Setting up a woodshop

Thursday, January 1, 2004
By KRISTINE KISKY, for The Columbian

The craft of woodworking is as old as sticks and stones. "(Wood) is such a classic medium. You can do so many things with it, in so many areas," asserts Don Baiar, an avid woodworker for over 40 years.

    Transforming a raw log or lumber into functional furniture, a work of art or any number of other things wouldn't be possible without tools. And when you start talking to the hobbyists about their craft, one can't help but wonder if their true passion lies in the wood or the tools they use to work it.

    "I'm fascinated by tools, most people who work with wood are," said Baiar, a retired middle school shop teacher who presently teaches bird carving, does commission work and competes in local shows. "I have come to the point that I can not justify purchasing any more tools but still search the catalogs for new and better ones," he admits. "More than occasionally, I weaken and buy a new one or a replacement, if only to know that if I ever need it, it is there in the drawer. Sounds a bit compulsive, doesn't it?" he asks, tongue in cheek.

    Piece by piece

    Building a woodworking workshop is typically a long-term proposition. "I have focused 40 years on a variety of endeavors in woodworking and as an admitted tool freak everything I own in tools seems to be a 'must have' (or the) basics to me," says Baiar. "But one can not start with them all," he concedes.

    "What usually happens is a gradual accumulation of tools," observes Baiar. "You start with simpler projects and graduate to difficult, adding tools as you go." Acquiring tools over time allows a woodworker to learn about the tools at their own pace, "so you're not trying to absorb so much (at once)," he notes.

    Before investing in any tools, it makes sense to pick a niche within the wide world of woodworking. "Some woodworkers concentrate in one narrow field and if the commitment and interest is there, may only possess the specialized tools needed for that one process. Others may start with hand tools and move up to power tools gradually as their skills and knowledge increase. It is difficult to list tools (required) unless one's interests and goals are considered," concludes Baiar. "My advice is find out what areas you are most interested in, concentrate on those and get the tools necessary for those functions."

    "There are many opinions on what are the basic necessities for a home woodworking shop," begins Bill Cogswell, a member of the board of directors for the Evergreen Woodworkers Guild and the group's Webmaster and newsletter writer and editor. "It is limited only by space and budget. Most people agree that a good 'contractor' table saw is the centerpiece of a woodworking shop. For accuracy and power, a contractor saw is a good compromise between the less expensive tabletop saw or circular saw and the more expensive cabinet saw which requires (240) volt outlets," he explains.

    Bob Winfrey, a hobbyist for over 20 years who recently left the corporate, 9-to-5 world to pursue professional woodworking full time, agrees a quality table saw is a good place to start. "It will do anything a chop saw or radial arm (saw) will do."

    "After the table saw, the beginning shop should contain a drill press, a hand-held router, a miter saw and sanding equipment," lists Cogswell. "Additionally, a shop needs to have good layout tools such as rulers, squares, marking gauges and compasses. One of the first things that I learned from a mentor in our club was that all rulers are not created equal. So, if you are measuring for a project, use the same measuring tape throughout the entire layout," he recommends.

    Woodworking aficionados "can get by with a saber (or jig) saws, but at some point in their hobby they will likely purchase a good bandsaw, which is an extremely versatile tool," says Cogswell. "A bandsaw can be used for many woodworking tasks and projects. Drills, cordless and corded, are also used extensively."

    "Clamps of various types are also essential to a shop," continues Cogswell. "They are used for glue-ups as well as holding things down. There is a famous woodworking saying: 'You can't have too many clamps.' "

    "Sharpening is one of the most important woodworking areas and it is one of the basic areas that needs to be mastered," says Cogswell. "Hobbyists will need to have sharpening stones and grinders to keep everything sharp. Some people use a thick plate glass base with various sandpaper grits adhered to it as a sharpening method. This actually works as well as some of the more expensive options."

    "A good, solid workbench with a vise is probably as important as any tool in the shop and for most woodworkers," and many of them build their own, says Cogswell. "One member of our group has a workbench top that is made out of a section of a bowling alley. It's flat, 6-inch solid maple and yes, it is the envy of everyone who sees it."

    Fledgling woodworkers should not expect instant gratification in the craft. "Patience is a big thing" in successful woodworking. "People can buy power tools, but it will not give them skills," reminds Winfrey, who creates custom and plan-built furniture inspired by Gustav Stickley, Frank Lloyd Wright and styles from the Craftsman, Mission and Shaker traditions.

