The Old Saw

A More Manly Cigar Box Transformation

2012-01-19T16:16:00.006-05:00

I was getting tired of carving flowers into empty wooden cigar boxes and transforming them into jewelry boxes and tea caddies. I needed to make something more manly; something a man could appreciate. I wound up making a box for my son-in-law for Christmas. A woman puts her “stuff” in a jewelry box. A man puts his “stuff” into a…valet box, or utility box, or something. I guess it doesn’t have an official name.

The design is a Celtic snake which is an adaptation of a tattoo design. That’s manly. I call it the Snake Box…very manly. The cigar box is made in Honduras using sapele wood, which is native to Africa. Sapele is pretty nice to carve, sort of like mahogany, but it can get splintery in spots. You also might run into hard knotty areas and irregular grain patterns. Most of the side pieces of these cigar boxes are made of quarter sawn sapele which usually shows a brilliant ray pattern.

After carving and sanding, I used an Ebony stain to darken the recess area. I then stained the entire box with a Golden Oak stain. I lightly sanded all the raised areas of the design to give added highlights.

I made the interior trays entirely from wood from other scrap cigar boxes. The sides are Spanish cedar and the bottoms are thin plywood. It is not shown here, but I left the cigar manufacturer’s imprinting and brand on wood on the bottom of the trays. It sort of keeps a connection with the original use as a cigar box. It says “Made in Honduras” and “Hecho a Mano”. I added small wooden feet, which helps the transformation from an ordinary cigar box to handsome valet box.

I used a maroon felt with an alligator skin pattern, adding to the manly look. The top tray slides back and forth over the bottom tray to expose or hide the bottom compartments.

If, like me, you are tired of carving flowers, find a Celtic tattoo pattern and carve something manly.

Christmas Traditions, Symbolism, Religious Tolerance…and Trees and Wood

2011-12-20T21:15:00.003-05:00

At this time of year, it seems that anyone who can type words on a keyboard gets involved with controversial issues. Some Christians say that Christmas is really a pagan holiday. I’m amazed by how much is written on the internet regarding this subject. These anti-Christmas Christians say that the holiday is based on the Roman festival of Saturnalia and the Celtic Yule and the Winter Solstice. They say that the Christmas Tree itself comes from the Babylonian pagan Nimrod, whose followers believed that, on his birthday, December 25th, an evergreen tree would spring forth from a stump and bear presents. “Not so”, say other Christians. The Christmas Tree tradition comes from the Paradise Tree used in the old mystery plays of 16th century Germany. A play was performed on December 24th, the feast day of Adam and Eve, and the tree represented the tree from the Garden of Eden. It was adorned with red apples and later small white wafers to symbolize the Eucharist, the body of Christ. These apples and wafers gradually evolved into fruits and cookies and then into the ornaments we see today. And what about St. Boniface. Supposedly he cut down the Tree of Thor in the German town of Geismar in the early 700’s. Later a fir tree grew among the roots of the old oak. He is reported to have said: “Let Christ be the center of your households and use the fir tree as a symbol of Christianity.” Now I’m really confused.

Ah, but just calling it a “Christmas Tree” can be offensive to some other religions, so in 2005 the city of Boston renamed the spruce tree used to decorate the Boston Common a "Holiday Tree" rather than a "Christmas Tree". The name change drew a poor response from the public and was changed back to "Christmas Tree" after the city was threatened with several lawsuits.

If the Christmas Tree is considered to be pagan by some Christians, you can just imagine what they think about the Yule log. Burned at the time of the Winter Solstice to welcome the return of the Sun God, it has roots in Nordic, Celtic and Roman religions. In Slavic traditions, the log is called Badnjak, and it has become part of a totally Christian ritual. In both the Roman Catholic Croatian tradition and the Orthodox Serbian tradition, an oak log is cut with great ceremony on Christmas Eve morning and then brought into the house. There are elaborate prayers and blessings tying the symbolism of the burning log with the coming of Christ. The Serbian tradition includes priests burning oak saplings on a large fire in the public square. It’s interesting to consider that both sides in the Bosnian Conflict during the 1990’s must have celebrated the same Christmas Eve religious tradition while they were trying to kill each other. Sort of like the Germans and the Allies singing Silent Night together across the trenches during World War 1.

Orthodox priest places the badnjak on the fire during Christmas Eve celebration.

Wood and trees indeed play an important part in many Christmas traditions. But what does it all mean? Should we really use fuzzy historical details and twisted logic to segregate our beliefs from those of others? This special time of year is too wonderful to separate ourselves into “us and them”. Can’t we all just join hands, dance around the tree, or sit around the fire and focus on all that we have in common rather than the few things that separate us? Can’t we just celebrate in peace? Jesus, the Prince of Peace, would like that, I’m sure.

I wish you all a very Merry Christmas!

Colorful Carved Coffins of Ghana

2011-12-11T17:18:00.003-05:00

In one of my previous posts, I talked about wood carving in Ghana. There is another important expression of wood craftsmanship in Ghana that should also be mentioned. I’m talking about hand-crafted wooden burial coffins, in the shape of everything from a Coke bottle to a Mercedes. This colorful art form is unique to Ghana.

For most tribal cultures in Ghana, especially the Ga people from around Accra, funerals are not only a time of mourning, but also a time of celebration. They can last a week with food and music and every relative and friend in attendance. The people believe that their departed loved one is moving to another life, and they make sure they do it in style.

In the 1960’s a creative carpenter named Seth Kane Kwei started making custom designed fantasy coffins which were called Abebuu adekai (" boxes with proverbs ") by Ga people. The concept became very popular and the construction of these coffins is still carried on today by relatives and former apprentices of Kwei in a number of wood shops scattered around southern Ghana. The coffins are designed to represent an important aspect of the deceased person’s life. It may be a taxi cab, if the person was a driver; or a fish if the person was a fisherman. It may be symbolize the person’s hobby, pet or even a vice like a bottle of beer or a cigarette.

The coffins are custom-made and can take up to three weeks to complete. During that time the deceased person is kept in a refrigerated morgue. Most coffins are usually made from a light, inexpensive wood such as wawa or alstonia boonei (cheese wood).

These special coffins are works of art, built by skilled carpenters; designed and finished by talented wood artists. Unlike many works of wood art that remain visible for centuries; these wood creations are buried with the deceased, never to be seen again. It is truly art for the moment, transitory art, like Tibetan Buddhist sand paintings. Each coffin is returned to the same earth that nourished the original tree which gave the wood to build the coffin. The cycle is complete.

The concept of hand-worked wood returning to the earth is the same for any wooden coffin, whether it is Ghana or an old cemetery here in the United States. The wood decays in the ground and a new tree grows, but the skill of the wood craftsman remains constant through all generations.

Not Ghana, but the Moravian Cemetery, Bethlehem, PA

Good Wood

2011-11-26T20:50:00.002-05:00

Alpha Box
cherry, redwood lace burl, and mahogany trim

If you have been reading my blog, you must realize that most of the wood I use in my creations is found wood. The old silver maple tree that was cut down in the back yard several years ago has provided many spalted maple boxes and spoons. The apple tree provided a nice walking stick. And the trunk of the huge old cedar shrub was cut into pieces for many different projects. Call me cheap, but I hardly ever spend money to buy "good wood".

During last year’s excursion to a woodworking expo, I was tempted by a wood vendor with beautiful wood for sale. I succumbed to the temptation and purchased some good wood. I bought some nice cherry planks and a small, expensive piece of redwood lace burl. I planned on making my first constructed box using those power tools in my workshop that make very loud intimidating whining sounds. I’m talking about the table saw and the router table. These tools demand a certain respect since they can change your anatomy and send you to the emergency room in the blink of an eye. Up until now I have been using less harmful tools, like a small band saw, a drill press and carving gouges. These tools also require careful use, but they are nowhere near as fearful as the hungry rotating blade of the table saw.

I read books on box making, and I used some of the suggestions in the books, but as usual, I found my own ways of doing things. I took my time, and measured carefully. I’m pretty pleased with the result, which I named the Alpha Box. Of course there are several small flaws that are probably hardly noticeable to most people, but seem very obvious to me.

I learned that I still have a lot yet to learn about finishing wood. I learned that setting the hinges takes more time than building the pyramids. And I learned spending some money on good wood really improves the overall look of even my first attempt at a constructed box.

The Other Golf

2011-11-13T10:38:00.004-05:00

During recent hikes into the woods, I found several nice pieces of wood that I plan on turning into carved walking sticks. I was also playing golf at the time. No, it wasn’t that my golf balls were slicing deep into the woods. I wasn’t even using any golf balls. My sons and I have discovered disc golf.

Forget Big Bertha drivers for over $300. Three throwing discs and a carrying bag will cost you about $60, and that’s all the equipment you will need. Forget $80 greens fees. Disc golfing is free. The set courses are in public parks and woodland preserves.

