Lost Art Press

How to Cut Wide Tenons

Posted on by meghanlostartpress
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FIG. 1. WIDE TENONS WHICH ARE AWKWARD TO SAW It would be difficult to keep the saw to the line over so wide a rail. The planing method outlined here is generally followed in the trade.


This is an excerpt from “The Woodworker: The Charles H. Hayward Years: Volume III” published by Lost Art Press. 

A reader has been making a piece of work which has involved the use of a tenoned rail some 12 ins. wide, and tells us that he has had difficulty in sawing the tenons. Whilst it is possible to saw the tenons, we should not advise it. It would take too long, and it would be difficult to keep the saw true across so wide a tenon. We give here the simplest method.

We show a wide rail in Fig. 1, the cutting of the double tenons of which is a typical example of the process to be followed. A similar case of even wider tenons is that of, say, a table top with clamped ends, the last named being mortised for tenons cut at the ends of the top.

Mark out the joint in the usual way, squaring in the shoulders and marking the tenons with the mortise gauge. The chisel is used for marking the shoulders, and a shallow sloping groove is cut on the waste side as at X, Fig. 2. This forms a convenient channel in which the saw can run when cutting the shoulders, the next operation. The tenon saw can be used for this. Saw down to a fraction short of the gauge line, and be careful to keep the saw square.

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FIG. 2. CHOPPING WASTE AFTER SAWING SHOULDERS. This can be done only when the grain is straight.

Assuming that the grain is reasonably straight, chop away the cheeks with a chisel as at B, Fig. 2. Do not attempt to remove all the waste in a single cut, but start the chisel about halfway down, and finally take it to within about 1/8 in. of the line. Of course, the grain must be watched. If it tends to run downwards the chisel cannot be used so close to the line. If it runs upwards, it can be taken almost on to it. A fairly wide chisel is desirable for this work.

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FIG. 3. PRELIMINARY USE OF THE REBATE PLANE. The shoulder acts as a fence for the plane.

Now take the rebate plane and work across the grain, the side of the plane pressed against the shoulder as in Fig. 3. If you have the metal type of rebate plane you can set the depth gauge so that the plane ceases to cut when the tenon is reduced nearly to the gauge line. Be sure that the cutter does not project on the shoulder side as this will damage the latter. At the near side the grain is sure to splinter a bit, but this does not matter. It cannot splinter on the shoulder side as it has already been cut with the saw.

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FIG. 4. FINAL REDUCTION WITH JACK PLANE. Work the plane inwards from each end.

To finish off use the jack or any other bench plane as in Fig. 4. Carried out in this way the reduction of the wood is quite rapid, certainly quicker than when the saw is used throughout, and it enables the tenon to be trimmed to within fine limits. The remainder of the work, that of cutting the separate tenons and the haunches, is as in normal tenoning.

— MB

Recipe for Happiness

Posted on by Kara Uhl
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“Traditional Chair Making – High Wycombe,” photographer unknown. © High Wycombe Furniture Archive, Bucks New University

“It is one thing for the man whose daily work offers him a really creative job, the engineer, the skilled craftsman, the artist, the writer, because with the work comes the discipline. He has to stick it, in spite of the weather or his feelings at the moment, because he who will not work neither shall he eat, neither, in fact, shall he have anything else that is worth having. But because the job is a job into which he can really put all his powers, he has the chance of extracting real satisfaction, real happiness, from it. Or at least as much as we can hope for in an imperfect world. Because to become absorbed in an interesting job is happiness. But when a man takes up some form of creative work in his spare time, he has to be his own taskmaster. And that is not so easy. There is always the temptation to cry off when he doesn’t feel like it, or to drop it altogether when difficulties crop up—as they are bound to do when a man is learning to do a thing on his own. In short, it takes character and grit to stick it long enough to acquire real skill. But once that is attained he has achieved something that will set him on the road to still greater achievement in the future. And that is at least one recipe for happiness.”

— Charles Hayward, The Woodworker magazine, 1942

‘Carving the Acanthus Leaf’ Off to the Printer

Posted on by Lost Art Press

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Mary May’s first book “Carving the Acanthus Leaf” has been delivered to the printer and we will open pre-publication ordering on Friday.

The book will be $49 (which includes shipping in the United States and Canada). All customers who place pre-publication orders through Lost Art Press will also receive a free download of a pdf of the book. The book should ship before Thanksgiving.

