A Sharpening Station, At Last!

Many of my tools will benefit from regular sharpening.  This includes handplane blades, bench chisels, carving chisels and woodturning tools, all of which I use often.  It's well known among woodworkers that sharp tools are necessary to achieve the best work, while dull tools are inefficient at best and dangerous at worst.  My problem was that I had no regular place to sharpen my tools.  Instead, every time I wanted to sharpen my plane blades or chisels, I had to get out my stones and set them up on my workbench, then move them out of the way when I was finished with them.  My woodturning tools are sharpened on a heavy slow-speed grinder that was inconvenient to lift from under my workbench every time I wanted to do some turning.  I use a Koch sharpening system and Shapton stones for my carving chisels and, once again, it was stored in an inconvenient location.

The eventual outcome of all this inconvenient, of course, is that the job of honing gets put off until no small amount of resharpening will suffice to restore the tools to peak condition.  And it means that tools get used when they are dull, poor practice indeed, but one I'll admit to practicing.

Gluing up the drawer

The solution is a dedicated sharpening station, something I've yearned for over the years and even planned but never built.  Fortunately, my good friend and business partner Jeff Fleisher came up with some surplus property that provided a solution.  First was a slightly damaged cabinet with a wide drawer opening and double doors leading to a moveable shelf inside.  Then, a local restaurant was renovating and he snagged some thick Formica table tops for each of us.

With these two pieces in hand, my job became simple.  I attached rotating wheels, pin nailed the table top to the case and built a drawer to fit the opening just under the new tabletop.  Then I added drawer pulls and finished it all with a coat of shellac.

My sharpening tools

Even before the drawer was completed, however, I put the station in operation.  The tabletop measures 48 X 30 inches and is large enough for all my sharpening equipment--a Tormek T-7 water-cooled grinder, a Koch sharpening system for my carving chisels, a low-speed grinder and a tray with my Shapton stones at the ready.  My strop is hanging on one side.  Tormek accessories and other small tools are in the large drawer.  Water jugs (I have no water in the shop) and other large items are accessible through the double doors.  Being on wheels, the whole sharpening station can be easily rolled near the workbench when wanted there and then rolled back out of the way when the floor space is needed for assembly and the like.

The finished sharpening station

I feel certain that this improvement to my shop will greatly enhance the speed and quality of my woodworking.  If you don't have a sharpening station, consider building one similar to this.  If you can get hold of a surplus cabinet or tabletop, so much the better!

Norm

Learning to Plane - Part III

When Should You Regrind a Bevel?

You only need to regrind after you have honed your secondary bevel, say, six times, if it is taking a long time to get a good polish, the secondary bevel has grown large or if you've hit a nail or dropped the blade and nicked it.  Chris Schwarz grinds on sandpaper, starting with 80 grit and moving to 120 grit.  Grind until the secondary bevel is small, unless it has been damaged.  In the latter case, grind it off entirely.

If you need to regrind on a grinder, grind the point flat, because the point is the most likely place for the blade to burn.  Alternatively, you can quench the blade while grinding.  If you burn a blade blue, hone it and use it anyway.  It will need honing sooner than if it had not been burned, but otherwise it will be OK.

When using a grinder, Chris draws a square line with a magic marker--red shows up best.  Then he grinds the bevel flat using an 80 grit wheel.  He prefers the gray wheels over the white ones because the gray breaks down easier and stays cooler.

How do you tell if your blade is dull?  When you can see a bright line across the end of the blade.  If it's sharp, you can't see the end at all.

Cambering Blades

Some planes will have straight blades.  Others, especially those designed to flatten boards, should have a curve to them.  Jack planes, when set up as fore planes, should have a curve with an eight inch radius.  You would create this camber on the grinder.  Jointer or try planes can be straight or curved.  Chris prefers them curved.  They get a much smaller curve, about .006 inch from the center of the curve to the edge of the blade.  This would work out to a radius of about 37.5 feet.  Bench planes get a smaller curve yet, about .002 or .003 inch.  In case the case of jointer and bench planes, you grind the blade flat, then hone it curved.  The goal is to have enough curve to the blade to avoid tracks and still take a good shaving.

Chris's method is to use a honing guide that allows some rocking motion side to side.  He holds the blade square against the 1000 grit stone, putting heavier pressure on one outside edge, then pulling the blade 10 times.  Then he shifts the heavy pressure to the other side and pulls 10 times.  After that, he moves the pressure to the midpoint between one side and the center and pulls the blade 5 times, repeating that motion on the other side.  Finally, he puts the pressure in the center of the blade and gives it two pulls.  This sequence is then repeated on the 4000 and 8000 grit stones.  There is no need to repeat the ruler trick on the back of the blade.  Stropping is about like using the 8000 grit stone.  Stropping the blade is unnecessary after honing and may even lead to rounding over the bevel.

