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Before I get into the topic of this post, I would like to preface it by saying that I have been working with and around machinery for most of my adult life. That list includes construction equipment, printing presses, pipe benders, wire pulling machines, fork lifts and earth movers. Of course this list also includes power tools for woodworking. All of the equipment I listed could and can seriously injure or even kill.
Lately, while woodworking, I have been exclusively using hand tools. This has not been a philosophical decision. The projects I have been working on are generally small, and because my daughter has been with me ( I will not use a power tool with her in the vicinity), and because I could just as easily crosscut a few boards by hand, I have been avoiding the table saw. But over the past weekend I broke out the table saw for the first time in quite a while, and truth be told it may be a long while before I break it out again.
Last year my father-in-law brought me some hickory and ash logs from his property in upstate Pennsylvania, so I split them into smaller pieces and set them aside to dry. When inspecting them on Saturday I deemed them dry enough to use, so I decided to further prep the wood (namely the hickory) into smaller billets to be used as handle stock for some antique farm and logging tools that I have been attempting to restore. This prep work consisted of a lot of sawing and hatchet work, and I don’t recommend it if you are working under any kind of time frame because it is a long and arduous process despite what anybody will tell you. Regardless. I ended up with four “sticks” roughly 2 ½ feet long and 2 or so inches square. I planed them down mainly to get a flat reference face (this wood will be shaped into contoured handles, so there is no need to start off with a perfectly square board), and rather than spending another hour rip sawing and cross cutting, I decided to use the table saw to get all of the wood to uniform size. That is when things got weird.
The first thing I wanted to do was cross cut the boards to uniform width. I have an Osborne EB-3 miter gauge, which I feel is a top of the line product, and it has never given me any real trouble. It is accurate, and safe, and I feel comfortable using it. The blade on the saw is new and sharp. So I set the blade height, and decided on an off-cut of around 2 inches just to be sure to remove any funky end wood. So I began a process I have completed thousands of times…My first off cut shot across my garage like a rifle shot. I turned off the saw, checked the blade height-which was right where it is supposed to be-and got back to work. The second off cut, which was the other side of the same board, did not shoot across the garage again, but it wanted to. Instead, it seemed to “tug” the board into the blade slightly, and I believe the only thing that kept the board from being pulled laterally any further was the fact that my miter gauge is lined with 60 grit sand paper just for the purpose of keeping the wood from shifting. At this point, I unplug the saw and check the blade-it is tight and sharp; I check the miter gauge and it is 90 degrees to the blade (not that it should have mattered in the least but I checked anyway) I even checked the voltage at the receptacle that the saw is plugged into-121 volts. So I chalked up the missile launches to the dense hickory board and began again.
The next 3 boards yielded generally the same results: flying wood, pulling boards, and overall chaos. After the boards were sawn to length I was planning on ripping them to width as well, but by then I was becoming worried. I have always had a very healthy respect for all machinery and I am always very cautious when using it, because I’ve witnessed several gory incidents as well as surviving a few near-misses myself. But this was the first time that I can ever recall being afraid to use a table saw.
At this point I decided on some more detective work. I went back to the blade, which is a brand new 40t combination blade, a Diablo from the Depot. While I don’t consider the Diablo blades anything special, I have used them in the past many times without incident. Nevertheless I doublechecked it, and found no wobble, the teeth were nice and sharp, and as I said before, the height was set where I always set it, with the gullets approximately 1/8 of an inch above the cut. Hickory is a hard wood, very hard, so I decided to cross cut a piece of scrap pine to see the results, and while it did not shoot across the room or bog, something definitely did not feel quite right. So I re-checked the Hickory; there were no wild grain patterns or large checks, and while the boards likely have more moisture content than a kiln dried board you may find in a lumber yard or home center, they were definitely not openly wet or even damp.
However, one area of concern did crop up, and that was the throat plate on my table saw. The plate is wider than it should be, and perhaps an offcut just a few inches long will dip, even slightly, due to lack of support, causing it to touch the revolving blade, possibly shooting it back? I have always wanted to make or purchase a zero clearance throat plate, but because I use the table saw so little I haven’t considered it much lately. So to test this theory out I cross cut a scrap board so that much of the off-cut would be supported by the table and the results were improved, though I still seemed to feel a slight tug that I had honestly never noticed before until that day.
Here’s the thing, not too long ago I came to the conclusion that I am probably going to sell my table saw. I don’t use it much, but more importantly it takes up a lot of space. At the same time a table saw can be a useful tool to have around. I know that I can work without it, but I also know that there are times it will be greatly missed, in particular on those days when I need to cut a few dozen dados. I’m not sold on the notion of “all handwork, all the time.” Once again, I have nothing against it, I just don’t have the free time for it; I woodwork for fun, not as a crusade. Yet, I haven’t really used the table saw in earnest this entire year, and we are heading into September. Either way, for the first time in my life I did not feel comfortable using a familiar tool. It’s worth the $25 investment to add a zero-clearance throat plate, but that may not be the issue, and that issue may be a problem with the saw that I cannot necessarily identify without a true expert checking it out for me.
