Saturday, December 18, 2010

Cove, Astragal and an Introduction to Side Rounds

Again, ask and you shall receive.

This cove and astragal will introduce a side round. It is a very specific plane. If you want to do anything and everything you must have a pair. They allow you to plane up to another facet.


Rabbets

Side round. 
I use this just I like a rabbet plane. Mark a gauge line and carefully start the cut using your fingers as a fence. After a few passes you can zip through it. 

This diagram shows the side round knocking off the tip of the highest rabbet. I usually avoid this by laying out a circle that's slightly bigger in diameter. In this case, where the diameter of the circle is equal to that of the side round, I attacked some of those rabbets with the 10 round in step 1a, which is not pictured.

I try to avoid the scraping cuts that happen near 90 degrees. Like a snipes bill, most of the time I only use the tip of the profile.

This is as close to freehand as you'll get. I used a #10 in the pictured profile below

#2 hollow

Why is a side round necessary here?

#10
vs.
Side round

The astragal prevents the #10 from reaching into the corner. 

Like snipes bills, side rounds come in pairs because there are times you will want the profile facing the opposite direction.

There are other uses as well. We'll see some of those later.




Completing Layout: Rabbets and Chamfers as Depth Gauges

Hollows and rounds have no depth stops. The idea can be intimidating. Let's fix that.

(What follows is probably going to overwhelm at first. This post is in regards to perfect world layouts. Accuracy results in less steering, less scraping, less tinkering. You don't have to be perfect, but as you get closer your results will become more consistent and quicker.) 

Take a look at this cove.

The cove is at 30 degrees. As we've discussed, the tips of the two rabbets that act as a chute for the plane to follow are also at 30 degrees. Notice that the bottom of the fillet (where the two purple triangles meet in the 3rd picture) is on the circumference of the circle. This is intentional and desired for any concave arc that is less than 60 degrees, which is the full width of the iron for any and all hollow or round planes.

To use these points of the rabbet as an accurate guide you will have to make certain that the plane is cutting both tips. As you plane the rabbets away you will notice that there are two shavings being ejected from the escapement. As you get farther into the cut the two shavings, which start out as thin wires, will increase in size. Eventually these two shavings will become one. It's at this point that the profile is complete, you've reached the bottom of the fillet. 




It won't be obvious in a short piece like this, but as you progress in a longer profile you will see that, due to human error, the rabbets are not disappearing uniformly. Your goal has to be to take that one final pass that creates a single, full width shaving to happen at once along the entire length. This will often involve gauging your progress by looking at the disappearing rabbets and taking several short passes at the beginning, middle or end. 

Now let's look at an ovolo.

Again, this ovolo is laid out at 30 degrees. The chamfer is at 30 degrees (there's actually a small green chamfer in the 3rd picture that is at 60...easy to execute in the perfect world of sketchup). Notice also that the chamfer touches the circumference of the final profile. Again, as you plane you will notice two shavings being ejected in increasing width. Eventually those two will become one. Your goal has to be to take a single, full width shaving along the entire length in one final pass. You will see the chamfer vanishing. Make it uniform. 


This rule applies for anything less than 60 degrees of a circle, which is a full width shaving for one of these planes.

This brings us to layout and introduces the luxury of geometry. There is only one solution in each of the examples that puts the chutes (tips of two rabbets for a round and edges of one chamfer for a hollow) at an attack angle of 30 degrees and that single point on the circle.

Take it another step further and apply this logic to these three profiles:
There's only one solution for each.

Let's look at a few erroneous examples and see how they fail:
In these examples you can see that the bottom of the fillet is on the circumference of the circle, but the tips of the rabbets are not at 30 degrees. The plane is not being presented at the proper angle


Here you will see that the tips of the rabbets are at 30 degrees but they're too wide. The plane is being presented at the proper angle but you'll be left with facets of the rabbet when you are at the proper depth.

In this last example the plane is being presented at the proper angle but you have no depth gauge. Err in this direction.

This last example also leads us to cutting greater than 60 degrees. You will not be able to use the rabbets as depth gauges in these larger examples because the two points of the rabbets or on the chamfers is greater than the width of the plane's sole. You'll be attacking with no proper depth gauge.

Draw the intended profile on the ends of your stock. It will help you achieve your desired results. Once you reach full width shavings, you will leave plane tracks as you swing the plane in subsequent passes. Stop before you are leaving plane tracks by both sides of the iron on consecutive passes at different angles. (That's horrible advice, I know.)


