I recently had the wonderful experience of attending the two day seminar on saw sharpening and tune up at Bad Axe Tool Works, along with about a half-dozen other enthusiasts, presented by BATW owner and founder Mark Harrell who was assisted by his impressively skilled crew. I learned a lot, starting with the realization of how much there is to learn.

Several key aspects of making a world-class saw stood out.

First, and I think foremost, is hammer setting the teeth. For a very long time I stayed away from even the best available Western backsaws, instead preferring Japanese saws. The best way I can describe the problem that I felt with the Western saws that I tried was an annoying subtle vibration or tension at the bottom of the kerf.

Bad Axe saws are decidedly different. They transmit a palpable sense of resolute ease and smoothness as the saw cuts, which, frankly, raises my confidence as I track a layout line. The teeth undergo sophisticated hammer setting that relieves them of the stress and saw plate distortion induced by merely bending over the spring steel teeth, problems that ultimately transmit unease to the hand of the sawyer.

Second, I learned how the folded sawback does more than merely add weight and stiffness to the saw plate. It almost magically contributes to making the toothline dead straight. In fact, it can be rather easily adjusted if needed to straighten an errant toothline. This is quite different from the saw plate being fixed in a sawback with a milled slot.

Further, all of us were especially grateful to learn that excellent saw sharpening does not have to be complicated. Mark coached us through real deal sharpening techniques that we could bring home and directly use in our shops. What a relief! In particular, we all saw the value of Mark’s “hybrid” sharpening pattern that uses intermediate rake and bevel (fleam) angles to produce a toothline that is remarkably versatile in the shop.

As I thought more about what I learned that weekend, a couple of rough analogies came to mind. In writing and classes on sawing technique, I emphasize how core stabilization and balance are essential for steady ease and control of the distal motion of the hand and saw, somewhat similar to the how tension of the heavy folded sawback produces precision at the toothline.

Producing these saws involves automated steps early in the process with increasing amounts of hand skills that infuse exquisite quality, culminating in sharpening. This is analogous to how most of us make high quality woodwork. We prepare stock with machines but the special quality comes from skilled handwork.

In summary, the seminar brought me to appreciate the depth of understanding and refinement of craft for each element of making the saw, and I could see how it all comes together to produce the saw performance I have been experiencing. And of course, the customization options available from Bad Axe are irresistibly cool.

Without doing controlled side-by-side tests, I have had the opportunity to try at least one backsaw by almost all of the high quality American and Canadian makers. I generally shy away from superlative statements but here goes: these Bad Axe saws are hands down the best. And they are indeed tools with souls.

Above, Mark Harrell is finishing work on my 14″ sash saw and yea, I’m happy.

Here’s a great idea for your next woodworking project!

The Patriot Guard Riders of New York, members of the 1/4 million-strong national PRG, honors United States military veterans. One of their efforts, the Veteran Recovery Program, has as its mission to identify and honorably inter the unclaimed cremated remains of veterans. The Northeastern Woodworker’s Association, based in the Saratoga Springs, NY area, contributes to this effort with some of its members crafting superb wooden urns to contain cremains. They have been aided by generous donations of lumber from Downes and Reader Lumber and Leonard Lumber, suppliers to Curtis Lumber.

In solemn ceremonies befitting the honorable service of the deceased veterans, the urns are placed by military honor guard in inscribed chambers in a cemetery columbarium. Read about one such ceremony at Saratoga National Cemetery in this article from the Times Union, which also gives more information about the program. [The photos of the ceremony are used in this post with the kind permission of the Times Union.]

I learned of this program when I visited the PRGNY’s booth at this year’s fabulous NWA Annual Showcase in Saratoga Springs. As a woodworker, and especially as an American, I was honored to participate by building the urn pictured below and shipping it to the program.

Heartwood readers, here is an opportunity to step up and use your woodworking skills and creativity for a great and honorable cause. The urn can be made in any shape, design, wood, and finish to yield an interior volume of 230 cubic inches. Urns have a fixed top panel but are filled via a removable bottom panel fastened with screws. A small plaque with the name of the veteran will be placed on the urn. The urn you build will be permantly placed, in ceremony, in a sealed inscribed compartment 10″ wide by 14″ high by 18″ deep that holds two urns, in an outdoor columbarium.

