Thursday, April 30, 2009

"Firewood to Fine Art" at John Campbell Folk School

This was my second class at John Campbell. I returned to the wood turning studio and joined seven other students for a class taught by Bobbie Clemons of Tennessee (pictured at the left) and Charles Watson of South Carolina.
The instructor from my first wood turning class at John Campbell had recommended this class since it emphasized both bowl and green wood turning.

We started our week on dry wood bowls using a chuck with a screw to hold 2" thick 10" maple turning stock. Immediately I started learning some "tricks of the trade" that solved some problems I had been experiencing in my turning. I learned to use a plastic bushing between the headstock spindle and the chuck to make it easier to remove the chuck. I also saw the value of using beeswax or parafin on the screw to help load the stock onto the screw chuck.

The turning steps we used were:
Mount the stock and turn the outside of the bowl.
Finish bottom with dove-tailed tenon
Finish sand and apply finish to the bottom. Remove screw from chuck and insert bowl blank foot into chuck.
Complete rim of bowl
Turn inside of bowl
Finish sanding and apply finish to the inside
Reset bowl between jam chuck and tail stock to finish the foot
Refine bowl foot chisel or Dremel off small nub

I completed two shallow maple bowls and had a third blow up due to a crack (see picture above left). When I returned home I band sawed off the broken rim and turned a small holder for my wife to display some of her larger decorated eggs.


The third and remaining days we spent on green wood and natural edged bowls. We used greenwood blanks that Charles cut for our use.
We turned the inside of the bowl leaving a thickness of 1 inch for each 10 inches for the bowls that would be dried and returned in a few months. We completely turned other practice pieces to a 1/4" thickness. In real circumstances we would have wrapped the thick blanks in newspaper or a paper bag for a couple of days
and then store for 3+ months in cool place out of sun and drafts. Once the blank had dried and warped sufficiently, we would then be able to return both inside and outside to final thickness and form.

We completed the week doing several natural edged bowls. We used a two prong drive spur on the lathe and used a 1 1/2" Forstner bit to remove the bark area where the drive spur would enter the wood. The turning processes were essentially the same as the green wood.

On Friday we displayed some of the pieces we had finished during the week. I had several natural edged bowls that were displayed. We treated the unfinished wood with lemon juice to remove some of the staining.
I brought home several extra green wood blanks to rough turn and save for returning this fall.
This was another excellent class. We have so much enjoyed the experience and the chance to learn at John Campbell. We are already planning a return in the fall. I am enrolling in a class to make a "Campbellin" - a style of mountain dulcimer.





Monday, February 16, 2009

A sneak preview

I spent several days at the lake wood shop working on a variety of projects. I turned several more bottle stoppers and packed up the remaining pieces and parts for another time. I used several of the yellow plastic stopper kits and used them as stoppers for vinegar/oil bottles.

I also worked on rough cutting the pieces for the post office box trucks. Poplar for the test pieces and cherry and walnut for the final products. I have to clean many of the post office box doors and I am sure there are several sizes, so I will clean and apply a finish to the doors before I start the final cut to size for the wood.
Finally, I couldn't wait any longer to use the sharpening station. So, I installed the casters and attached the top so that I could mount the grinder and sharpen a couple gouges. I'll have to disassemble the top so that I can install the case back and interior divider. It will be nice to have a permanent set up for the grinder.



Thursday, February 5, 2009

Woodturning at John Campbell Folk Art School

My wife and I ventured to Brasstown, North Carolina, for a week at John Campbell Folk Art School. Situated in the far southwestern corner of North Carolina and nestled in the Appalachian Mountains, the school offers hundreds of classes in over fifty different crafts - art, fabric arts, music, dance, cooking, gardening, nature studies, photography, wood carving, wood turning, and writing. For Mary Lou it was quilting with a nationally known instructor. For me, what else, it was wood turning.
The school is an example of non-competitive learning with simple living arrangements, excellent food, and time to learn and relax.