If I add a new throat plate and I still don’t notice a difference I can only see two options: sell the saw and put the money toward a band-saw, or sell the saw and put the money towards a Sawstop Saw. For the record, this is not a commercial for Sawstop. I’ve used a Sawstop saw a handful of times and I think highly of them. I don’t know if they do any more to stop kickback on crosscuts than any other saw will, but I do know that if that kick back causes my hand to slip, or jerk, or what have you, and my hand happens to touch the blade in doing so, I have a far better chance of not sustaining a serious injury. Yet, even if I sell my saw and get top dollar for it, the money raised would still be less than half of what I need. I can get a nice bandsaw for half the cost of a Sawstop, and bandsaws, in my opinion, are a far safer option, perhaps the safest option of all when it comes to sawing wood with a motor.
When it comes down to it, I’m not a kid anymore, and I’m not a professional woodworker. Maybe my months long lay-off from the table saw has me somewhat gun shy. Maybe my reflexes aren’t what they used to be, and I have definitely had some issues with my hands and fingers, so maybe that is the problem. Whatever the case may be, I was honestly rattled this past weekend, and that is no way to woodwork, and until I figure it out, the power switch to that table saw is remaining in the “off” position.
With spring slowly but surely creeping into my area, it’s finally about time for me to consider what projects I would like to work on going into the summer. Normally I would take some sort of woodworking class to start off the season. Taking a class usually got me psyched up for trying some new project or technique, but as of now I won’t be taking any classes that I can foresee. Time, money, and philosophy have all played a part in that decision, yet that doesn’t mean I don’t want to do anything woodworking related when it comes to my continuing woodworking education. So I’ve decided to sign up for the Hand Tool School internet woodworking course. Wait a minute!! Am I not the guy that is always beating his chest about hand tool snobs and woodworking elitists? Yes, that is still me, and I still stand by my statements. But I never said that I don’t like hand tools.
The truth is that I use hand tools on every build. I use hand tools more than power tools when it comes down to it. I would not be able to woodwork without hand tools. I’ve even made some projects completely by hand if you can believe that. My issue was never with hand tools, but with those that feel you should only woodwork using them and nothing else. I will always hold that you should woodwork however it makes you happy using whatever tools you have, not using some rigid guidelines which limit you to one mindset and one toolset. That being said, I am always open to new ideas, unlike quite a few woodworkers I’ve encountered on the internet. I’ve always enjoyed certain handwork operations and I will even brag a little bit and say that I am actually pretty good at it, especially considering the relatively short amount of time I’ve been a woodworker. The other side of the coin is that I am already fairly adept at using a tablesaw, which is really the only powertool I use on a regular basis (and will always use). So a hand tool course is the next logical step in my woodworking progression. The Hand Tool School is reasonably priced, has gotten some great reviews, offers and interesting list of topics and projects, and I can take the classes whenever I feel like taking them. All of that made my decision pretty easy.
The only question now is when to begin. I want to finish my two tables project first, and then I want to get the new top for my workbench finished. The old top has taken a beating and in fairness was only supposed to be a temporary solution that has lasted more than two years. Last week I took a big step in getting my workshop organized, but I still have one or two more things I want to do in there before I call it ready-to-go. I’ve also promised to make a Stickley #72 magazine cabinet for a relative, but I will probably save that for the summer. Another thing to consider is the recommended tool list on the Hand Tool School website. I had most of the tools on there but I was missing a few, namely a rip saw and a scrub plane. There is nothing more I would like to do than drop a few Benjamins on some new tools, but I also don’t want to anger the little lady. I have to do a little research and see if I can start the course without every tool on the list without it holding me back. Another thing is the use of rough lumber. I don’t have direct access to a lot of rough lumber in my area. I either get my stuff from a small place not far from my house, which sells more pre-surfaced wood than rough boards, or I go to a home center. So I also have to check and see what the situation with the course is in that regard. I want to be thorough and get the most out of the course. You may not know it to look at me, or by reading my blog, but I was actually a very good student at every level of schooling; I’m just a little rough around the edges is all.
If all goes well I’m hoping to be enrolled and started in roughly three weeks. That should leave me enough time to get the shop finished, my tables finished, and my new benchtop on its way. I’m really looking forward to this; it’s something I’ve wanted to do for a while now. It should be a great time and a great learning experience. Who knows? I may throw away my table saw (actually there is no way) and become a hand tool snob. I might even change my last name to Handtool.
***NOTE*** There are weblinks to many of the sites I go to most at the bottom right of the blog page, including The Hand Tool School.