Contact Bill Schaaf, the coordinator of the program for the PRGNY, for more details and to arrange shipping your completed urn. Your work will surely be deeply appreciated.

Heartwood readers, I invite you to check out Craftsy, an online craft instruction site that has recently added woodworking to its blog repertoire, with your devoted scribe as one of the authors. Craftsy offers hundreds of extensive videos on many crafts.

I have just completed a series of nine posts on the Craftsy woodworking blog on making the through dovetail joint. With more than 8,000 words and 74 photos, this is a down and dirty, at-the-bench tutorial that is about as in-depth as you will find written anywhere. I think novices as well as experienced craftsman will find beneficial direction and tips.

I will be regularly contributing to the Craftsy woodworking blog, along with several other woodworkers who consistently produce excellent reading, including two bloggers with whom you are surely familiar, Wilbur Pan and Mitch Roberson.

Heartwood will continue as it has since 2008. I again thank you for reading and very much appreciate your comments. I will continue to endeavor to provide worthwhile, real-deal content “from the shavings and sawdust of my shop.” Meanwhile, take a look at Craftsy and consider adding it to your RSS feeds or bookmarks/favorites.

Rob

Here is an excellent resource for every woodworker by the maker of Bad Axe saws. It will, of course, be extremely valuable if you have plans to restore a backsaw, but just as much if you want to improve the performance of any backsaw, or if you simply want to expand your understanding of hand saws.

With photos and text, in six detailed posts, Mark walks you through the processes of cleaning up a saw plate, restoring a handle, and, what I found most interesting, how to adjust the interaction of the saw back and plate to produce a dead straight tooth line. He also explains his straightforward approach to sharpening and how he uses a nineteenth century device to hammer set the teeth.

Heck, the colonel even advises you on how to smooth your horns and free up your frozen nuts – in a family-friendly context, of course. And by the way, I like that he calls the wooden part of a saw a “handle” instead of a “tote,” which seems more like something you’d get for free at a shopping mall.

Mark has more DIY articles on his Bad Axe Toolworks site, along with articles on how to evaluate a vintage saw, tooth geometry, and saw filing.

Great stuff, even if you don’t (yet) have a set of Bad Axes like I do. (See unabashed display of show-off photo, above.)

The NWA’s 23rd Annual fine woodworking Showcase, attended by 5000-6000 woodworking enthusiasts each year, will be held Saturday and Sunday, March 29-30, 2014 at the Saratoga Springs City Center in Saratoga Springs, NY.

The event features:

• Lots of free classes and demonstrations to help you broaden your woodworking skills.
• A large trade show with tools and materials from national manufacturers and local suppliers for exhibit and sale.
• An exhibit of over 500 pieces of woodwork by amateurs and professionals ranging from small accessory items to large furniture.

This year, as one of the featured demonstrators, I will present two topics on each day, Saturday and Sunday: “Hand Planes – Choices, Set Up, Use,” and “Drawer Fitting – Steps To Success.” The demo schedule is here. Of course, I will also be around for chatting, questions, and enjoying the Showcase.

Heartwood readers, I hope you have a chance to attend and I will see you there. Saratoga Springs is about 30 miles north of Albany, NY. If you are there but don’t happen to attend my presentations, please do say hello anyway.

Learning and laughing, I had a great time at WIA. Here are a few snapshots with preceding captions. A few closing thoughts follow the photos.

I spent much of the weekend hanging out with Mark Harrell of Bad Axe Tool Works, here demonstrating one of his superb backsaws. Looking on are Vic Tesolin of Lee Valley and Al Flink, a student of Mark’s who became my saw filing teacher for an afternoon. In the world of saws, BATW is playing chess while most are playing checkers.

The same goes for shooting boards and Vogt Tool Works. Tico has added to his line of inclined shooting boards with models designed specifically for new shooting planes available from Lee Valley and Lie-Nielsen. If you don’t already own a Vogt shooting board, you owe it to yourself to check out Tico’s products.

When Matt Vanderlist talks, woodworkers listen.

