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Wood Shop

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Production & Precision Woodworking

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Have you ever wondered how a furniture builder can replicate several pieces that are all exactly the same without the use of any fancy CNC machines? Well fortunately there is a method that won’t break the bank, and can be done in a reasonable amount of time. All it requires is some scrap wood or MDF (your choice), a pencil and straight edge for marking lines, a French curve if you want to get extra fancy, blue tape, CA glue, and a router with two different types of pattern cutting bits—one top bearing and one bottom bearing.

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Custom Rosette Head Blocks

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Thirty years ago, if you needed an old house head block with a bullseye or rosette in it, you would have had to buy one pre-made or seek out one of the few rosette cutters on the market. Either way, it would’ve been too small for a typical renovation of an old house. Today, there are some rosette cutters that have interchangeable blades with the ability to have custom knives cut. But they’re too expensive, especially if you only need a few. And rosette cutters are hard to use on a drill press because they tend to chatter, ruining the work. My 1975 Craftsman has a little play in the bearings—it certainly won’t work with a rosette cutter! Read the full article…

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Moulding Planes

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Have you ever worked on an older remodel and needed a couple of sticks of trim to match but couldn’t find anyone who still stocked that profile? How about a piece to mate to a change in pitch on a rake run? Or have you ever had a designer draw something and then ask for a mock-up? There isn’t enough lineal footage (LF) to warrant having a knife made, much less the setup cost to run it. But there is an alternative—a good one. Make the moulding yourself. With a few moulding planes and some guidance, custom pieces can be made in the time it takes to find a millshop, explain what you need, and provide them with a scaled drawing! Read the full article…

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Making Louvered Doors

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…with One Router Sled

I live in an old stone barn that was converted to a house in the 1950s. The master bathroom needed a makeover, so I gutted it in preparation for a complete overhaul. I wanted to build a new closet and separated toilet area, both of which needed doors. I decided to build louvered doors out of Mahogany, which would normally cost approximately $600 from an online supplier. Read the full article…

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Adjustable Closets

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Custom closets with adjustable shelving are the norm for my business today.

About a year and a half ago, my friend Gary Striegler gave me the idea of building closets with adjustable rods and shelving. At first, I was a little confused about how the rods could be adjustable, but after I read an article Gary wrote for JLC, it all started becoming clear. The shelves adjust like any cabinet with adjustable shelves, but it’s the adjustable rods that make this system really cool. Read the full article…

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Jobsite Work Table

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Ever wish you had a work table that could handle all your jobs?

When I first started out over fifteen years ago, I would use anything I could find as a table. I’d lay plywood on the ground, I’d set plywood on wood blocks, and, finally, I grew up enough to use sawhorses. But most of the time my “table” was never big enough for the project I was working on. And it was never efficient. Read the full article…

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Wooden Miter Saw Stand

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I am a cabinet maker. I own and operate a small shop. I do it all, from making the sale to installing the pulls. Crown molding is standard on all my cabinets, unless the client wants something different. So on 99% of my installs there is crown molding involved. I used to use a small 10-in. single bevel miter saw that worked just fine for most of the crown I needed to install. Occasionally, I would run into something that was too big for my saw to cut, but I was always able to find a way to “make do.” Sound familiar? Read the full article…

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The Benefits of a Work Van

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Finish carpenters carry a lot of tools. In fact, we carry more tools than any other trade I know, maybe more than any two combined. Sure, plumbers carry a lot of weight, but that’s mostly pipe. We carry tools: table saws, table saw stands, outfeed tables, miter saws, miter saw stands, work tables, nail guns (at least four), drills (at least four), routers (at least four), planers, grinders, sanders, circular saws, track saws, compressors, air hoses, extension cords—and that’s just the big stuff. Then there’s the nails, screws, glue, sand paper…the list goes on and on.

You’d think that after 15 years in this business I’d hate tools, but I love them. The problem is, how to get them to the job, and how to store them so I can find them! Read the full article…