Guitars, Gaps and Jointers.....

Hi Folks

Remember the electric guitar project I've been working on? It's just about complete. I've got a couple of small tweaks left to do, but the guitar is playable (and I've been playing it!). I get such a thrill from playing an instrument I bungled together myself - the feeling of shock when I hear it ringing out. And the relief when it is still in one piece five minutes later - when the strings are tuned up to tension I expect the thing to implode any second. I'll post a sound clip soon.

Following the bandsaw blade drama I thought it was time I upgrade another machine that was waiting to "get me". I have a 12 inch disc sander that has become an invaluable tool for me - shaping curves, cleaning up end grain and even shaping metal parts. So I decided to buy a second machine so I could keep one dedicated to metalwork. Sadly the new machine had a large gap (9mm) between the edge of the table and the sanding disc - when working small pieces it is possible (and yes, I've done it) to have the workpiece pulled down through this gap. With the usual underpant threatening consequences.......... ;)

So I fashioned a new table from 3/4 MDF - it only took ten minutes to remove the old one and replace it. And I now have a tiny (read SAFE) gap. I'm so please with this I need to do the other table now (yup, the sander is a double-header).

Plane news.....

It's Jointer season - I'm building a 30 inch beech jointer at the moment (with a similar plane up next). That's a long plane!! More pics as she comes together.

Cheers

Philly

New Balls, Please....

Hi Folks

Thought I'd tell you about an "incident" that happened in the workshop today. I was cutting a wedge on the bandsaw in some 15mm thick beech - got halfway through the cut when there was an almighty bang!!

After the initial shock I managed to turn off the power and count my fingers - still all there, I'm pleased to say. And once I'd changed my underpants I was able to investigate further - the blade had snapped.

It's been a while since I've had a blade snap on the bandsaw (three years, in fact) and thinking back I've noticed this blade starting to misbehave. And this was a 25mm wide blade, so a big one - hence the boom when it let go!

But on the up side, it made me realise how safe a machine the bandsaw is. If the blade disintegrated on the table saw it would of been a much nastier outcome, I'm sure.

So with clean underwear fitted I'm ready to venture back into the workshop. I'm working on a new plane at the moment and I'm very, very excited about it. More details in the coming weeks - but its going to be cool!

Cheers

Philly

Favourite Things Part 2

Finishing is a tricky subject – it can make or break a project. There are many different finishes, and almost as many different ways to apply them. After using most of the types of finish available I find myself reaching for the Shellac nine times out of ten.

So what is shellac? It is a resin excreted by the Lac bug which feeds on braches of certain trees. The resin is harvested and then purified – the different levels of purification give different shades of shellac, from dark brown through to clear. It is dissolved in alcohol (methylated spirit is fine) and by varying the amount of alcohol to shellac (or the “cut”) you can get different strength solutions (i.e. thicker for bodying up).

Shellac has some excellent traits :

• It will bond to pretty much anything
• It dries very fast
• No strong smell
• Easily removed – just wipe off with an alcohol soaked rag.
• Each application melts into previous layers, so no problems with “sand through”
• Most other finishes will bond to it, so it can be used as a sealer (i.e. between an oil based finish and a water based finish)

For me one of the best things about shellac is its versatility – you can wipe on a single thing coat to seal the timber against fingerprints (think Jim Krenov’s method of finishing) or you can continue to add layers of finish to get the desired sheen or thickness. And the speed with which it dries means you can make some serious progress – no waiting overnight for the finish to cure. Only a couple of minutes are needed for it to be dry.

Ease of application is another plus – I’ve used paper towels, rags, mini-rollers and brushes. You can also spray it, but I’ve never felt the need to.

So what downsides are there to shellac? Well, it is dissolved in alcohol, so shellac probably wouldn’t make the best finish for a bar top – a few splashed drops of whiskey would spell disaster. Its also not water proof, so is only suitable for indoor use. But that’s about it.

Shellac is a wonderful finish for wood – it brings out the beauty of the grain and figure and makes it shine. It is a natural finish that has been used for centuries and just looks “right”. My favourite technique is to apply a coat of oil to the piece, buff it dry and then apply shellac. This gives a deep shine and makes the figuring jump out at you. And its quick and easy to do!

One final comment – there are many different shades of shellac. Experiment with them on different colour timbers – I love garnet on walnut, and lemon adds an interesting “vintage” tint to most timbers.