Speaking of great communicators, I asked Marc Spagnuolo to look as cool as possible for this photo. Yes, I know, that’s like asking Kareem Abdul Jabbar to look tall. The Wood Whisperer met my request with his ready sense of humor.

Popular Woodworking magazine Editor Megan Fitzpatrick and I, your devoted scribe, made a deal, or so I thought, to look as sappy as possible for this shot. Megan, no doubt quickly bringing to mind some Shakespearean plot, opted to appear quite levelheaded, while I succeeded rather spectacularly with the original plan – don’t you think?

I will not reveal what Chris Schwarz did moments before this shot, but only say that he switched the anatomical focus of his jocularity from his customary posterior to anterior just in time for the photo. (No, he’s not adjusting the square on his shirt.) Can you tell that Deneb Puchalski and Tom Lie-Nielsen are covering for Chris with forced laughter?

Seriously, it is hard to appreciate the beauty of the Lost Art Press books until you handle them in person. The same is so for the grace and functionality of Lie-Nielsen tools.

Recognize the guy in the middle?

Ron Hock of Hock Tools has done so much for woodworkers for many years.

Woodworkers are similarly grateful for the contributions of Joel Moskowitz of Tools for Working Wood and Gramercy Tools, here chatting with Fred West.

It was wonderful to be around so many people who love what they do, in this case, woodworking. The joy was palpable and contagious, while the learning flowed naturally. The direct link between action and result inherent in the craft of woodworking punishes pretension, so the down-to-earth nature endemic among woodworkers comes as no surprise.

I am grateful for the many conversations I was able to have with sincere, masterful makers. Some that I especially savored, such as with Mark Harrell of Bad Axe Tool Works, and Robin Lee of Lee Valley Tools, were alone worth the airfare. Thank you also to the many people whom I met who kindly mentioned their appreciation of my writings.

Special thanks to the Popular Woodworking crew for putting on a wonderful event!

Take a look at two lists: the Speakers and the Toolmakers who will be at WIA.

Every woodworker can learn plenty from that bunch. In fact, we can probably learn just by breathing the air at WIA. I’m only half kidding: seeing Mary May in person carving oak leaves, and hearing Silas Kopf discuss where design ideas come from, to cite just a couple of examples among the classes, are sure to elevate my skills and confidence.

Browsing the toolmakers’ booths is going to be fun – handling and trying out fantastic tools cannot be done online. Yes, this is dangerous territory, especially if your credit card is handy, but as a woodworker, isn’t that just the kind of living on the edge that you crave?

Exchanging ideas about tool design with these outstanding makers will be just as enjoyable. My first mission will be a reconnaissance op to the Bad Axe Tool Works bunker and Col. (Ret.) Mark Harrell.

Heartwood readers, I cannot think of any better or more enjoyable way to improve your woodworking skills, knowledge, and perspective than to visit WIA and hang out with lots of people who share our passion for the craft. I hope to see you there!

There are places available in the class I will be presenting tomorrow, Sunday, September 22, 2013, at the Woodcraft in Walpole, MA, 10:00 AM – 3:00 PM on “Fundamentals of Hand Plane Selection, Setup, and Use.” The location is about 15 miles southeast of Boston, two miles north on Route 1 from Gillette Stadium.

The presentation will be in a clear, logical, at-the-workbench manner, much as topics are presented here on Heartwood. It will include plenty of guided hands-on, as well as demonstration and discussion. Beginners as well as experienced woodworkers will benefit from the class, which will include bevel-down and bevel-up options and tuning. Bring a plane or two. DVR the 1:00 PM Pats game and beat the Route 1 traffic going in and going home.

Please see the Woodcraft website for directions and details.

Other upcoming classes I will be teaching:

• How To Make and Use Mortise and Tenon Joinery on Saturday, November 2, 2013, 10:00 AM – 3:00 PM.
• Choosing and Using Hand Saws – Western and Japanese on Thursday, November 14, 2013, 6:00 PM – 9:00 PM.
• Fundamentals of Hand Plane Selection, Setup, and Use on Sunday, December 15, 10:00 AM – 3:00 PM.

If you are in the area, and especially if you like reading the Heartwood blog, come on over – we’ll have a blast.