This is a massive book. It’s 336 pages and filled with more than 1,000 full-color step photos and illustrations demonstrating how to carve 13 different acanthus leaves, from an understated Scandinavian version, to the classic Greek to the gorgeous Renaissance-style leaf. Woodworkers of all skills – from the beginner to the seasoned carver – will find lots of techniques explored and explained.

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“Carving the Acanthus Leaf” will be a hardbound book with a tear-resistant dust jacket. The binding will be sewn and glued so the book will sit flat on the bench for many years without the pages coming loose.

We will have more details on the content – including a free excerpt – on Friday. As always, we will offer this book to our retailers across the globe but it is up to them to stock it. So I don’t have any information on who will carry it.

— Christopher Schwarz, editor, Lost Art Press
Personal site: christophermschwarz.com

I Don’t Use These as a Rule

Posted on by fitz

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Well that’s not entirely true, of course. I do use them when I need to make up a cut list from a full-scale drawing or story stick to tell a machine in numerical code (be it metric, Imperial or shaku) where to make the cuts. The cut list is, however, rarely necessary in the hand-tool approach to construction. So in typical layout work, I go with pin-point perfect real placements of cut or location lines.

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For example, if I need to lay out the location of slats in a bed’s headboard, I simply stack the slats together against the post (or its location on a story stick) and find the intervening gaps by stepping out the number of gaps needed between the slats (number of slats + one). Layout follows as shown in the next drawing. The accuracy of the layout will be a function of however sharp I make the points of my dividers.

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Of course, you can use algebra to generate dimensions with numbers:

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As for me, I don’t want to spend the time doing it and then having to deal with reading tiny numbers on some ruler and coping with rounding errors!

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As another example of rulers not always ruling: Say you want to locate placement buttons (the ebony plugs in the set shown here) on a pair of winding sticks so you can quickly locate the sticks on the edge of a board. In this case, the location is not a number at all (at least not until after the fact). You could, of course, measure the length of the sticks and divide by two to get a numerical center point.  Or, to avoid rounding error, you could step off an even number of intervals to locate the middle division line and then enjoy the accuracy of a pin prick. But both would miss the point so to speak. What we are really looking for here is not the center of the stick, but its center of gravity. How do we find that? We just balance the stick on a sharp knife blade!

— Jim Tolpin, byhandandeye.com and one of the authors of “From Truths to Tools“

Saalburg Workbench: The First Cut

Posted on by Lost Art Press

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When a woodworker threw two workbenches down well No. 49 at the Roman fort at Saalburg 1,800 years ago, he (or she) likely anticipated retrieving the benches once the Germanic tribes attacking the fort (or attacking the nearby limes) were defeated or retreated.

That didn’t happen, and so in 1901, and the workbenches were retrieved during massive excavations and reconstructions at the fort at Saalburg, resulting in thousands of surviving artifacts in wood, leather and metal.

During my visit to Saalburg in June, I was allowed to measure the workbench to a make a reproduction for my upcoming book, “Roman Workbenches.” During the last few months, I’ve been getting ready to build this bench. This is one of those cases where preparing for the project will take much longer than building it.

The bench itself if simple: A slab with five to seven sticks driven into it. Placing those sticks and selecting the right material is what has vexed me since June.

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The primary problem has been what 1,800 years in a well will do to a slab of wood. Rüdiger Schwarz at Saalburg explained the problem perfectly this summer when he showed us a wooden yoke that had been pulled from one of the wells. The wooden yoke was shriveled and distorted, like someone had made a Shrinky Dink of a yoke and left it in the oven too long.

Next to the yoke was a casting that had been made of the yoke right after it has been rescued from the well. It looked like a brand new farm implement. Schwarz explained that wooden objects, such as the workbench and the yoke, had distorted noticeably after they dried.

So the workbench was likely much less twisted than it is today.

Also: The bench’s legs are not original. They were added shortly after the bench was recovered so the bench could be shown. As the “new” legs were wedged in place from below, there is no way to know how the mortises are angled. In other words: Who knows what its rake and splay are really like?

So the last couple weeks has been all about laying out the joinery on my benchtop, performing trigonometry equations to determine some sample rakes and splays and them comparing the results to my photos. Oh, and lots of wondering and thinking and imagining. (I know this doesn’t sound scientific at all.)

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In the end, my numbers were driven by several factors aside from the photos of the Saalburg bench, including other low workbenches I have used and their working characteristics.

Today I bored out the waste inside the square mortises. There is no going back now.

— Christopher Schwarz, editor, Lost Art Press
Personal site: christophermschwarz.com