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Morley Bar Stool Lumber
After downloading plans from the Wood Whisperer Guild I thought hard about the lumber in my shop what wood I would prefer to work with and what my ‘customers’ would like. There is some very nice Walnut that I have for another project that I looked at very seriously but the dimensions did not lend themselves well and the amount of waste a little concerning.
I decided to use maple for the seat and cherry for the structure. Since I didn’t consult my clients they readily agreed. Hopefully the maple and cherry will work well together. The lumber yard I use here in San Antonio has worked out well, they have a unique system, commented on a few months ago. I was very surprised at the cost of the Cherry, pleasantly surprised! Once it was in the shop I didn’t waste time cutting it into smaller pieces. My shop works fine but the 10’ lengths of lumber are quite a tripping hazard.
Starting with the Maple I crosscut it to lengths and began milling it into blanks for milling and shaping. I admit that the virus certainly took a little bit of my breath away but it felt very good to cut these by hand and I couldn’t have asked for a better saw. If you haven’t visited Bad Axe Saws lately they appear to be doing well and as they move through a change in ownership Mark Harrell is still next door and providing teaching and saw sharpening through his new company sawsharp. You can find him on instagram at SawSharp6. BTW I recommend his saws because of the excellent quality and service he has provided me over the years and have no financial or other relationship with or Bad Axe Toolworks.
The design of the seats will require a couple of jigs and the bandsaw as I move into the power tools.
Power Tools?
The final weeks of the year were busy, finally slowing when a little virus called Covid visited for the holidays. Still recovering I began slowly working on what will become the first project of 2023. Last fall I began a search for plans for bar stools. With family members living in apartments and moving frequently it seems like a good answer to providing simple seating for meals etc. Most apartments now have a high counter that can be used as a seating area and a couple of stools eliminates the need for a table and chairs.
After a lot of searching I came across the Morley Bar Stools in the Wood Whisperer Guild. Photo from the Wood Whisperer Guild.
This is a very different project from anything I would typically take on and that is where the attraction lies. The design is more modern and the techniques used based upon power tools. Initially I contemplated using hand tools but decided that it would be a unique learning experience to walk on the “Dark Side” of wood working.
On my all power tool project the first step was breaking down the stock, i immediately set about cutting the lumber into reasonable lengths using my Bad Axe D8, did you really think I could go all power tools?
Walnut Coffee Table – Legs
There is a point in the woodworking journey that an epiphany occurs. As you look at the work of others and study pictures on line or in articles you realize that all of you hard work to make tight joints and smooth tops doesn’t make for the perfect piece. Suddenly you realize the importance of wood selection and grain, shadow lines and many small details. I’m not sure when that realization occurred but I’m certainly aware and trying to work on executing on that knowledge.
One of the people that raised my awareness was Mike Pekovich. I’ve seen articles and videos where he uses grain to its greatest potential, producing stunning projects. Paying attention to the grain in the legs of many of his projects really shows what a dramatic difference can be made. Focusing on a cross section of the 8/4 walnut board
Cherry Coffee Table – Prep
Several months ago while picking up lumber for the Walnut Coffee table, I also purchased lumber for a cherry table. I’m glad I made the purchase at that time since prices have increased dramatically. My vision for the table changed at the last minute when I thought about how much I enjoined the joinery on the Paul Sellers table I made a few years ago. I used a similar shelf on the bar cart as well. I’m just a gluten for mortise and tenon joints.
When I purchased the lumber I had smaller legs in mind so was content with 8/4. Now I’m going to need to stretch it so that I can get 2 1/4 finished legs out of it. Several of you have noticed an increased use of power tools in the last year. I have always used power tools where it makes sense and hand tools where they are most effective or I get more joy. Most projects start with the break down of stock and I always reach for my hand saws. Today I grabbed the Bad Axe D8. It’s pure pleasure to use this saw. As I write this post I went back and realized that I have had this saw for five years and It seems that long enough to truly recommend it.
Since I am using rough lumber, I flattened one edge with my hand planes, in this case a Stanley #7. Then used the planer for the remainder of the dimensioning, I talked about the use of sleds in the planer rather than the jointer in a previous post.
In order to make the legs the correct dimensions I needed to glue a 1/2” strip before cutting the board into individual legs.
Now the hard part, which side faces out…….
Saw Blade Returns
The saw blade that I damaged with the saw stop a couple of weeks ago has returned with the repairs complete and resharpened. I’m absolutely amazed with the speed of the service. It was shipped on a Monday and back in my hands 12 days later!
Walnut Side Table Top Update
As several of you pointed out the last post concerning the crack in the side table top was unclear and incomplete. I must have accidentally sent it out over the weekend before I finished writing. Here’s the full story….
The underside was chamfered to lighten the appearance of the top. While I was using the router clamps were used to hold it in place. Unfortunately I did not ensure that the top was fully supported and after completing the routing and putting the router away the top cracked. It is a clean break over most of the length with a jagged edge on one end. I do not have pictures of my poor clamping method which consisted of a couple of boards underneath to allow the router to travel around the outside without touching the table top. I certainly should have used a better method.
Walnut Coffee Table Top Refinish
The finish was Shellac, covered with water based poly. Used many times without a problem, however this time it looked like there was cracking and scratches across the top.
My best quests is there must be something that interacted with the polyurethane so It all needs to return to bare wood and start again. Not what I wished to do but I need to correct the finish.
Walnut Side Table – Legs
As I looked for designs and possible dimensions for the table I came across an article and really liked the design and the challenge of using a Bridal Joint. I also like the original design used a few years ago with the exposed through mortises. I have used the exposed joints on a couple of projects from Paul Sellers, Coffee Table and Arts and Craft Side table. Use the links if you want to go to those project pages. I think that the table should use both joints. It also will allow me to try a couple of things that I have not done previously.
The article that I saw the bridal joint was actually a video series #193 Sept/Oct 2007. I also looked at other sources.
I spent some time making sure that the grain worked for the project and then squared everything up. I found the card shaper handy with the tear out that I’ve been experiencing. Anyone used one of the high angle frogs in heavy tear out?
The mortiser again made quick work and only a little clean up was needed with a chisel. Next the bridle joints which I did with hand saws and my band saw. I measured very carefully and it paid off, only minor plane work on the tenon to get it all together.
Tidy Shop
The sound was normal, the swish of the plane communicating its sharpness and performance, air blowing through the vent with a sigh of warmth, a hammer’s tap as someone builds a garden shed. Turning around, looking for the source of my discomfort, it hit me like a sudden scent of danger….my shop is a mess!
There are three projects in different stages of production, boxes that have not been put away from a move a year and a half ago, drawers left open from hastily grabbed tools and a great need to sweep the floor, oh and a full dust collector and trash can.
I did not see it coming but my mind sounded the alarm through a sense of discomfort that something needed to be done and it need doing now. A couple of hours later the bench and table saw were clear and the floor swept but there was more that needed doing.
Walnut Coffee Table, Chamfer and Finish
Finishing is certainly not my strong point and not my favorite part of a project, however it’s the final step to seeing it all complete. I have been struggling with chip out on the edges of the table top and finally decided to chamfer them to remove the damage and prevent any more from occurring. Not sure if this is a Walnut normalcy, but I have not had this problem with other lumber.
The finish for the table is shellac, polyurethane and wax. Simple, and allows the wood to speak for itself.
The final step is attaching the tabletop to the base. Fortunately when I was cutting the side rails I remembered to cut slots for the
orepass 