This doesn't have to be as complex as I've made it. These are perfect world examples and should be your goal. Try it. Try laying a profile out and be willing to fail. FAIL, FAIL, FAIL! You'll get it right within a few tries. It's obvious where the mistakes happen: wrong angle, wrong depths, rabbets left behind, plane tracks. The answers are above

With Big Pink as my witness, I've learned 85% of this by failing in my basement. You will learn quick. You will have fun. You will change the way you work. 

Learn the skill that goes along with the absolute most versatile tool in the workshop (other than, I'll guess, a chisel). 

As a side note, I was asked about accuracy. There are, maybe, five things in my workshop that I actively push (other than my planes). I don't know if these are the best things out there. I do know that they changed the way I work overnight. 

I quote the measurements for rabbets in 64ths. A few months ago I would have quoted those rabbets in +/- 16ths. I recently bought a Titemark marking gauge. It's quicker to be accurate to the 64th with this thing than to the 16th with my others. I quote in 64ths because it takes no more time. I don't know if it's the best marking gauge. I do know that I'm not in the market for another one. (It also has the advantage of having the cutter at the very end, which comes in handy when marking the depth of the third rabbet of an ogee after cutting the previous two.)

P. S. I do work









Friday, December 17, 2010

Frame 3

I better get this up quick before I lose half my audience due to my previous post.

This is the third of three frames that I'm making for gifts. I ran out of attractive frames in my house to copy so I googled 'picture frame profiles' and came up with this one.

Red Rabbet: 12/64w x 34/64h
Black: 4/64w x 40/64h
Green: 34/64w x 27/64h
Purple: 48/64w x 16/64h
Yellow: 23/64w x 16/64h
Orange: 8/64w x 25/64h

#10 round followed by #2 hollow


Rabbet followed by #4 hollow

#6 hollow followed by #4 round



The results:

Oval segments make it.
(Paint on my new sticking board!)


Look at the process. As I noted earlier, rounds follow the tips of two rabbets and hollows follow the edges of a chamfered rabbet. It holds true in everything we've done so far. 

Layout is the key to success.


Google molding profiles and see if you can sketch out a probable lay out.

This is the last time I make one out of oak. 

Send in requests or your going to get a Harry Potter wand carving seminar. 

Thursday, December 16, 2010

Ask and You Shall Receive...20 minute/$10 sticking board

If you've seen me at a show you've probably seen my 4 foot sticking board. It used to be 7. I spilled a cup of coffee on it a while back. The board swelled and got chopped in half.

The longest moldings I have recently stuck (sticked? planed? profiled?) have been 16" ogees and ovolos at these various shows. I just haven't done much that has demanded a longer board until recently.

What's a sticking board and what are the advantages? Take a look at me last night and tell me if you notice a problem.

You can see the piece moving while I'm working. It's obvious if you look at the end near the camera. It bows throughout. Like everything else you can work around it (just like I do every day on Big Pink) but sometimes the planes will clog because it skips across the surface. Sometimes you do a belly flop on the bench as the molding comes unleashed and crashes against the back wall.

There are several methods for holding work steady. I like a sticking board.

I was asked by a reader for a brief tutorial in what one is and how I make mine.

I make mine out of melamine.

I cut a few 2" strips and screw them together

Joint an edge and then screw it to a 5" wide board 

I countersink a few screws into both ends because there are times that I work briefly in the other direction.

You now have a sturdy backboard that can be clamped to a surface in only a few areas without having to worry about piece flexing in between. Tomorrow I will add a much lower backboard to the other side that I will use when working thinner pieces or when I want to tip the plane and the fence gets in the way. The fence not being used will hang over the edge of my bench.

That's it. The beauty of this option is you won't care if something gets spilled on it.

Next week I will give a lesson on a crosscut sled made out of mis-chopped mortises


Finally, I've been working on an interactive invention that allows you to gauge the the sharpness/dullness of any edge in any steel. Tell me what you think.










 HAPPY FRIDAY!

Another Step by Step (Frame 2)

I'll need to keep this one quick. The piece started 1 3/16 wide. 

From the top right corner
Red Rabbet: 16/64 w x 16/64 h
Greed: 8/64 w x 24/64 h

From the to left corner
(again, you'll need a sash fillister, straight grain, a table saw, etc)
Purple: 16/64 w x 16/64 h

Rabbet for chamfers followed by #2 hollow


Rabbet for chamfers followed by #6 hollow


#10 hollow to make ovular shape

Rabbet followed by #4 hollow

Like I said yesterday, frame profiles often look pretty strange. They come together once mitered.

The Results





For the record, I spent 20:10 with the profiled planes, much of which is battling Big Pink. I have it on videotape but couldn't bring myself to post it.

I'll fix my longer sticking board soon and get something more substantial up here.