Hand Production Techniques - Lesson Thirteen

During this lesson I decided it was time to create the groove for the back and divider of the cabinet. I did this using the methods previously explained further ↓ the blog ;)

The main problem I had during this lesson was the fact there were only two combination planes, and I left mine at home :( . However I decided it would be better to go home and pick it up, rather then waste lesson time.

I also had to put on a wooden guard on the plane to stop it from marking the cabinet wood. The groove that I created was 4mm deep, and 6mm wide.

Wood attached to guard

Groove cut in wood ready for cupboard back

I then used a combination of chisels and a number 71 plane to create the divider groove. The biggest problem was tear out along the edge of the groove, but I learnt from the first one that I did and chisels deeper first. This meant that the second groove was much better. This groove was 16mm and 4mm deep.

Grooves complete

Hand Production Techniques - Lesson Eleven

This lesson was primarily used to sort out all the wood which was going to be used to create the carcase of the cupboard.

This wood had been ordered  and delivered, so all we had to do was mark any defects, cut it to length and plane a face and edge.

To begin I first used chalk to label the piece of wood with my name, and also any defects on any of the edges, so when I marked out my cabinet pieces there would not be any chips or dents.

Once I had marked out the the defects, I then cut it into length using the Radial Arm Saw.

Above: Radial Arm Saw

Finally I began to hand plane one face and an edge. To stop the wood from warping I also lightly planed the top service of the other side. I used a variety of hand planes, including a number 4, 5, and 7 jointer plane.

Above: Wood being planed to create a flat face

Although this was quite an easy task to understand, it took a long time, and A LOT of hard work, as I still haven't finished planing yet and will continue in tomorrows lesson. However I did hit a problem when I realised one corner was lower then the rest, which meant I have to plane the rest of the face to meet this corners height. 

Hand Production Techniques - Lesson Nine

Today was a lesson about how to create a rebate in a piece of wood. This will be used in future modules and pieces of work for things such as a cupboard back, drawer bottom or even shelf's and dividers to sit within the carcass.

There are a variety of different ways such as a Plough Plane, Rebate Plane or Combination plane. To create the groove I used the latter.

Above: Combination Plane

It is made up of a guard which runs along the edge of the piece of wood, a depth stop which you set to the required depth, and finally the actual blade, which can be removed and changed depending on the size or style of groove that you require.

Along the edge of the guard you normally attach a piece of hardwood with rounded ends, as this allows stops the metal rubbing against the wood and creating marks.

To create a rebate, the first thing you have to do is to start it on the furthest edge, and work backwards to to other side, as shown below.

Above: Groove at one end, and planing away to other edge.

Once you have created this, it will look something like this:

Above: Groove created by Combination Plane

Creating the groove was simple and easy to do, I had no problems, however I learnt from some that they hadn't done the guard up tight enough, and ended up with the groove running out of a true straight line from the edge of the piece of wood.

Finally I also learnt about a machine called a 'Wood Welder'. This cures glued pieces of wood in seconds, as is done using microwave energy.

Above: Wood Welder

Hand Production Techniques - Lesson Three

In this lesson I made the Bridle Joint. This joint involved similar tools as the previous lesson, however there was also the Mortice Gauge. This was used to mark out thirds and mark out two lines equally on a piece of wood. I also learnt a new technique of sawing, which is shown in the image below:

Cutting this way allows you to cut much straighter, and with much more control of the saw and the cut.

I also learnt about how to set up and use a hand router. This is hand router or "Router plane", has a small cutting blade at a 90 degree angle, and allows you to smooth off joints and make sharp edges. This was much more accurate and quicker then using a chisel like I did previously, and was so useful I went and purchased my own second hand one.

Overall the joint went really well, however I quickly learnt to hold the Mortice Gauge tighter, as it kept jumping and following the grain. Also I had to pair down along the cutting line as it was to tight, so next time I will cut closer to the line.

Hand Production Techniques - Lesson One

Well this was the first lesson of "Hand Production Techniques", or making, and I was really excited to start making. Sadly we didn't get into the workshop today, however learn't some valuable information to prepare us for tomorrow (when we will be in there).

Process Plan:

We first learnt about the process plan, which is a table where you list all the operations, their estimated time and then finally their actual time, like below:

This kind of preparation is incredibly useful, as it allows you to see exactly what steps need to be taken, and what time needs to be allocated to each one. Also if anything takes longer then expected, you will know and can factor it in on further operations. Crucially you can also work out WHAT ELSE YOU CAN BE DOING!

I also learnt how to basically plane a surface, which is shown in the diagram below:

This diagram shows the direction (arrows) which you should plane. You should plane from corner to corner, then straight up, moving the pressure from the toe of the plane (front) at the beginning, to the sole of the plane (middle) and finally the heel (at the back) when you are at the far edge of the wood.

Finally I learnt how to sharpen tools. This is done so you can make more precise cuts and joints, it takes less physical effort and also saves a lot more time then trying to do it with a blunt tool. This includes learning about the grinding angels and honing angles of both chisels and plane blades.

Will blog again tomorrow about what happens during the lesson and hopefully add some photos.