My sons and I have been playing on local courses. I find the sport very enjoyable and rewarding, even though I’m not very good at it. Perhaps it’s the “hiking in the woods” aspect of the sport that appeals to me. We have played on a local course which makes its way up and down hills through an open forest on a mountaintop. Even if you are staying on the course, you are walking over rocks and small logs. If your disc spins off course, you will find yourself rambling through bushes and thickets. No manicured fairways and “carpet” greens. It’s my kind of golf course.

Teeing off through the trees

For me, there has been the added benefit of finding nice pieces of wood for carving when I’m traipsing through the woods. What could be better? A competitive sport of skill which costs next to nothing, and a chance to acquire some found wood for creative projects.

Wood Carving in Ghana

2011-10-25T20:39:00.003-04:00

"I am coming to cut you down and carve you, receive this egg and eat…do not let the iron cut me, do not let me suffer in health.

…a prayer said by a carver to the spirit of the tree.

Documented by Prof. R.S. Rattray in a thesis “Religion and Art in Ashanti” (1927)

my souvenirs

Many years ago, I had the opportunity of spending a week in Accra, Ghana on business. Like a typical tourist, I brought back a few carved wooden souvenirs. Not until recently did I become aware of the extent of woodcarving in Ghana and its importance to the economy of the country.

Wood carving is done throughout Ghana, but it is mostly centered in the Ashanti region just north of Accra. The small villages of Aburi and Ahwiaa are mentioned often on the web as wood carving centers. The wood carving tradition was always an important part of the culture of the ethnic Akan people who, for centuries, have occupied all of Ghana and part of the Ivory Coast.

modern Ghana sculpture

Today, Ghanaian wood carvers produce an endless variety of figurines and plaques for the tourist trade, or for export to other countries. Some are cleverly designed with modern African figures and animals. If you go back 100 years or more, however, you wouldn’t see such individual creativity. In the old days, carving was done as a communal, not individual, form of expression. Deviation from community accepted standards and designs was tabooed. Carving was done under the strict direction of clan leaders, and was totally done by men. Not every man carved. The carvers were seen as a privileged minority endowed with special skills from God. They even had their own secret initiation rituals for apprentices.

carving a djembe drum

The traditional Ghanaian carved wood items include: drums, masks, (Akuaba) fertility dolls, mortars and stools. All these items are still made and exported today. The form and design of these items has changed very little over the years.

an Ashanti stool

The stools are a topic by themselves. They were a symbol of status among the tribal leaders and can also be a carved record of maternal genealogy. They are carved from a single piece of wood. The seat part is curved and represents the warm embrace of a mother. The center middle section contains symbols that indicate the owner’s beliefs, history or values. Most stools had an Adinkra symbol on the front. These symbols were also stenciled on cloth. They are used today on many handicraft items. Most modern Ghanaians know the meanings of each Adrinka symbol. The symbol on the stool in the photo above is called Gye Nyame, or "except for God", and indicates the supremacy of God.

carving stools

Since ancient times, trees in Ghana were considered dwelling places of supernatural spirits and powers, both benevolent and malevolent. The trees felled for carving were given certain ritual purification rites. When a carver acquired a new set of tools, the tools had to be pacified to solicit good and cordial relations from the spirits. Strong alcoholic drinks were poured on the tools and special libation prayers were offered. (See an excerpt from a prayer at the top.)

In Ghana, the primary woods used in carving are Sese (Holarrhena wulfsbergii) and Tweneboa (Cordia millenii). The tweneboa is a sacred tree. Its name literally means "drum tree". It is relatively soft and easy to carve and sometimes already hollow, which makes it ideal for drum making. Most Kpanlogo drums are made from tweneboa. Other woods used include: Afromosia, Mahogonay, Odum “Iroko”, Cedrela and Sinuro.

a young carver

The wood carvers in Ghana today work 10 hours a day, 7 days a week. They make their own tools out of iron and steel and keep them very sharp. Do a video search on-line for “Ghana wood carvers” and you will see some amazing carving with simple tools, and no fancy vises or fixtures. I especially like the drum carving video.

The information in this post was obtained from various sources on the web including an informative report entitled "Carving Tradition in Ghana", by the Ghana Natinal Commission for UNESCO.

Mass Production...sort of

2011-09-21T15:59:00.004-04:00

I’ve been selective is scavenging empty wooden cigar boxes at my local cigar emporium. One particular brand of cigars comes in boxes that are made from thick sapele wood. The tops are extra thick and ideal for carving. I decided the size of the box would make a great tea bag caddy. I carved the top in an Oriental fashion with the Chinese (also Japanese) symbol for tea. I was pretty pleased with the result, but there were a few things I thought I could improve upon if I did another one. Then I thought, since I have more of the same size cigar boxes, why not make two more. It was an experiment in mass production on a small scale.

Perhaps I could make lots of these tea bag caddies and sell them at craft shows, or give them away as gifts. I hear stories of other artisans who make many pieces of the same design and give them away. One ambitious person actually made several hundred small band saw boxes; one for every guest at his daughter’s wedding.

The result of my experiment was that I came to the realization that mass production is not for me. For one thing, carving boxes does not lend itself to mass production. It’s not like baking cookies or making a jar of peach jam for each of your relatives and friends. Other than using the same design, there is no economy of scale in carving since there are just as many wood chips removed no matter how many boxes you carve.

Even if there was a time benefit, I just don’t like making the same thing over and over again. I like to experiment with new approaches and different techniques. After I made the second tea bag caddy, the third one really became a chore. As I was making it I was thinking of all the other creations in my head that I could be making instead of this duplicate. I guess I’ll just stick to individual pieces.

Wooden Spoons: a novel by Dennis Ruane

2011-08-27T14:57:00.000-04:00

My daughter pointed out a novel that she thought I might be interested in. It’s called “Wooden Spoons” by Dennis Ruane. It is promoted as a novel about life, death, love and art. The title and description intrigued me so I bought the novel and read it. It was easy reading and a good summer vacation novel; more like a made-for-TV movie than a great work of fiction, but enjoyable none the less.

It is about a professor who abandons his position at the university, leaves his wife and isolates himself on his old family homestead on a mountain top in southwestern Pennsylvania. He lives in the old ways and begins carving wooden spoons. Don’t expect a lot of details on the wood carving itself. That area is presented in a pretty general manner. The novel touches on themes like: finding out what you were meant to do in life, and then having the courage to do it; preserving historical sites; making utilitarian things from wood with hand tools in the traditional manner; and focusing on what is important in life. All good stuff. There is a plot conflict with a treacherous land developer that makes things interesting, and a nice ending.

“Wooden Spoons” is a semi-autobiographical novel. The author Dennis Ruane grew up in southwestern Pennsylvania like the character in the book. Also, like the character, Dennis abandoned a career in science to become a full time wood carver. More than just a carver, Dennis is a creative wood artist. Visit his website at: http://www.dennisruane.com/, to will see examples of his work.

You can buy a used (like new) paperback on Amazon for about $10. Enjoy.

Carved Carousel Horses at Knoebel's

2011-07-11T19:05:00.021-04:00

I’ve heard about Knoebel’s Amusement Resort for many years, but never had the opportunity to visit until the family went there to celebrate my Aunt Millie’s 80th Birthday last month. Knoebel’s is a very unique and wonderful place. It is an old fashioned amusement park with no admission charge and free parking!

The Grand Carousel

The prices for the rides are so low, at first I thought I was reading them wrong. The kiddie rides cost 75 cents and the big wooden roller coaster costs only $2.25. Knoebel’s is not located on some busy interstate, but rather in a quiet valley on the back roads of rural central Pennsylvania. It’s been family owned and going strong for over 85 years. It’s probably the cleanest and best maintained amusement park that I have ever been in.

The Stein & Goldstein Carousel

There are hundreds of free picnic tables available for use, in various roofed pavilions, in “the grove”. We reserved four for the party. No charge. You may have never heard of Knoebel’s but you can bet the people of central Pennsylvania have. They keep it a secret for themselves, even though Knoebel’s has won international awards.

But Knoebel’s is more than just an amusement park. It is a “must visit” sight if you are interested in carved carousel horses. They have not one, but two carousels with carved horses, and an excellent carved carousel animal museum.

The Grand Carousel was built in 1913 by George Kremer, who bought the carved wooden horses from wood carver Charles Carmel. It is a four-abreast machine that used to be at Riverside park in Rahway, NJ. The Kiddieland Carousel was built around the same time by Stein and Goldstein in Brooklyn, NY. Both carousels have beautiful examples of carefully restored carved horses from that period. You almost think they should be preserved somewhere instead of being exposed to daily wear and tear. But then, that’s what they were carved for in the first place.

The Carousel museum is small but it contains a complete history of carved carousel horses and shows how they developed from crude figures to the elaborate styles of the early 1900’s, the Golden Age of Carousels. They also have a fine collection of carved carousel animals other than horses.