Favourite Things Part 1

Hi Folks

I thought over the next week I would blog about some of my favourite things. But don't worry, its about simple, useful (and cheap!) things around the workshop that I use everyday and wouldn't be without.

So to the first item - Superglue.

I'm sure most of us have used superglue at one time or another (and have a bad memory of sticking your fingers to the item to be repaired!). Its cheap, easily available and dries fast.

I was interested to find it comes in different thicknesses - I'd only used the regular stuff. You can get a thick gel version (which doesn't run - useful on vertical surfaces) and a low viscosity thin version, too. The thin stuff has become a workshop favourite of mine - it has hundreds of uses. The cool thing is this - due to its watery consistency it wicks into cracks and openings. So you can sit two pieces together then wick the glue in afterwards - cool! And it also draws itself into cracks, so the next time you have a piece of timber chip or split just let some glue seep its way in and then hold the chip down for a few seconds until it sets. Perfect repair!

Over in the guitar making world repair guys use superglue for many, many things. And turners also use superglue as a finish! Is there no end of uses for this wonderful stuff?

A perfect companion to superglue is accelerator - just spray one surface with it before putting the two parts together and the glue sets almost instantly. Or you can use a drop of accelerator to set a layer of glue before adding another, allowing you to build up a repair quickly.

So - some of my applications for superglue:

As a filler - just add sawdust.

For gluing metal to wood.

Repairing splits, checks and cracks.

To glue up quick jigs.

To temporarily tack pieces together (pry them apart within 10 minutes though)

To strengthen soft areas of timber.

As a thread lock.

For me the best attribute is speed - apply the glue, hold the pieces together for a few seconds - done! And its a surprisingly strong bond, too, once it cures fully.

Just remember not to glue your fingers together - maybe an emergency tube of superglue dissolver would be a good thing to add to the list.

Cheers

Philly

Binding

Hi Folks

Found some spare time on the weekend to do some more work on my guitar project. I've added the binding around the body and given the guitar a good sanding - the top was then stained with a thinned lemon dye. A coat of cellulose sealer keeps the dirt out of the pores.

Next step is to finish inlaying the fingerboard and then I can spray the finish.

This week sees a smoother in Greenheart - a very hard and dense timber. More pics soon!

Cheers

Philly

Coffin Smoother with Norris Adjuster

Hi Folks

Had a good day finishing off the brass soled coffin smoother - take as look at the photo's, I think you'll agree it came out quite nicely!

I was very pleased with the adjuster - it works smoothly and accurately. And the plane is a pleasur e to use, the substantial weight means you only have to push the plane forward - it holds itself onto the workpiece!

Cheers

Philly

Black Magic

Hi Folks

Just putting the finishing touches on my current plane - its a brass soled coffin smoother in African Blackwood. This one is special as it has a norris-style adjuster, the first on this particualr model.

I've completed all the major components and have only the final shaping and finishing to complete. So tomorrow will see this beauty complete - looking forward to seeing this one polished up!

I was flicking through the current issue of "British Woodworking" magazine and was pleasantly surprised to see me featured in an article on scrapers - I vaguely remember demonstratrating how to sharpen and use them at the recent WL West show. And the article also shows my Toted Smoother in use, too.

Over at Karl Holteys website he has started blogging - very enlightening to see some of his methods being demonstrated. Well worth a read!

Cheers

Philly

News....

Hi Folks

Been a lot happening here over the last week or so and its been busy! I only just found time to sneak in my birthday ;)

Completed a trio of planes for an American customer - he wanted some custom touches on two of them. First, a Jack - an offset tote, styled like an 18C plane. And then a smoother, but shaped like the one in Moxon's book. Interesting styling, but surpringly comfortable to use. Once the customer gives me his feedback I'll post some pics.

Current plane in progress is a brass soled coffin smoother in African Blackwood. This one will be the first with a norris style adjuster, though. I think this will turn out to be quite a plane and I can't wait to see it completed.

Other news - Karl Holtey has launched a new website. Take a look here...... He makes the most astonishingly wonderful planes, and to the highest possible standard. I don't think I'm out of line to say his are the finest in the world - his attention to detail is otherworldly!

In the pipeline are some exciting new projects - I'm so excited about them I want to blurt out the details. But you're just going to have to be patient - watch this space :)

Cheers

Philly

West Dean

Hi Folks

Just about recovered after the Hand Tool event. It was a fantastic weekend and I hope everyone enjoyed it as much as I did. Highlights for me were having my bench next to planemakers Karl Holtey and Bill Carter - the chance to chat throughout the weekend with them both about plane related things was heaven! It was also interesting to compare their work - Mr Holteys planes are sheer perfection, every detail being spot on. Mr Carters planes on the other hand, while made to the same high standards, are aged to give a "vintage" appearance and could be mistaken for being pristine examples of classic infill planes.

