I’m havin’ fun and I do consider myself a bit of a woodworking historian.  So…I’m living history.

nut blank in place – tapping in progress

The nut being made above will replace the right hand support, thereby eliminating the temporary “lunette”.


right support replaced with permanent model

Alignment is critical.  At 2 2/2″ diameter, there is no “give”.  Lesson learned this morning; If threads are not filed absolutely evenly, they can be overstressed if there is the slightest misalignment.  The good news is, the screw works well even though two threads have chunks missing equal to about 1/5th of their circumference.

This screw is made from cherry.  It was what I had on hand, but it may not have been a great choice.  Something “tougher” like elm, hickory, apple or even sycamore (with it’s interlocking grain) are probably better choices.  When the threading “machine” is complete, I’ll try a few other species.  Stay tuned…

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