It’s interesting to think that a century ago, when these beauties were carved, the carvers who created them were probably considered as little more than laborers, yet their artistic skills and craftsmanship would make them well respected artisans today. Visit Knoebel’s and appreciate their work.

Musical Wood in the Woods

2011-05-09T17:52:00.000-04:00

You know I like clever things made out of wood. You know I like forests. You know I like music. Well, this video obviously rates very high on my "like" list. It's totally amazing. Enjoy.

You can see the full width version at: http://www.flixxy.com/musical-wood.htm

Spirit in the Wood

2011-04-26T18:24:00.013-04:00

“…The tree, which is used for the body of the drum, contains a living spirit. Great care is taken to make sure that the wood of the drum is alive.”
from: “The Beat of My Drum: An Autobiography” by Babatunde Olatunji

Ask my family. Most of my adult life I have wanted a hand drum. That might seen to be an unusual desire coming from a retired white guy in the suburbs, but it was an itch that just wouldn’t go away. At first I thought I wanted a conga drum. Then I attended a drum circle where they had an assortment of African drums to use for the evening. Most of the drums were djembes, the familiar West African style drum, but a few were different. They were taller, had a slightly different shape and a much deeper, richer sound. They are called bougarabou, a bit of onomatopoeia, since the drum name is the sound it makes (bou-gara-bou). I immediately knew what type of drum I wanted. It was a perfect fit for my baritone soul.

Last week I finally got my drum. I love it. I bought it from a shop called “Spirit in the Wood”. With a name like that, how could I do otherwise? Spirit in the Wood is a small, one-man operation. That man is Conrad Kubiak, a professional drummer, drum teacher and drum maker. Conrad is an interesting character. He may be a reincarnation of Leonardo DaVinci. He works out of a small house with detached garage/workshop, on a small road in rural Bucks County, PA. There is no sign and most people would just pass it by. Most people, yes, but any person who works with wood would notice the collection of hefty log sections sitting in his driveway, especially since half of them have large, interesting-looking burls on them, waiting to be turned into works of art.

There is no doubt that Conrad is a wood craftsman. Just like all other wood turners, Conrad has a lathe. The only difference is that while some turners make pens, Conrad makes conga drums. He turns his own drum shells on a monster industrial lathe that must be 100 years old, and takes up half of his workshop. He has personally developed special tooling and techniques that sets his craft apart.

Sure he makes high quality drums out of fine hardwoods, but if you look closely on the dusty shelves you will also fine beautiful bowls turned out of burl and fine crafted wooden boxes that will be magnificent, if he ever gets to finish them. Conrad knows drums, and he also knows wood.

My bougarabou drum

I bought my drum from Conrad, but not one of his hand-crafted works of art. Since this is my "beginner’s” drum, I bought one that was hand carved out of iroko wood by a craftsman in the Ivory Coast, a genuine West African drum. But who knows? If I get good, maybe I’ll upgrade to one of his eye-popping cherry wood originals.

The Look, Touch and Smell of Wood

2011-04-09T11:04:00.002-04:00

I remember visiting Duckloe Furniture in Portland, PA several months ago. They have exquisite examples of American hand-crafted furniture. Their showroom is filled with everything from Arts and Crafts and Shaker styles to Windsor Chairs that they have been making themselves for over 150 years. The woods and grain patterns are awesome. Words like bird’s eye, tiger, quarter-sawn and burl are used a lot in the wood descriptions of the items on display.

Like a naughty child, I found myself touching everything. As I ran my hand across the top of a table or over the carved decorations I realized how much I love to touch wood. There is a tactile sensation that brings me joy. The smoothness of the finish, the beauty of the grain pattern, even the smell of the beeswax and oil, all contribute to my sensual enjoyment.

I get a similar feeling in my own workshop. It may be the fine sawdust that remains in the pores of your hand after sanding; or feeling the contour of a piece you just carved. I’m sure many of you fellow woodworkers know what I mean. I remember finishing a spoon with wax and mineral oil and then sitting watching TV and just rubbing the finish with my bare hands for quite some time. It was a comforting sensation. You may argue that velvet or leather also gives tactile pleasure, but when it comes to hard materials, nothing beats wood.

I just completed my Salamander Cane. It was my first attempt in carving a critter wrapped around the cane. Instead of carving a detailed snake with hundreds of tiny scales like the award-winning artist, Dave Stehly, I chose a much simpler piece for my first attempt. The salamander is a lot smaller and its skin is smooth and easy to carve. I liked the feel of the wooden cane handle. I realized why canes and walking sticks are made of wood. For some reason, it just seems natural.

Has working with wood heightened your sensual awareness?

Making the Canary Wood Box

2011-02-18T21:00:00.028-05:00

As promised, here are instructions, photos and tips that follow my work on the Molten Wood band saw box made from a chunk of canary wood.

I purchased this slab of canary wood about 6 years ago from a bargain table at Woodcraft. I've been waiting for the right project. The first step is to draw the design on the wood.

I used power carving tools to get the deep wave grooves. A round bur works best. Start coarse and work to fine.

Rough shape of the wave grooves completed. It's time to go to the band saw.

Here's where it gets a little tricky. Instead of just sawing off the top of the box like you would in making a normal band saw box, you saw up to a marked point and then saw at 90 degrees to that line to create the overhang.

Next, use the band saw to cut out the overhang shape. This is hard to explain, but it is probably obvious to any woodworker.

Here's the way the overhang looks after sawing. As you can see, I cut a little too far into the first wave. This will have to be fixed up later.

Now, cut off the bottom as you would normally do when making a band saw box.

The trickiest part of making this box is getting the barrel hinges to align perfectly. If they are off by even one millimeter, the box will never open and close properly. Accuracy is essential. Wood crafters have many tricks for getting proper alignment. You can find them on the internet. As for me, I have found that careful measurent and a brad tipped drill bit can get you right on the money. I start by exact measurement lines and precise marking with a push pin to set the exact hole center.

The barrel hinges are cylinders 5 mm in diameter with a hinge pin in the middle. I bought a 5 mm brad point drill bit and I am very pleased with the results.

I clamped the wood loosely on the drill press and then carefully guided the brad tip of the drill bit into the hole made by the push pin. I then clamped it securely and drilled the hole. Since the box top is thin, be careful with the depth of the hole. The objective is to position the tiny center pin shaft of the hinge exactly at the surface of the wood on both the top and the end of the box.

The next step is to make a 45 degree cut in the lid and the base. The angle must intersect the exact middle point of the hinge at the pin so the lid will open correctly. Needless to say, this can be very tricky. Again, precise measurement is very important. Of course experience and a little luck doesn't hurt either. I used my table saw which is set up with a very accurate 45 degree crosscut sled. In the past I have also used my router table. My wood craftsmanship is far from perfect, so I wound up doing some "corrections" work on the belt sande to get everything to work properly. No glue yet. This is just a dry fit at this point to make sure all the parts work.

Up until this point I have been working with a squared off block of wood. It is important to have this "right angle" frame of reference for proper alignment and measurements. Now it's time to add some curves. I cut the outer shape of the box on the band saw.

Here's what the box looks like at this point. Remember, the inside is still solid wood.

Take off the top and bottom and use the band saw again to cut the box interior out of the middle section. I entered near the corner so it would be easier to glue and hide the entry point. The dark lines on the curved corners indicate that I need to change my saw blade. A rubber backed sanding cylinder on my rotary tool will get these marks out without much effort.

Gluing. I use Tightbond II. First glue the center section of the box together at the saw blade entry point. An elastic band clamp works fine for this. Make sure the alignment is exact.

The next step is to glue the bottom to the box side section. Use good clamps for this. Once clamped, I usually lightly sand the outer surface at the glued joint. The fine saw dust will stick to the glue and fill up any voids in the intersection.

Now comes the sanding, and lots of it. Notice how the box lid slightly overhands the side of the box. This is caused by gluing together the kerf void on the perimeter section. One side is now a bit shorter. To the belt sander! At this point I am also still forming the waves on top of the box with power carving burs and rotary sanding tools. Hand gouges were also used. Anything that works and is within reach. I mark areas that need wood taken away with a red pencil. I do this regularly during the forming process. Shape. Stop and take a look. Mark. Shape some more. A lot of patience and a lot of sawdust.

Next, I gave the whole box a light coat of wipe-on polyurethane varnish. In this photo of the back of the box, notice how the 45 degree cut is precisely at the center of the barrel hinge hole. I use epoxy to secure the barrel hinges and open and close the box severall times during the 5 minutes it takes the epoxy to set to make sure the cover sets and opens correctly. After fine sanding, I put a few coats of satin poly varnish on the box as a finish coat.