The UK Workshop crew dropped by to say hello and it was good to meet customers who I previously only dealt with via email. David Charlesworth was also at the show, which was a special treat - I haven't seen David for almost a year so it was good to see him out and and about.

Last week I had a few emails from a Gent in Norway asking questions about planes and planemaking. It turned out that he was coming to the UK to attand a violin making course - I told him about the Hand Tool event and he managed to catch an earlier flight so he could attend the show before going off to his course. So say hello to Stig - I have a feeling he'll be turning up at my workshop in the near future ;)

After getting home and unpacking the van I was pretty wiped out on Monday. So I spent some time cleaning the workshop - a perfect way to recharge my batteries! This week I've been making a trio of planes for an American customer from Beech, but with some interesting details - a smoother like the one featured in Moxon and a Jack with an off-set tote. I'll have some photo's for you later in the week .

Be good,

Philly

Three Days To Go....

Hi Folks

Been busy on various bits and pieces for the upcoming West Dean event. Completed the Moving Fillister plane, too - some fantastic Beech on this one. The Fillister is a complicated plane to build, not only because of the skewed iron, but because of the depth stop mechanism. But its worth all the hard work to produce such a handsome and practical plane. Chris Schwarz was very pleased with his - read his review here....

Had a phone call from the editor of Furniture and Cabinetmaking magazine yesterday - they want to come down to the workshop for the day and do a feature on me and the planes. Yes, I'm very excited about that! Stay tuned for more details.

My Canadian customer has received his Moulding planes and he seems to be happy with them - see his blog here...

Cheers

Philly

West Dean Hand Tool Event

Hi Folks

Only a week or so to go until the West Dean "Hand Tool Event". This will be the second year of this show, and I'm real excited about it. Last years event, being the first one, was very enjoyable (and attracted some stars - Brian Boggs and Garrett Hack!) and was quite a success. It was also unique in that it was only hand tools - no power tools in sight. All the attendees were hand tool nuts, and there was a real buzz in the air.

Word has gotten around about that show and I have no doubt that this years event will be twice as big. I'm feverishly working away to have new items to show off - so do make sure you call by my bench and say "Hi!".

Cheers

Philly

Template Routing

HI Folks

Had an excellent week in the workshop and made some good progress. The Hollows and Rounds are about complete, just need to finish testing them out - pictures soon. And I've been busy starting some fillisters and skew miters.

The guitar project.....

All the components have safely arrived and I'm really pleasd with the service I received - I bought everything I needed from Axes R Us, and they were superb -quick delivery and excellent prices. If you need any guitar components they are worth checking out. 

So its routing template time......

I made the template for the pickup cavities so, after removing the majority of the waste with a forstner bit in the drill press, I attahched the template with double sided sticky tape (yes, it does work) and cleaned up the recesses with the router. A very neat and professional looking result! 

After drilling a hole between the two pickup recesses with an extra long spade bit I turned my attention to the back. The controls recess needed to be made as well as a lip around the recess for a cover to sit on. Another template! This time I made a female for the recess and a male to make a matching cover. With the waste removed with the drill press I routed the lip and then cleaned up the bottom with the router. Job done!

Next task is to decide exactly where the controls will go and drill out for them. Then the fingerboard need completing and we can get sanding - exciting stuff!

Cheers

Philly

On the shelf..........

Hi Folks

Had a busy week working on non-plane related things. First up were a set of fitted shelving units for a friend. Made from oak veneered MDF, they came out a treat - now the Wife has designs for something suitable for our lounge.

Then I installed a fitted bedroom suite for a another frie

nd - lots of woodwork fun!

With those tasks out of the way I was happy to get back to the comfort of my workshop. The Hollows and Rounds are coming along nicely and I've been roughing out timber for upcoming plane orders, as well as stock for the upcoming West Dean "Hand Tool Event". I hear that Karl Holtey is attending this, and I'm really looking forward to picking his brains!

The electric guitar project has fallen behind a little, so I knocked up a router template for the pick-up cavities. Hopefully I'll rout those tomorrow and make some more progress - all the components I need are now safely in the workshop.

Cheers

Philly

Good Show!