My wood turning class was held in what can only be described as the perfect set-up for wood turning. The Willard Baxter Wood Turning Studio is said to be the nation's largest wood turning school offering over 50 classes per year. A 2 year old building equipped with full size Powermatic lathes, Jet mini-lathes, quality tools, and ten roomy work stations. The lighting was excellent and a newly installed central dust collection system made it a comfortable setting. The instructor's lathe had a video camera and television set to enable the students to watch each demonstration. Everything you needed for helping me learn more.
To top off the learning experience, our instructor, Troy Bledsoe from Social Circle, Georgia was an experienced turner with a gift for making the class productive and fun. The projects were candlestick, tea lights, "confetti" lights, bowls, and bottle stoppers. Each project was helpful in learning to properly use and control my gouges. I also spent part of the last day practicing sharpening my own tools with a lot of guidance from the instructor. Now I am able to transfer those grinds to my own sharpening system and hopefully maintain the sharpness I like.
This has to have been the single best class I have ever attended. It is the reason that I am intending to return to the school in April for another turning class.

Monday, January 19, 2009

Mahogany and Birds eye Maple box

I finally got around to putting the finish on the lidded box I started in a Woodcraft class and wrote about back in October [link]. I just didn't like the combination of mahogany with a walnut veneer top, so I built a new lid with a bird's eye maple top. The finished project is a combination of mahogany sides, veneered maple top, veneered mahogany/walnut bottom, and walnut dividers.
The mahogany/maple combination has turned out to be more attractive to me so I am glad I remade the top. I used a wipe on poly for the finish and installed two small hinges. I will probably add a small brass knob to the lid.

Friday, January 2, 2009

Sharpening Station starts to take shape

I saw a sharpening station in Issue 81 of Shop Notes that I thought came close to fitting my needs. I was looking for a place to house my grinder and Wolverine Sharpening system for my lathe tools. The station in the Shop Notes had everything I wanted but it had an expandable top with a built-in water basin for water stones. I was more interested in having a permanent site for my 8 inch slow speed grinder and also a place for sharpening with sandpaper and stones. I didn't think I wanted to have to move the grinder in order to access the water basin.
I did remember seeing a grinder mounted on T-track that slid to the back of the station when not in use. I think that approach gives me the multiple sharpening situations that I think I will encounter.
So this drawing indicates the physical structure and layout of the cabinet I am building. There are several changes from the Shop Notes station. I am putting it on casters so I can move it to the lathe or workbench depending on what type of sharpening I want to do. I made the top solid double layer of 3/4" MDF with melamine and hardwood edging. Two T-tracks are embedded in the top to allow the grinder platform to slide from the back to the front. The grinder itself is on a platform to accommodate the height necessary for the Wolverine sharpening jigs. I am adding a movable work light to help with fine honing.
I'll start adding pictures of my actual work station as it takes shape over the next weeks. Right now I have the cabinet shell and face frame assembled and I have the top completed and ready to attach.

Thursday, January 1, 2009

2008 Projects become 2009 Ideas

Last year at this time I created a notebook that had all of the wood working projects that I wanted to do in 2008. And I even made a resolution, "I will complete all of my wood working projects.
Well, life intervened and I was redirected to different activities for a large part of the year. And I also discovered that I was picking up new project ideas and working on them instead of the projects on my list.
So, this year my resolution is much more general - to enjoy working on projects in my shop. And it gets more to the heart of why I spend time in the shop without setting number goals.
Aside from the old resolution, I had a good time learning this year. I spent a lot more time wood turning and completed a number of projects on the lathe. So maybe by concentrating on enjoying the projects instead of just how many I completed, I will make room for more learning and for new discoveries.

Monday, December 22, 2008

Prairie tree ornaments become a future project

A recent article in The Daily Record opened up a new interest - scroll sawn prairie tree Christmas ornaments. The ornaments by Glenn Tschantz of Orrville, Ohio, are three dimensional and involve a lot of fret work. Most popular after the Civil War, they have a delicate and detailed Victorian look. I found a book at Border's, Holiday Ornaments for the Scroll Saw, by Rick and Karen Longabaugh, owners of The Berry Basket Collection. Full of over 300 patterns, it appears many are three dimensional and ornate like the ones produced by Mr. Tschantz. They certainly will be a step up from my present scroll saw work.
I made some simpler ornaments this year that were featured in a project article in Wood magazine, November, 2007. I stacked two pieces of thin plywood together with a layer of copper in between. I turned the metal picture into the front of a Christmas card to each of my relatives. They each got a matching wooden ornament. Four of the seven designs are included in this picture. They are cut from 1/4" baltic birch plywood and finished with a satin polyurethane spray finish.
I'll look forward to trying some of the more complicated designs to decorate our own tree next year.