As any artisan will tell you, you have to know when to stop improving what you have and call the piece "finished". I had a perfect reminder of this on this box. I kept on sanding away on the wave grooves until I sanded right through the wood. Yikes! After hours and hours of work, I now had a hole right in the key focus spot of the piece. A tiny hole, but to me it seemed like you could drive a truck through it. Of course I panicked and thought it was the end of the world. But a little wood filler and some very precise staining and you can hardly notice the flaw. Look at the second groove from the left.

So that's how I made the box. I probably could have included another 8 or 9 photos, but it is very lengthy as it is. I hope these instructions and personal tips will be of help to you. Let me know if they were.

Molten Wood

2011-02-12T12:02:00.005-05:00

Ask any kid. Sculpting with clay is fun. Playing with Silly Putty is even more fun. If you let it sit on an edge, it would ooze and flow over time. Sculpting with wood is a lot harder. You can’t just push the wood around like clay to change the shape. You can’t just let it ooze over the edge. But maybe you can make the wood look like you just formed it like clay. Maybe you could make the wood look like it was melting. This is what I have tried to accomplish in my latest experiment with hinged-lid band saw boxes.

The light rectangular box is made out of spalted maple from my yard. The darker, squarer shaped box is made of canary wood. Each is cut from a solid piece of wood using band saw box techniques. Each uses small barrel hinges for the lid, so it remains attached.

I took pictures during the entire process of making the canary wood box. I will show them with step-by-step instructions in my next post for anyone who is interested.

Trees With Names

2011-02-04T17:46:00.014-05:00

Chapman's Baobab

Some trees are important enough to have names. I don’t mean their biological species names like quercus rubra for red oak, or acer rubrum for red maple. I mean real names given to them mostly out of reverence and respect. A few posts back, I mentioned Herbie the oldest elm in New England. During my research I found out there are many more important elm trees. Just look up “elm” on Wikipedia. There was the Metaxades Elm of Greece, the Biscarrosse Elm of France, and “Elmo” the beloved elm on the campus of Brown University. All were old and historical in some way. All succumbed to the dreaded Dutch Elm Disease.

Of course there were also many famous oak trees throughout history, such as the Royal Oak in Britain and the Charter Oak in the United States. There were at least 3 different Treaty Oaks in USA history. Wikipedia even has a listing for individual oak trees which lists 44 famous oak trees by name.

Biscarrosse Elm

In the evergreen category, there are a few superlative trees with names. There is General Sherman, a giant sequoia, which is the largest tree by volume in the world; and Hyperion, a coastal redwood, which is the tallest tree in the world at 379 feet. In Africa, several baobab trees, such as the Chapman’s Baobab, compete for record girth and age. All these trees are on a great blog site called Ten Thousand Trees.

General Sherman

One of my favorite named trees is the Gernikako Arbola in Basque Country, Spain. It remains a strong symbol of freedom for the Basque people. It is shown on the Basque Country coat of arms, and is the title of a song which has become the Basque anthem. It is located in Guernica and survived the terrible bombing of that city by the Nazis in 1937. After the bombing, volunteers formed an armed guard around the tree to protect it against the Falangists, who wanted to destroy it because they knew what a powerful symbol it was to the Basques. The current tree is the “great grandson” of the original old oak planted in the 14th century, each generation grown from an acorn of the prior tree.

Gernikako Arbola

Yes, these old trees with names are revered and respected. Perhaps we should give every old tree in Sherwood Forest a name. That way they might not be cut down for commercial lumber or developed into golf resorts as is being considered by the new government of Great Britan as part of their budget austerity program. But that's a story for another day.

The Good, the Bad, and the Ugly

2011-01-12T19:42:00.008-05:00

As I mentioned in a previous post, I have been experimenting with creating things out of old cigar boxes. I’ve been using carving, pyrography and decoupage to transform these old wooden boxes into interesting works of art. The photo above shows a “good” result: a jewelry box for my daughter made from beautiful sapele wood with a nice thick top for carving. Unfortunately, on some other attempts I ran into problems. I’m glad the boxes are inexpensive, because a lot of them wind up on the scrap wood pile. Most of them are made to look exquisite in the cigar store, but a closer inspection shows their flaws. Here are some of the problems I have found working with recycled wooden cigar boxes. I hope you an learn from my experiences and save yourself some grief.

Severe Warping – Cigars demand a moisture rich environment. The wood for the box is probably newly cut and very moist. The air in the cigar store is kept humid. Then you bring the empty wooden box home to an atmosphere that is very dry by comparison. The result is severe warpage. See the photo below. Beautiful wood…nice box shape…but totally useless.

Laminated Wood and MDF – Some boxes are painted or stained. You sand of the finish only to find medium density fiberboard or cheap plywood. Bummer! The plywood is also a prime candidate for warping.
Label Removal – Otherwise known as a time-consuming exercise in screaming and cursing. Why is it that the nicest looking boxes have labels attached with glue that could be used to build steel bridges? Forget water as a solvent. Try paint thinner or mineral spirits. I even tried acetone. The label came off, and so did the finish. Because the labels are so hard to remove, you can easily scrape the surface if you are not careful. Labels on the inside of the cover are especially troublesome to remove. They are usually very colorful and foil coated. I tend to leave them on as reminder of the fact that the finished box was a cigar box at one time.
Cheap Hardware – Don’t expect the hinges and clasps to be top quality. In some cases, you might want to replace them with better hardware.
As a result of all this, I have become pickier at the cigar box bin. I now know what brands of cigar have the best boxes to work with. I still enjoy recycling these old ladies into beautiful maidens.

Winter time is fireplace time.

2010-12-30T19:05:00.008-05:00

At Christmas time we had our first fire of the year in our fireplace. I gathered some old wood from outside and also a box of scrap wood from my workshop; the remnants of a variety of projects over the past few months. My 5 year old granddaughter was helping me throw the small scraps on to the roaring fire. Then I realized that she was keeping about every third piece because she liked the way they looked, especially the ruby stains in the box elder. Ah, a girl after my own heart.

Here's an old English poem about firewood:

Beech-wood fires burn bright and clear

If the logs are kept a year;

Store your beech for Christmastide

With new-cut holly laid beside;

Chestnut's only good, they say,

If for years 'tis stored away;

Birch and fir-wood burn too fast

Blaze too bright and do not last;

Flames from larch will shoot up high,

Dangerously the sparks will fly;

But ash-wood green and ash-wood brown

Are fit for a Queen with a golden crown.

Oaken logs, if dry and old,

Keep away the winter's cold;

Poplar gives a bitter smoke,

Fills your eyes and makes you choke;

Elm-wood burns like churchyard mould,

E'en the very flames are cold;

Hawthorn bakes the sweetest bread -

So it is in Ireland said;

Apple-wood will scent the room,

Pear-wood smells like flowers in bloom;

But ash-wood wet and ash-wood dry

A King may warm his slippers by.

Anonymous

Do the dancing flames really symbolize dancing wood nymphs?

Keep the home fires burning brightly this winter.

I wish you all a happy and a peace-filled new year.

Herbie's Auction

2010-11-30T15:34:00.006-05:00

I’ve always been fascinated by trees with names, but we’ll talk more about that some other time. Right now I want to focus on one specific tree by the name of “Herbie”. Herbie was a 217 year old elm tree, and held the official title of the biggest elm tree in New England. It towered 110 feet above Yarmouth, Maine. It was about 8 feet in diameter at the widest point. Herbie died from Dutch elm disease. The only reason Herbie lived as long as he did was because of the loving care of Yarmouth’s tree warden, Frank Knight, who cared for the tree for over 50 years. Frank is 102 years old himself. I’m not making this up folks. It’s a great story.

Herbie had to be cut down in February of 2010. That in itself was no simple task. We’re talking about over 40 tons of wood, and about 6,000 board feet of usable lumber.

If you read this blog, you know I believe there is something special about these old trees. You also must know that I believe that the spirit of the tree is, in some way, reincarnated in the beautiful and useful objects that are made from their wood. The good news is that even though Herbie the tree may be gone, he is still alive in his wood. When Herbie came down, Chris Becksvoort, a New Gloucester furniture maker found himself in charge of the wood distribution. He had the great idea of letting artisans and craftsmen use the wood from Herbie to create objects that could be auctioned off. The auction would raise money for the Arbor Fund of Falmouth to plant new trees. He got his idea from the Onetree Project in England where artisans did the same thing with a 170 year old oak tree that was dying and had to be cut down.

Over 80 artisans and artists participated creating over 300 objects for the auction. Objects included benches, tables, carvings, lamps, bowls, vases and an electric guitar. There was even a mobile made from paper from Herbie. The auction was held two weeks ago and netted $25,000 for the arbor fund. Click on the links to see an article on the auction and a video of a news report on the entire story.

This is the guitar made from Herbie wood by Andrew Olsen of AO Guitars.

These turned and carved vases were made by Jacques Veresy.