HI Folks

Finally recovered from my infection - took longer than expected, and probably not helped by the sawdusty atmosphere of my workshop. But thanks for all the thoughful emails, much appreciated!

Last weekend was the WL West woodworking show at Petworth, West Sussex. I've been meaning to make a visit there for a while and the opportunity to attend the show and demonstrate my planes was perfect. It is held at their sawmills, a very professional and smart location, which has a hobbiest shop and self-selection timber yard too. 

The show was very enjoyable and there was a lot of different woody things to see, from turning demonstrations, carving, musical instrument making and displays from colleges. There was also top axe man Steve Woodley on display, carving a beam from a huge oak log. I know it was huge as I helped him move the thing into position - my back still feels slightly shorter ;)

British Woodworking editor Nick Gibbs was also there spreading word about his magazines (as well as whittling away at branches on his clever shavehorse. And Mike and Alex from Classic Hand Tools were there with their usual range of high quality hand tools to make woodworkers drool.

So I'm back in the workshop and getting stuck into some more planes - this week some more hollows and rounds for a customer in Canada and a moving fillister, shoulder plane and brass soled smoother. 

Cheers

Philly

Caution -Man Flu

HI Folks

Had a rotten week so far - been struck down with "Man Flu". Spent most of the week in bed and generally accomplished nothing,  which has driven me mad. Hopefully I will be back on my feet soon - got a lot happening in the next week :(

Managed to start another project last week, though. I was so pleased with my acoustic guitar I thought an elctric version would go down a treat. So I've put a couple hours into it and its starting to look good already. I'm waiting for some parts to arrive and I'll be able to take it to the next step (assuming I get over this infection).

Back soon,

Philly

More on the Weissy

Hi Folks

Well I've had a good few days living with the guitar, and I'm pleased to say it is sounding better and better as the days pass. I'd read that the sound changes as the instrument beds in, but it has been enlightening to experience it firsthand.

I've put the rest of the build photo's on my Philsville site, so you can see how I put it together. The only shots missing are where I applied thje binding to the top edge of the guitar - my recent computer disaster meant those pics are lost :(  Anyway, the binding was made from  three layers of veneer - walnut, maple, walnut. These were applied with PVA and masking tape to clamp them in place, and it was a messy little job. But worth it :)

I recorded a quick ditty on the guitar so you can hear it in action (although I need to spend some time practising!)

Now its time to get back in the workshop - I have planes to finish.

Cheers

Philly

It Lives!!!!

Hi Folks

Hope you all had a good Easter? Spent some time away with my parents and also managed to make some serious progress on an old project - the Acoustic Guitar.

Well, the picture probably gives it away. Yes, she's complete! I put the strings on about an hour ago (and boy, was that nerve-wracking!) and she plays nicely. The sound is a little bass shy compared to my other acoustic but I think it will take a while to bed in before its true character is revealed. All I know is this - if its still in once piece in the morning I'll be a happy bunny :)

I've been taking some pictures throughout the build and will put them up on the Philsville site shortly.

Cheers

Philly

Touching Base

Hi Folks

Had a great time at the Yandles Woodworking show - a pleasure to meet so many of you! Show season is officially started and I'm preparing for the next one in a months time.

A few weeks ago I got involved with a project with a friend - it was to build a base for a Yurt, a kind of round tent. I gave a hand to get the footings and main members in and then the easy stuff was finished off by "Workshop Steve" (whose head you've seen in pictures on this Blog). Just joking Steve, you did a marvelous job!  

The base was 18 foot in diameter, a good size, and was eight sided. So some serious brainwork was involved witht the geometry - and thank goodness for sliding miter saws! It was also on quite a slope (about two foot over the width) so was quite an exercise. The customer was very pleased, though, and I look forward to seeing the Yurt erected.

I've also managed to grab a few more minutes work on the guitar project. I'm hoping this weekend I can glue the back on, giving me something that looks very much like a guitar. Pics soon!

Cheers

Philly

It's Alive!!

Hi Folks

And we're back!

Web site has been uploaded and looks very smart - please take a look and let me know what you think.

www.phillyplanes.co.uk

Thanks again to Elephant Media for their top notch work - I would of pulled all my hair out by now. Cheers

Philly

Don't Worry - I'm Still Here!

HI Folks

Just a quick message. If you've visited my website and found it missing its because my new "professional" site is being uploaded and de-bugged. So I should be back up (and super-shiny!) real soon.

Stay tuned.....

Philly