    The next level

    At some point, the hobby becomes a passion. Naturally, it's time for more tools.

    "Like any hobby, there really is no end to the 'nice to have' list of tools," says Cogswell.

    "One woman in our guild decided that woodturning was her passion and she purchased a lathe and the requisite chisels. It was a serious investment of well over $1,000," he recalled.

    "Woodworkers who decide to process their own lumber rather than buying it 'ready to go' from a lumber store or warehouse store will buy a power jointer and planer which are designed to flatten and square up the wood for use," says Cogswell.

    A short list of practical tools for the more advanced woodworker includes a drum sander, a compressor for air tools, a router table or a shaper, a bandsaw, a lathe, a mortiser, a plate (biscuit) joiner and an array of routers.

    "Some woodworkers decide to 'return to basics' and begin to acquire hand tools in lieu of power tools," notes Cogswell. "There is a wide range of vintage and reproduced hand tools available for the woodworker, including scrapers, bow saws, carving chisels, dovetail saws, tenon saws and hand planes in almost endless variety."

    Dream on

    "If money were no object, the first thing most people in our group would probably do is upgrade to a cabinet table saw if they didn't have one already. Then they would build a new, bigger shop. Few people have the luxury of a big enough shop," remarks Cogswell. "Some people are sharing space with a car in a garage or are in a basement or small shed."

    One Evergreen Woodworkers Guild member has a laser engraver. "It is a very specialized tool and probably not for everyone, but it does some fine work," says Cogswell. "Another person in our group has a Legacy ornamental milling machine." It has a price tag of several thousand dollars "but will make intricate shapes in wood that are beyond the time available to most woodworkers," he adds.

    Serious woodworkers might want to check out the Festool USA line. "They make an integrated set of tools that combine dust collection, sanding, sawing, routing and shaping," said Cogswell. "They presented a demonstration to our Guild in July, and they were very impressive -- and expensive." Since they are German ... I suppose they are the Porsche or BMW of tools rather than the Cadillac," he quips.

    Whether a tyro or a professional, "Always buy the best tools you can afford," Baiar recommends. "Cheap ones are inefficient, inaccurate, frustrating to use and often more dangerous to operate."

    Names and places

    Obviously, hardware and building supply stores are places to purchase woodworking tools, but there are other outlets, as well.

    Garage sales can be a treasure trove for woodworkers. "I've gotten a lot of tools over the years that way. It's fun and you can find some pretty good bargains at times," says Baiar. He also suggests scanning the classifieds. "If you look in the paper, people are always selling bandsaws and table saws."

    Tools can be found on eBay, or shoppers can walk into Bridge City Tool Works in Portland and find a nice array of high-end hand tools for the woodworker, suggests Cogswell.

    According to Tom Pranger, president of the Evergreen Woodworkers Guild, prices for woodworking tools "range from affordable to status symbols, usually all performing adequately for most all wood workers."

    "The 'average woodworker' could spend $15,000 to $25,000 to setup a new shop after the building is sized and available," estimates Pranger. "The 'ultimate dream shop' could cost upwards of $50,000 to $85,000 - (or) even more, only limited by your imagination," he notes.

    While some might pledge allegiance to a single brand of power tools, Winfrey's shop contains a smorgasbord. Bosch, Makita, Craftsman, Porter-Cable, Delta, DeWalt and others share space on his shelves. He suggest people select tools "based on how comfortable it feels when you're operating it," rather than the name on the label.

    Before investing in any tools, "I would recommend that one take a class, read books and manuals on the topic of interest and coordinate one's interests with (the) budget constraints that plague us all," suggests Baiar.

    "One thing is true about this hobby: a person with the most rudimentary set of tools can produce some of the most beautiful woodworking pieces you could ever hope to see. So it is that experience is often a great substitute for top-of-the-line tools," declares Cogswell.

    Sage advice

    Fledgling woodworkers needn't go it alone; there are numerous avenues of for obtaining friendly advice.

    "(Online) there are a lot of forums, people very willing to share their knowledge," said Baiar, who is a fan of the newsgroup rec.woodworking. "That's an awfully good one. You can talk to professionals. ... Everybody I've met in woodworking is willing to share their knowledge and expertise."