Reclaiming the wood from any old tree is a great idea but I think that using the wood from an important historical tree is very special. Apparantly The people at Historical Woods of America agree with me. Visit there website and find out more.

Have you ever crafted something out of wood from a special old tree?

Art Nouveau and Arts and Crafts and Wood

2010-10-31T19:47:00.012-04:00

Lately I have really been immersing myself in the flowing beauty and simplicity of Art Nouveau and the Arts and Crafts Movement that flourished in the early years of the 20th Century. The Art Nouveau style is exemplified by artistic geniuses such as Alphonse Mucha, Gustav Klimt, Louis Comfort Tiffany and Charles Rennie Mackintosh. During the same time period, other artisans such as Gustav Stickley, Elbert Hubbard, and Charles Rohlfs, and architects such as Frank Lloyd Wright and Greene & Greene contributed to what came to be known as the Arts and Crafts Movement. Both movements became interwoven and formed a new design style which was a deliberate departure from the overly ornate Victorian style that preceded it. Each artist, artisan and architect had his or her own style, yet each expressed a common belief in simplicity of form and a communion with nature. The art of this period took a critical look at the new age of machinery and mass production. As an alternative, it emphasized hand craftsmanship and locally skilled creative workers.

Personally, there is no other period of time which has produced so many pieces of art that can take my breath away. Walking through a Greene and Greene home gives me more pleasure than eating an ice cream sundae…and at zero calories. My wife and I had the opportunity to tour the Gamble House in Pasadena, CA, a beautiful city which is the “Mecca” of Arts and Crafts on the West Coast. The house was built in 1908 as the winter retreat for the son of the founder of Proctor & Gamble. It was designed by the upstart young architect brothers, Charles and Henry Greene, who had just been to the World Columbian Exhibition in Chicago, where they became influenced by Japanese architecture. The whole place is a symphony in wood. Mahogany, teak, maple, oak and cedar. Each room is a new treat. The joinery, the carving, the details! It’s an overdose of some of the best wood craftsmanship I have ever seen. If you are ever near Pasadena, a tour of this National Historic Landmark should be on you itinerary.

The above photo shows a detail of the carved cedar frieze in the living room of the Gamble House. The artist used the deep natural grain of the weathered cedar plank as part of the carving. This freize circles the entire living room. It was subtle yet overwhelming at the same time...if that's possible. I found myself staring at it with an open mouth.

If you’re stuck on the East Coast but still want some indulging Arts and Crafts desserts, I recommend the Gustav Stickley exhibit at the Newark Museum going on until Jan 2, 2011. I was especially impressed by the inlay work in some of the pieces. See Stickley chair on the left.

If that isn’t enough dessert for you, I suggest the special exhibit at the Metropolitan Museum of Art in New York City called “The Artistic Furniture of Charles Rohlfs”. It ends Jan 23, 2011. See Rohlfs chair on the right.

Immerse yourself in the pleasures of Arts and Crafts and Art Nouveau as I am doing, and let me know what you think.

Ah, the burn of a good cigar... box, that is.

2010-09-27T15:42:00.006-04:00

I picture one of my early ancestors, thousands of years ago, forging a metal spear point out of bronze and laying the hot metal object down on a piece of wood. “Hey, would ya look at that!” he would say, as the hot metal spear point burned a design into the wood. Thus, the art of wood burning or pyrography was born.

As crude as that early experience might have been, my recent experiences have not been much better. I have taken up the art of pyrography, which means I have invested in a decent burner transformer unit, a few tips of assorted shapes and a tip holder pen. I’m just a beginner, and still in the experimentation stage, but I’m starting to really enjoy this new hobby.

I am very fortunate to have a cigar superstore about 5 miles from my house. They sell empty wooden cigar boxes for one dollar each, ten for $6.00. There are sitting in a huge crate right near the entrance to the store, which doesn’t seem to stay full very long. I’ve been stocking up on boxes for several months now. Some of these boxes are very well made out of solid exotic woods with beautifully crafted box joint corners. Why do I feel like I’ve just given away my secret? Oh well, there are lots of boxes to go around.

This new interest of mine combines art with recycling, which makes me feel good about the enterprise in general. I’m still not sure what I will be doing with the finished boxes, but Christmas is coming up and they might make good gifts.

Have you ever tried pyrography? Have you ever tried to turn old cigar boxes into new works of art?

The Shape of Spoons to Come

2010-08-09T15:18:00.007-04:00

My family has a lot of left-handed people. I am not one of them, but my wife is and so are two of my four children. We once had a family celebration at a restaurant and out of 12 people, 8 were left-handed! This brings me to the subject of left-handed and right-handed spoons. I like carving wooden spoons. They are so utilitarian. You can be very creative and they make good gifts. Recently I have made several non-symmetric, ergonomic shaped spoons. I used cherry and maple “firewood” branches from my backyard. I have designed one shape for a right-handed person; and the other for a left-handed person. In the photo above, the top spoon is the righty; and the bottom spoon is the lefty. “Not so”, says my wife. She would prefer to use the one I designed for a righty, and she is left-handed. I showed her photos of similarly shaped spoons on the Internet. They are all labeled “left-handed” and they are shaped sort of like my design. To make matters worse, all the other lefties in my family agree with her. I guess it’s not right to label things…or people, for that matter.

What do you think? Which spoon shape would you prefer using? Perhaps you would rather use a straight, symmetrical, old-fashioned wooden spoon instead of one with a curvy shape.

One Awesome Walk in the Woods

2010-07-12T20:05:00.012-04:00

"This is the forest primeval. The murmuring pines and the hemlocks,
Bearded with moss, and in garments green, indistinct in the twilight,

Stand like Druids of eld, with voices sad and prophetic."

Evangeline A Tale of Arcadie
by Henry Wadsworth Longfellow

My wife and I took a weekend trip to northwestern Pennsylvania, to attend a regional woodcarving show at the Sawmill Arts Center in Cook Forest State Park. The show was enjoyable, but the highlight of the trip was a hike through an amazing old growth forest of ancient white pine and hemlock trees aptly named: “the Forest Cathedral”. The big ones were over 36 inches wide and over 150 feet tall. Most of these giants were over 300 years old. The forest floor was covered with fallen tree trunks and, as Longfellow said, blanketed with moss and ferns. I took photos, but they just don’t do justice to the grandeur of the place.

The history of this forest is interesting. It seems a lumber baron by the name of Anthony Cook became very rich in the late 1800’s, by stripping most of the area of trees and floating the logs down to Pittsburgh. However, he never touched the old growth in the center of the property. In 1928, he became somewhat of a conservationist and deeded 7200 acres to PA which became the State Park. Fact: By 1920, two-thirds of the trees in Pennsylvania’s forests were gone as a result of the lumber industry.

I would recommend a trip to Cook Forest State Park to anyone. It might not be Muir Woods, but it’s one of the best old growth forests in the East and very accessible, by a short two mile hike. Looking straight up the trunk and seeing a 150 foot tall, 36 inch diameter pine tree swaying in the breeze, is a sight I won’t soon forget.

The Joy of Regional Woodcarving Shows

2010-06-06T17:26:00.016-04:00

I recently attended the 37th Annual Woodcarving & Wildlife Art Festival sponsored by the Lancaster County (PA) Woodcarvers. It was an enjoyable and inspiring experience full of beautiful carvings and friendly people. The exhibitors were willing to share their knowledge with anyone who would stop by to chat. They were competing for ribbons. For some, this is a serious hobby. For others, it is their primary source of income. There were carved waterfowl, song birds, funny characters and Santa Clauses. If you were looking to buy beautiful hand-crafted works of art, this was the place to be.

I was totally in awe of some of the wildlife carvings on display. I have never tried to carve a detailed, life-like waterfowl, and I don’t think I ever will. I just don’t have the skills or the patience. No doubt, many of these carvings took several weeks or even months for the artist to complete. The prices on the tags would never compensate the artist for the amount of time spent.

Whether you live in Pennsylvania, or Kansas, or Oregon, these regional woodcarving shows are precious gems. They demonstrate that we are still a nation of talented artisans with wood craft skills passed down from generation to generation. The craftsmanship is honest, down-to-earth and surprisingly good. Many of the exhibitors I spoke with had never taken an art class in their life, yet their work is museum quality.

What has been your experience with regional wood carving shows?

These are for the birds

2010-04-29T11:38:00.005-04:00

Spring is here so I built a few birdhouses. Actually I built one new one and refurbished two others, all with scrap wood. Admittedly, they are not much to look at, but they meet all the latest recommended birdhouse dimensions and include all the latest recommended features. I’m not sure the birds care how the outside of their houses look.