You also want to trim the corners of the blade.  This only needs to be done the first time you set up the blade and is done by pushing a fine file against the corner of the blade, using a rounding motion.  This helps prevent blade tracks on your work.

Thanks to Jeff Fleisher for these photos.  Next time I'll cover setting up planes.

Norm

Learning to Plane - Part I

I've got the planes.  I described these in an earlier posting.  I've read the books.  Especially good are Christopher Schwarz's Essential Handplanes and Thomas Lie-Nielsen's Sharpening.  Now it's time to put what I've been learning into action.

 I started with a wide board of curly red oak that I wanted to use to make some cutting boards.  I set out using my Lie-Nielsen no. 7 1/2 low angle jointer to flatten the board, then my Veritas low angle smoothing plane.  To remove a peak in the center of the board, I first planed a trough in the center with the jointer plane, then planed across the board on a diagonal to remove the high places until the board was level.  Then I used the smoother to produce a surface that barely needed sanding.  The result was good if I do say so myself, considering I started with a tough board to plane. 

I learned a lot from the process.  One lesson was that I need to know more about sharpening.  A second lesson is that I need to know more about setting up my planes for optimal performance.

Fortunately, I'm having a chance to learn how to do both of these things.  As I write this, I am midway through a class on handplanes taught by none other than Thomas Lie-Nielsen and Christopher Schwarz.  The class is being held at the Marc Adams School of Woodworking in Indianapolis.  Already, I've sharpened and set up two of my planes and have taken a perfect thin shaving with my Lie-Nielsen No. 4 smoothing plane.  It was an exciting moment!

I'll have more to say about this class later, along with photos.

Norm

Learning to Sharpen Chisels

Let's face it, I never started out to be a hand tool guy. There is something about power tools that just draws me to them. Among other things, they have (for me, at least) a mystique about being precise in application. Though I'm finding out they are only as precise as their user, still, the whole idea of hand tools leaves me with the impression of their being susceptible to misuse by my unpracticed hands.

Be that as it may, I have already found chisels handy enough (OK, essential) that I broke down and bought a set. I didn't pop for an expensive set but instead caught Woodcraft's Wood River brand when it was on sale. What I didn't count on was the fact that while they are not exactly dull when they arrive, they do need a basic sharpening to make them really useful.

The first thing I did was purchase a basic grinder, which is needed to shape the front of the blade. But after asking my friend Jeff Fleisher how to sharpen them properly, he put me on to an article about David Charlesworth's method. Finally, today I drove out to his shop in New Market, Virginia, and he helped me sharpen the first chisel so I could see and experience the process for myself.

The process is fairly straightforward, if a little tedious when doing it for the first time. Charlesworth's method calls for a series of Japanese waterstones. You first flatten the back (flat) side of the chisel to remove all the tooling marks as it comes from the factory. This involves working the back of the chisel up and down and then back and forth on either a 200 grit stone or wet or dry sandpaper laid wet on a sheet of glass. When the factory marks have been removed, only slight scratches from the stone or sandpaper should remain. You then move to a 1200 grit stone that has been wetted and repeat the procedure, working from there to a 4000 grit stone and finally an 8000 grit stone on which a slurry has been made with a nagura stone. By the time this has been done, few if any scratches should remain and the back of the chisel should be both flat and scratch free.

The next step is to work on the beveled side of the chisel blade. Here you turn to the fine wheel on a slow grinder. You mark the beveled edge with a Sharpie, then grind away the marked metal, holding the chisel at precisely 90 degrees to the wheel. When all the marking has been ground away, you should have a slightly concave surface on the bevel.

The final stage is to put a fine edge on the chisel. This is done on the 8000 grit stone using a device that holds the chisel blade at 30 degrees to the stone. Five or six pulls is all that is needed. Then you increase the angle slightly and repeat the process, again five or six times. All that's left now is to check and see if there's a burr on the flat side of the chisel and, if so, remove it by pulling the blade across the stone a few times.

The finished blade should be able to cut the top of your fingernail when gently pushed against it or should be able to shave a piece of soft wood like pine smoothly and cleanly.

So, I now have one sharp chisel. And a lot of work to do to get the rest of them ready for real use. The good news is, once the backs are flattened (the slow part of the process), I should not need to do more than touch up the bevels for a long time to come!

Norm