    "I have always believed that precise fit and finish is best accomplished with knowledge, experience, good tools and patience, patience, patience," declares Baiar. "Joining a club or group of like interest is a good way to start. I joined the Feather and Quill Carvers of Vancouver in the early '80s, and over the years have benefited from the sharing of techniques and from actively promoting the art form of realistic bird carving as chairman of the Columbia Flyway Wildfowl Show, now in our 16th year."

    Safety matters

    Since razor-sharp blades and power tools are intrinsic to woodworking, there are inherent dangers, as well.

    "Safety is always the first consideration," declares Cogswell. "No shop is complete without multiple safety devices and practices. Safety glasses in woodworking are like seatbelts in the car. You should get a ticket if you don't use them." For lathe work, a full-face shield is a must, he adds.

    Hearing protection is another important safeguard. In Winfrey's case, "The horse is already out of the barn," as he has tinnitus he attributes to the drone of power tools he's been exposed to over the years. Not wanting the problem to progress, he always wears sound-squelching earmuffs. Care should be taken when choosing goggles or hearing protection. "It has to be comfortable, or you won't wear it," Winfrey predicts.

    "Dust collection is essential. Most tools now have ports that allow a hose to be connected for dust and chip removal," notes Cogswell. "Working without managing the dust produced can lead to very serious long-term problems -- cancer and lung problems for starters."

    Exotic woods can be particularly toxic. For instance, "Teak is full of silica, which is not good to breathe, says Winfrey, who estimates his dust collection system captures about 70 percent of the airborne wood particulates.

    Julie Potluri, assistant editor of Chip Chats Magazine, reports, "In the ten years that I have been working here, the safety trends we often write about highly recommend a dust collection system for those using power tools." A dust collection system is especially important when using spalted wood, since the airborne mold spores can be deadly when they accumulate in the lungs, she notes.

    Historically, "Gloves are not often used because they can interfere with the sensitivity of the fingers which is in itself an important tool for the woodworkers," says Cogswell.

    However, advances in technology may increase hand protection. "Kevlar carving gloves have shown up in our annual Sources of Supplies listing, and leather thumb and finger guards are often recommended to those who whittle, especially those just learning to carve," notes Potluri.

    Winfrey suggests woodworkers invest in a good pair of tweezers, as slivers are an occupational hazard.

    Woodworkers should take the time to do their homework. "Instructions for tools should always be read and understood and then re-read before you are going to use that tool if it has been a while," says Cogswell.

    Another safety consideration that is rather intangible but very important is mental attitude. "A woodworker who is too tired or has other things on his or her mind should not be in the shop," cautions Cogswell.

    "More tools are being designed with safety in mind. There is even a new table saw on the market that will instantly stop when it detects something other than wood - a finger, for instance," Cogswell informs. "The SawStop system detects this change in the electrical signal and immediately forces a brake into the teeth of the blade."

    Resources:

    Donald F. Baiar, Alternative Environment Woodcarving Commissions & Classes: 360-892-6738; e-mail: dbaiar@comcast.net.

    Emerson Hardwood Floors and Crosscut Hardwoods: Hardwoods, softwoods and supplies for the professional and hobbyist. Portland store at 3065 N.W. Front Avenue, Portland 503-224-9663; online store and resources: www.emersonhardwood.com

    Evergreen Woodworkers Guild: Founded in 1999 by a small group of South Pierce County woodworkers, a mix of amateur and professional woodworkers, the non-profit organization is comprised mainly of members in the South Sound area of Washington State. Web site: www.ewwg.org

    Guild of Oregon Woodworkers: www.guildoforegonwoodworkers.com

    National Wood Carvers Association (also known by the title of its bi-monthly publication Chip Chats): Founded in 1953, the National Wood Carvers Association is dedicated to the interests of amateur and professional carvers and whittlers. NWCA's aims are to promote woodcarving fellowship among its members; encourage exhibitions and area get-togethers; list tool and wood suppliers, and find markets for those who sell their work. The NWCA has over 46,000 members. Web site: www.chipchats.org.

    Winfrey Woodworking: 19609 NW 9th Court, Ridgefield Phone: 360-907-8279; fax: 360-887-4891 Email: Robert_Winfrey@winfreywoodworking.com Web site: www.winfreywoodworking.com

    The Woodworkers' Website Association (producers of Chip Chats magazine): Dedicated to promoting excellence in woodworking through the Internet. Tool reviews, articles, interactive databases and announcements. Web site: www.woodworking.org

    Woodworking.com: Comprehensive Web site featuring tool reviews, project ideas, discussion forums, links to other woodworking sites of interest.