There are some interesting things to consider when building a birdhouse. For instance, the size of the entrance hole and height above the floor of the birdhouse is very important to appeal to the right species of bird. Also, the popular perch stick is just below the entrance hole is not needed, nor recommended. It provides a place for predators to sit and wait. Another feature to prevent hungry squirrels from chewing through the hole area is to reinforce the hole with a ¾” thick block of wood, making the entrance passage longer. All the specifications and suggestions you will need are on the internet. If you are interested, go to the following websites: http://www.wild-bird-watching.com/Building_Bird_Houses.html. or http://baltimorebirdclub.org/by/house.html

After I finished hanging the birdhouses on nearby trees, I got to thinking maybe birdhouses are an opportunity to get creative. As long as all the proper dimensions and features are included, and the birds don’t really care what the house looks like, why not carve something on the front. Perhaps a wood spirit or something humorous. Here’s a challenge: Design a clever birdhouse and send me a photo of it. I’ll publish the best ones on the blog.

"A Reverence for Wood" by Eric Sloane

2010-04-11T19:29:00.008-04:00

What books do you keep on the nightstand near your bed or on the shelf next to your favorite chair? Those books (and magazines) probably say a lot about who you are and what is important to you. The subtitle of this blog, “a reverence for wood”, was not chosen casually. One of the five or six favorite books on my nightstand is “A Reverence for Wood” by Eric Sloane, originally published in 1965. Actually, the book I have is called “Sketches of America Past” and combines two other Sloane books, “Diary of an Early American Boy” and “A Museum of Early American Tools” along with “A Reverence for Wood”, in a single bound edition.

I first read “A Reverence for Wood” back in the early 1970’s and remember being totally captivated by it. I have re-read it many times since then. It’s my kind of book, lots of interesting illustrations, all by Eric Sloane himself. It is also a historical book about “the old ways” of making practical things out of wood. It shows that our ancestors had close relationship and intimate understanding of wood that, for the most part, has been lost by our present generation. It is a book about history and the ingenuity of the early American pioneers. It has definitely been an influence on my life and my pursuit of woodcraft.

I was not going to post this entry on my blog since I couldn’t imagine my blog visitors, most of who are interested in woodworking, as not having already read “A Reverence for Wood”. It is practically required reading for anyone interested in wood. But then I thought perhaps there are people out there, especially visitors from other parts of the world, who may never have heard of the book. But even if you have read the book before, it is worth getting a copy and going through it again. Every time I open it, it gives me a new incentive to go make something out of wood.

Have you read “A Reverence for Wood”? What are your thoughts about the book, or other books by Eric Sloane?

Presto Box

2010-03-16T13:56:00.016-04:00

Well, here’s what I did with the box elder wood. I designed a new type of band saw box. I call it the Presto Box. It has two compartments, each with a lid, and normal hinge pin construction. However, I extended the top of the box beyond the hinge pin to create a, sort of, actuation lever. When you press the top ends of the box, “Presto”, the lid opens.

Construction was kind of tricky using templates and lots of careful cuts on the band saw. I made two boxes since I found it is always better to multiples of a new design to learn the most about what not to do next time.

A coat of tung oil on the finished boxes really brought out the red streaks in the box elder. Almost too vivid. It looks like my granddaughter scribbled over a maple box with a Magic Marker. The larger box is 7 1/2" x 4" x 2".

This shape is only one adaptation of the design concept. I can picture all sorts of shapes that would give the same effect. These first two boxes are really “proof of concept” prototypes. Don’t look too close, or you will see all the flaws and mistakes. The next ones will be much better now that I’ve learned a few tricks. I guess we should all learn from our mistakes and keep on trying to improve.

Old Growth Forests

2010-02-27T19:36:00.003-05:00

In 2003, a writer by the name of Kara Gebhart Uhl wrote an informative article about old growth forests. See http://karagebhartuhl.com/read.php?story=10007. In the article she talks about America’s historical usage of wood and the deforestation that occurred, especially at the end of the 19th century. She talks about old growth wood and ancient forests within the United States. She also talks about the value of using reclaimed wood, from old buildings and barns, and where to purchase it. A very informative article.

Kara Gebhart Uhl is no novice when it comes to knowledge of wood and wood working. She has done many articles for Woodworking Magazine and Popular Woodworking. She obviously knows the difference between a spokeshave and a skew chisel. She also knows the importance of preserving our natural forest heritage. Read the article and tell me what you think.

Also...do a Google image search for “old growth forest”. You’ll discover some amazing pictures.

Box Elders Aren't Even Elders

2010-02-14T20:31:00.006-05:00

About 2 miles from my house, they were cutting down a small grove of old hardwood trees to make way for a new assisted living facility. Most of the trees were 18 inches to 24 inches in diameter. Some were over 3 feet. They were carting them off for firewood. It was sad to see this thicket of trees destroyed. My boys used to play in it when they were younger.

There were piles of large cut chunks. My car is conditioned to stop upon approaching such tree cutting sites. I started roaming the piles. A workman shouted “Hey, what are you doing?” I explained that I was a wood carver looking for some wood. The foreman intervened. He allowed me to take two pieces. I grabbed a nice cherry stump that was 18 inches in diameter. He pointed out a box elder chunk that was about the same size. It was just cut and the red color streaks were very bright. It looked like it was bleeding.

I carted my trophies home in the trunk of my car. From my exuberance, you would have thought I just won a gold medal in the Olympics. I began to picture the boxes I could make out of the wood after it dries. As usual, my wife though I was crazy.

I did some research and found out that box elder isn’t really elder at all. It’s a type of soft maple. Scientifically, it is acer negundo, and also known as Ash-leaf Maple. The wood tends to be brittle with many internal splits and it has no real commercial use except for cheap wooden pallets and crates. However, most of the time, the wood has red or purple streaks which are created by a fungus that results from insects or other forms of distress. These “blemishes” make it very valuable to box makers or bowl turners. Distress and imperfections result in unique beauty. There is a life lesson in there somewhere.

I am in the process of making some boxes out of my chunk of box elder. I’ll tell you more about my progress in future posts. What has your experience been working with box elder?

Aunt Millie's Cane

2010-02-08T13:56:00.013-05:00

My Aunt Millie would always ask me when I was going to make her a carved cane. I was always willing to make one, although I wasn’t exactly sure how I was going to do it. And what would I carve? Flowers would be appropriate, probably roses. I’m not good at flowers, especially roses. I put off attacking this project for over a year. I started collected pictures of real roses and carved roses. I practiced carving roses in scrap wood, but nothing looked very good. They all looked like cinnamon buns.

I had a piece of cedar from a big old ornamental shrub I took down in my yard. It had a natural right angle bend in it. Perfect for a cane handle, but I was hesitant to start carving because I had no confidence in my ability to carve a rose that wasn't laughable. If I messed up, this nice piece of wood was useless for anything else. Finally, I took a deep breath and jumped in. A lot a times major projects are like that. Ya hafta just jump in and hope for the best. Like most of my first time woodworking adventures, I learned as I went forward; sort of like feeling my way in the dark.

I used the straight section of an old curved top cane I got at a yard sale. I sanded off the thick dark varnish. I think its ash. I bought a nice brass joining collar on the Internet. A little bit of epoxy, and a little bit of luck, and "Presto!" it looks like a cane. I must admit, the finished product came out pretty good…for an amateur. I have to learn not to be so hesitant before jumping in to challenging situations.

Have you ever had situations where you were afraid to start cutting beautiful wood for fear of screwing up? Tell me about it.

The Wild Horses of Newbury

2010-01-16T20:32:00.002-05:00

I firmly believe in the spirituality of trees. I can’t explain what it all means, it’s just that trees have been revered as sacred living things longer than we have been worshiping as Christians. There must be something to it. I believe that making beautiful or utilitarian objects out of the wood from trees gives them a new life after they have been cut down. I also believe that too many old growth trees are being cut down.

My recent research all started with the movie “Avatar”. (Great movie. Go see it in 3D.) In the movie, the great “Tree of Souls” is destroyed by the ruthless and greedy exploiters of the mineral resources of the planet. There is enough symbolism here to keep a discussion group busy for months. This giant tree is analogous to Yggdrasil, the great Tree of Life in Norse mythology.

Researching Yggdrasil I came across the website of an interesting music group from England called Moksha (see: http://www.mokshaproductions.com/.) (More on Moksha some other time.) Moksha’s website links to a video called: The Wild Horses of Newbury, which just blew my mind. It’s about the unexplainable spirituality of the old trees, a spirituality that we as a modern, progressive society, just can’t comprehend. Go to: http://video.google.com/videoplay?docid=4171383607583139639 . Watch this video and tell me what you think.

Lithuanian Wood Carvings – Part 2 – the Rupintojelis

2010-01-13T10:57:00.003-05:00

The Rupintojelis (pronounced roo-pinto-YAY-lis) is an important part of Lithuanian wood carving folk art. Derived from the Lithuanian word rupestis it can be translated as anxiety, concern and solicitude. This image is a repetitive subject in Lithuanian woodcarving. It depicts a man in a sitting position, leaning on his elbow, looking pensively and sadly at passers-by. At times the Rupintojelis is sitting on a tree stump or a stone wall. This image is carved in various styles, but always in a way that you immediately know he is suffering. Some scholars think that perhaps village woodcarvers consciously or unconsciously expressed their own worries, and fears through woodcarving. The Rupintojelis was found in the home, at crossroads and other public places.

The Rupintojelis image started as an a representation of a suffering human but, after Christianity came to Lithuania, the image gradually evolved into Christ, the Man of Sorrows, pondering all the ills of humanity. All emphasis is placed on the facial expression of deep thought and infinite sorrow. From what I understand, Rupintojelis can be seen along the roadside and in cemeteries throughout Lithuania…and of course at every tourist gift shop.

Some say the pose represents Jesus' anticipation of his crucifixion, after his scourging and crowning with thorns. Others say it depicts Christ after the resurrection and not yet ascended. Polish people have their version of the rupintojelis. It is very similar. They call it Chrystus Frasobliwy. One Polish legend says Christ travelled through the world with his crown of thorns. Tired from his journey, he sat on stones near the road and wept. This statue means many things to many people. Lithuanian Christians believe it shows how Christ was human and one of us. He shared our feelings and concerns. In it they see God's endless compassion and care for his people.

Here is a photo of contemporary wood sculptor Julius Urbanavičius with his wfe and one of his Rupintojelis sculptures. As you can see, some of them get pretty large.

Lithuanian Wood Carvings - Part 1 - Sacred Woods

2010-01-10T15:37:00.001-05:00

My wife noticed a book listed on my Amazon wish list and got it for me for Christmas. It is entitled: “Sacred Woods – The Contemporary Lithuanian Woodcarving Revival”. The book is a catalog of the exhibit held at the University of Wisconsin in 1998 with great photos of Lithuanian wood sculpture. These are works of contemporary sculptors that perpetuate the long history of Lithuanian wood carving. (See the photos in this posting.)

The introduction to the book by Ruta Saliklis gave me great insight into the Lithuanians’ close personal affinity to wood and wood sculpture throughout their history. If you have been reading my blog, you know that this personal harmony with wood, and the spiritual nature of trees, is a recurring theme. Here is an excerpt from the Introduction of the book:

“Vast Forests once covered Lithuania. Evidence of the importance of woods in Lithuanian culture can be found in folklore, religion and mythology. The Lithuanian language itself shows the importance by the numerous words for woods, depending on the type of trees within them. Lithuanians see wood not merely as an organism, but as a vibrant living entity. Thus traditionally a tree can only be chopped down during the dormancy of winter. In pre-Christian times certain groves of trees were considered sacred and no one (not even the King) would dare cut a tree from such a grove, or even take wood from the ground.”

The entire subject of Lithuanian wood sculpture and folk art is very interesting for a number of reasons. First, the Lithuanians were the last of the Europeans to be Christianized. This happened in the late 14th century. The close connection to their pagan past, as well as the conversion of pagan symbols to Christian ones, is reflected in their wooden sculpture. Also, they have been many political changes over the past few centuries. A great deal of their wooden sculpture is an expression of their resentment to occupation and oppression by other nations. Much of this is done in a coded message of symbols included in the carved object. The book goes into wonderful detail about the history of Lithuanian wood folk sculpture; more than I can talk about here.

Most northern European cultures (German, Polish, Danish, etc.) were big on wood carving, but it seems that the Lithuanians had them all beat. I get the feeling that every Lithuanian baby is given a set of carving gouges along with a teething ring.

Most of the sculpted wood carvings shown in the book are now on display at the Lithuanian Museum of Art in Lemont, Illinois, just outside of Chicago. I would enjoy going there someday to experience this art in person.

Are you familiar with Lithuanian wood carvings and their significance? If not, you might enjoy doing some research on Google. Tell me what you think.

Snowy Wood Spirit

2009-12-31T13:52:00.000-05:00

Not all wood spirits are made out of wood. This one took form as a result of the snow that my snow blower packed on to the tree. My granddaughter loved it.

I wish all of you a Happy and Blessed New Year. Let's hope that 2010 will be a better year than 2009 was.

Just like the snowy wood spirit, let's all keep smilin'.

Brad Sells - Wood Sculptor

2009-12-17T11:54:00.000-05:00

“A tree is a selfless mentor inspiring me to reveal its beauty, its truth.”
…Brad Sells

If you enjoy works of art created from wood, you are sure to enjoy the works of Brad Sells. If you have never seen his work you are in for a treat. Go to http://www.bradsells.com/. Make sure you click on “Media” to see the artist in action with his tools.

Brad is a wood sculptor from Tennessee. Like me, Brad believes in the spirituality of wood and the curious co-relationship between humans and trees. I saw his 30 minute show called Tree Safari – A Sculptural Journey, on PBS, and bought the video. (see: http://www.pbs.org/treesafari/) I was totally mesmerized. The video is about his trip to South Africa to find the rare pink ivory wood. But more than that, it talks about the spiritual nature of trees.

His magnificent work can inspire, but also intimidate a simple, hobby wood carver like myself.

What do you think of Brad’s work?

Ugly Wood

2009-12-10T14:20:00.000-05:00

I love trees, but not all trees. I loathe silver maple trees. When we bought our house, I inherited five of these monsters. The previous owner planted them because they are inexpensive and they grow very quickly. Those two attributes are the only positive ones I can think of. Silver maples are scraggily and ugly. If trees are God’s gift to us; silver maples are like an exploding cigar. God's gag gift.

The branches have brittle wood and break off easily all over the yard. In spring they produce seeds (My kids called them helicopters.) by the barrel full. Last year we used snow shovels to clear off the one inch depth on the driveway. No lie. Even if you get rid of 99% of these seeds the remaining 1% will produce a forest of little maple trees throughout your flower and shrub beds. In the fall, they produce lots of leaves, and because they are the last tree to shed their leaves. My sons and I are always raking leaves in frigid December weather. I hate silver maple trees.

Their wood isn’t even good hard maple. It’s relatively light density. We cut down a large silver maple that was too close to the house. I wrapped a few large pieces in black plastic bags to let them dry and age. That’s when I learned about spalted wood. Spalting is a by-product of the rotting process that is carried out by a vast array of stain, mold and decay fungi. The results are a bunch of random lines and areas of different color that are interesting to say the least. Some people love the unique patterns and view them as a work of natural art. Wood turners create wonderful bowl and plates. My silver maple chunks spalted like crazy. The spalting added to the natural grey streaks in the silver maple to produce some very interesting pieces for me to work with. I must admit, I enjoy the interesting effect, but I will always refer to spalted silver maple as "ugly wood".

My latest creation using spalted silver maple was a box for a good friend who was celebrating his 60th birthday (see photos below). Besides the spalting, it had many “bug holes” in it. I thought the rugged look of the box fit my friend’s personality. It's my first band saw box with hinges. I used small barrel hinges, but that's another story.

What has been your experience with using spalted wood?

David Stehly - Carved Walking Sticks and Canes

2009-11-22T17:10:00.001-05:00

David Stehly is a wood artist that specializes in walking sticks and canes. His work is outstanding. You can visit his website at: http://www.artsticks.com/ . I had heard of David and seen his work on the internet and in publications at various times. What I didn’t know is that he is practically a neighbor. His home and studio are about 5 miles from where I live. Small world.

I had a chance to visit David’s workshop as part of a local artisans’ “open studio” tour last weekend. He is noted for carving very realistic snakes that are twined around the walking stick. He starts out with a relatively large diameter log and carves it down to the normal walking stick diameter with the snake around it…a lot of work, but the result is certainly unique. His snakes and other creatures are very realistic with sharp details and life-like coloring.

His studio has a blue décor. Blue as in blue ribbons. David has won many first prizes in wood carving competitions. I went to his studio to be inspired. Instead I was humbled by his artistry and mastery of the wood. I've carved a few canes and walking sticks, but mine look like junior high school wood shop projects compared to David's. Nice work David!

Have you ever tried your hand at carving a walking stick?

New Saw for the Old Saw

2009-11-06T14:53:00.001-05:00

The Old Saw has a new saw. I finally replaced my old undersized 10” band saw with a new Craftsman 12”. I don’t really have room in my workshop for a full-sized 14” band saw, but the Craftsman 12” fits in very nicely. Besides, the new Craftsman 12” has a maximum cutting height of 7”, which is more than many 14” units. This was my main reason for getting the new saw. It's smooth and powerful and I love it.

With my old 10” Rikon, I was limited to a 3 ¼” maximum cutting height. Less, if you cut anything on an angle. Any band saw box I designed had to have two dimensions less than 3 ¼”, or some pretty clever cutting sequence. Just imagine how that limits your options. I could never make a decent-sized band saw box with multiple drawers.

With the new saw, my horizons have suddenly expanded. I look at my pile of logs and see all sorts of new possibilities. Ideas that were not possible with the smaller saw and stored in the back closets of my brain are now alive again. The creativity gates are open.

I wonder what other areas of our lives are limited because of the lack of the proper tool…or skill …or education. We make do with what we have, without making an effort to reach for something that is better. Something which would ultimately allow us to accomplish more. We get into a rut and settle for the undersized saw, the boring job. We lose the opportunity to grow or to succeed at new things.

Enough philosophizing. Does anyone out there want to buy a used 10” band saw? It’s a great "starter" band saw.

the Hope Box - Part 4 - Finished!

2009-10-15T13:10:00.003-04:00

Finished at last! So what did I learn from this project? Well, I learned that I get a little better with each piece that I do. I guess that’s good, but I still feel like an amateur when I compare my craftsmanship to what I see from others. Funny thing, when I finished the original Hope Box, the prototype made out of common basswood, I thought the result was the best thing I had ever done. My new Hope Box is a slightly different design, and made of beautiful old black walnut. I like it much more than the old one. Maybe I am getting better. I’m still making mistakes, but I’m learning from them. I look forward to the time when I can fully retire and devote more time to my wood shop / studio.

the Hope Box - Part 3

2009-10-10T15:56:00.001-04:00

Into the serious band saw work. With the ½” blade still on the band saw, and the sides still perpendicular to the base, I cut the box top and the bottom piece. Then I cut the side tapers by tilting the band saw table top. Of course, that made the previously cut bottom piece slightly wider than the sides, but it was easily adjusted with some shaping work on the belt sander.

I then changed to a 3/16” blade for the curved cuts. I kept the band saw table at the same angle setting so the inner sides would be tapered at the same angle as the outer sides. I took a deep breath and carefully cut out the box opening. This is always a scary operation for me. If you mess up here, you have wasted a whole lot of time. Sometimes I do a cut or two on an old piece of scrap wood just to get comfortable with the motions. Sort of like a pitcher taking warm-up pitches.

The smaller ring forms the rim of a hidden bottom compartment.

I have a fear of the band saw. I always have and I always will. My fingers are an inch or so away from a very powerful, sharp, whining blade. A small slip-up could cause some serious changes in my life. Fear is not necessarily a bad thing. My fear of the band saw is a kind of respect. I respect the power it has. At the same time, I know that its power is controlled within certain physical dimensions. If I do not come in contact with the moving blade, I will not be harmed, and the power will work for me. The power of the band saw becomes my power.

If using a powerful band saw creates a high level of keen awareness and excitement, then the repeated motion of hand sanding produces a level of boredom that would be at the exact opposite end of the scale. Sanding is boring. There are no two ways about it. Any beautifully crafted box must go through this dreaded hand sanding process. There is no way to skip it. Sure, there are power sanders that can get you most of the way, but the final finishing sanding must all be done by hand. All of the great wooden (or stone) sculptures that we admire in museums, or the carved wooden architectural details that fascinate us in churches and mansions, were all sanded tediously by hand by some poor artisan with tired forearms.

The finished form, all glued and ready for hand sanding.

Olive Wood - Assisi, Italy

2009-10-06T16:02:00.000-04:00

A few years ago, my wife and I visited Italy. We stayed near Assisi in an old farmhouse that was turned into four apartments. It was on the top of a hill in the middle of a working olive grove. It was wonderful week. It was there that I fell in love with olive trees and olive wood. Olive trees are usually all gnarled and twisted. Some people would say they are ugly, but I appreciate their rugged diversity. They have personality.

We were there right after the spring tree pruning and there were lots of one foot long branch pieces in a pile to be used for fire wood. I picked out a nice small log, 2” in diameter, wrapped it in a hand towel and put it in my suitcase. Later I wondered whether it would cause a problem going through the baggage X-ray at the airport, since it might look like a stick of dynamite, but it got through all right. I used the piece of olive wood to carve a spoon. (see photo) Not a work of art, but a nice memento of the trip. Olive wood is great to work with, easy to carve and cut, and the grain and color of the wood is warm and earthy.

Assisi, of course, is the home of Saint Francis, a very spiritual man and a lover of nature. The trip to Assisi was part vacation and part spiritual journey for me. Even though a few years have passed, I can still feel the spiritual awakening I experienced there. All my senses were filled with God.

This blog is about wood and art, and today I am talking about olive wood and St. Francis, so I can’t help but mention the most beautiful carved olive wood statue of St. Francis that I saw in Assisi. The humorous irony, however, is that this wonderful life-size statue was not in the basilica or in the garden, but rather in the foyer of the underground restroom facility for tourists. (see photo) Go figure.

the Hope Box - Part 2

2009-10-02T18:14:00.002-04:00

I finally found some time to get back to the box. I was about to say that cutting the shape with the band saw is a critical step, but then I realized that they are all critical steps. I use a small 10" Rikon band saw which has a vertical clearance of only 3 1/2". This severely limits the size of the boxes I can make.

Working with these smaller blocks of wood can sometimes put my precious fingers dangerously close to the saw blade. Believe me, I have a great respect for that blade, but more about that in some later posting.

I used gouges and power burrs to take out wood on the sides and approach the final rough shape of the arches.

The band sawing exposed a crack in the wood which wasn't visible from the outside. However, the piece seems strong, so I may be able to use some filler. I always save fine wood dust from sawing, sanding or power forming in a small tin for filling in such cracks or kerf cut marks.

Here is the new rough shape. There is still a lot of forming to do on the arches. I have left the sides square, not making the bottom box side angle cuts yet, so that I can easily saw off the box top at a right angle to the side, and parallel to the base.

Hand-Crafted Wooden Boxes

2009-09-28T14:30:00.002-04:00

Boxes have been used since ancient times to store, separate and protect things. They can store common things like corn flakes or sugar. Or they can store very precious items like jewelry and mementos and separate them from the every day items. These specially crafted storage boxes are the objects of my interest. They can be made of metal or glass; of plastic or cardboard, but it seems that the vast majority of these types of specialty crafted boxes are made from wood.

Storage boxes are somewhat of a dichotomy. They conceal, yet at the same time, they invite you to open them. When you open such a storage box it is usually to remove some special object. It can be an important moment in time. You are revealing the concealed. You are resurrecting objects and memories that have been hidden for a period of time, perhaps even a long period of time. You may be seeking a piece of jewelry to wear at a special event. You may be searching for answers to questions about the past. You may be in financial need and looking to sell something that has great value. Or, you may be simply getting out a good cigar for your enjoyment.

If the box has hidden its contents for a long period of time, opening it might produce surprise and excitement. It also may produce many other feelings. You may not remember what you put into the box. Once you open it, memories come to life. Each of the objects has its own story attached to it. Do you remember where you were when you first received that object? Do you remember who gave it to you? Do you remember the feelings at the time?

Crafted wooden storage boxes are indeed a very special part of everyone’s life.

the Hope Box - Part 1

2009-09-25T20:09:00.001-04:00

I make band saw boxes. I call my latest project “the Hope Box”. I got inspiration from a design, by an artist by the name of Ron Lowe, which I saw in the book called “400 Wood Boxes” by Lark Books. (Check out this book if you want to get blown away by wonderful creative design in wooden boxes.)

I first made a Hope Box out of basswood as sort of a prototype. There was a lot of tricky work involved, on the drill press, the band saw and with hand rasps and carving tools. I stained the resulting box to cover a few errors, but overall, I was pretty pleased with it. See the photo on the right.

I had a nice chunk of black walnut that I bought from the local sawmill for a few bucks. I thought it would be ideal for making a “good” Hope Box or two. The photos show the walnut block with the openings rough drilled. The next step is to cut the outer profile with the band saw. I’ll keep you up to date on my progress with photos.

black walnut block (left) with basswood "prototype" (right)

block with openings drilled through

The Green Man Revisited

2009-09-16T18:51:00.001-04:00

It has been about 5 years since I carved the Green Man. I became captivated by the whole Green Man mystery when I saw my first Green Man in Chris Pye's book "Elements of Woodcarving". Visit his website at: http://chrispye-woodcarving.com/index.html. Chris is a great woodcarver and his books have taught me a lot about woodcarving. He has a page on his website devoted to the the Green Man with links to other sites. There are many theories on what the symbol of the Green Man means and why the symbol appears in so many medieval churches. No one knows for sure, where the symbolism comes from, or why he was so ubiquitous during that period.

Some people think it is purely a pagan symbol. Personally, I think it is simply a symbol of re-birth which may have roots in pagan beliefs, but has been absorbed and transformed to represent Christian beliefs, like Easter and Resurrection.

I am quickly approaching retirement age, and a new phase of my life. Seeing the Green Man hanging in my living room reminds me that my passage into retirement should be a re-birth into a new life of creativity and appreciation of nature.

Have you ever carved a Green Man? What do you think the Green man symbol means?