I’ve been using quite a few different types of hatchets / axes lately, and many of them feel decent enough in my hand, but one of the older handles is top notch for me. The range of handles are from a number of makers that even the casual user would likely recognize, but the one that stands out for me, is a hickory one in my old Plumb hatchet. Other than the handle on my older Sears hatchet, which is fairly round in cross-section and unfortunately feels like it would be in a lower quality hammer, the rest have some aspect of similarity. These all have a cross-section that is somewhat oval (a bit flattened) or perhaps even leaning towards teardrop in shape, which I find much better than a round cross-section, at least for a hatchet/axe.
The handle in my old Plumb hatchet is much more “delicate” in grip girth, but it has been up for the task. I’ve used this hatchet for a number of years, and it was my grandfather’s before it made it to me, and it’s still rocking the original handle. Pretty impressive for a slim little handle!
When I find something that both feels great and works well, I take as many notes as possible, to help determine what it is that lends to the overall excellence. If applicable, I’ll replicate the design to see how it behaves, and how much time it requires to make by hand. This new version can end up as a replacement for the original, if needed, as long as it feels good in the hand. You never know when you might swing and unintentionally damage a handle, no matter how long its previously lasted.
I made a simple pattern for this handle, using a previously used Priority box from the Postal Service, as the box was of decent size.
I measured the dimensions of the existing handle, and found an off-cut in my bin that was close enough to call a match. I honestly didn’t know what type of wood I’d chosen (not 100% sure even now), as the majority of the piece had a dark colored and very rough cut exterior. I used a pencil to trace my pattern onto my blank, and quickly cut it out on my bandsaw. This was the only piece of powered equipment I used to make this handle. After cutting the blank close to my pattern lines, as well as then diving in at the pommel, and cutting a very light taper to create some swell at the end, it was obvious the grain was not nearly as straight-grained as the original hickory version.
From this point forward, I used a draw knife, my flat and curved versions of my Lie-Nielsen spoke shaves, a carving knife I made last year, along with a couple of chisels and scrapers (one was a purpose-made card scraper, but even though the other was a bit makeshift, it worked wonderfully for very light cleanup).
I find I have a tendency to work much more cautiously when performing the first of a given process, and with finding the blank lacked pure straight grain, I made sure I didn’t bite off too much with the drawknife. Even using the drawknife with the bevel down, as I did on this handle, you could dive into the grain, splitting away so much wood that you’d ruin the planned shape. On this handle, I also wasn’t sure whether I might end up going with an octagon faceting rather than the continuous curve of the original, but as I gradually approached the final dimensions, I decided I’d stick to a good likeliness of the original.
After using the scrapers, I applied a coat of Watco’s Danish Oil in the natural color, which provides a small level of protection as well as enhancing the wood grain. I also decided to sit the handle outside on the hood of my car, during the midday sun, to see if it would get a sun tan. Some woods are known to change in color, with direct sun light exposure, but I’m not sure whether this unknown species really changed all that much, if any. I took before and after photos, and it wasn’t completely obvious to my eyes.
I hope this might spur some of you to try making a handle or two for yourselves, and you might just find you can tweak them so they fit your hand better than anything you’ve ever purchased.
Please let me know if you have any questions or comments. Thanks for stopping to check out this posting!
@LeeLairdWoodworking – IG
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I don’t know about you, but I’ve always struggled a bit getting a spoon/bowl knife “really” sharp. You know, wicked sharp, where it wants to cut the wood from across the room? I’ve taught loads of people to sharpen chisels, plane blades,…, but these were all tools with a cutting edge along a straight surface. As you well know, the spoon/bowl knives have their cutting edge along a curve, which is what makes them more difficult to bring to the highest level of sharpness.
A while ago I recalled how I’d made two accessories that fit a small, tight-radiused gouge, and helped me hone it effectively. So why not use a similar process for these curved knives?
I found a scrap of Pine (I like using a softwood, but you can use what you have available) that I cut into two blanks that were about 4″ long and 1 1/2″ – 2″ wide. This allowed some extra material so I could hold it safely, while I was honing the knife. On the first, I used my spoon knife (made by John Switzer @BlackBearForge on IG) to remove some wood along a portion of one face, until I had a recess that matched the curve of my knife. This was just a shallow recess, just so no one works hard trying to fit the whole of the curved blade down into it. On the second pine blank’s end, I pressed a section of the curved knife’s blade into the end-grain, and then removed wood until I reached the cut line (curved).
As you can imagine, both blanks were made to these shapes so I could apply some honing compound, and then hone the blade against them. Having the blanks/jigs matching the shape of the knife creates a wider contact area, rather than just a point, which for me helps stabilize the knife and “jig”. When I’d used a flat piece of wood (with some honing compound on it) to work the outside of the spoon knife, I could tell I wasn’t as consistent.
You can use whatever honing compound you’d like, or if you are needing to sharpen, rather than hone, you can apply a section of PSA sandpaper to the “jigs” internal / external curves. I like to use the Tormek honing paste on the “jigs”, that my Tormek T-7 came with years ago, as it seems to cut most metal quickly as well as bring to a very polished surface. You can pick up a tube at Highland Woodworking (a link to their website is over on the right side of my page, and full disclosure, I do get compensated if you purchase through that link) or a number of other retailers.
Here is a quick video I made to show how I am using the “jigs” I discuss above, but if you cannot view this, the direct link for Youtube is here (or you can copy and paste this info: https://youtu.be/qOlaTIEUAVM ).
I hope this makes it easier for each of you to make your spoon knife as wickedly sharp as possible.
For the majority of the knives I’ve made, I split the handle down the middle (lengthwise) and fit it around the tang of my knife’s blade. On many of my smaller knives I have a hidden tang, so the tang doesn’t show at any point around the handle, except where it extends out the front.
For some of the knives, the tang is fairly narrow, but still strong for the intended type of work. With this size though, it can be a bit limiting as to the tools I can use when evacuating the wood where the tang will fit.
The width of the handle scales (when laid on there side) is also an issue, as one of the tools I’d normally choose would be my Lie-Nielsen No. 71 or my old Stanley No. 71. Even with the closed mouth version that I have, it is very difficult, if not impossible to stay registered on the outer wood, so the small square blade for the No. 271 is of no real use. As for shifting to the No. 271, I really prefer to have a fine screw-adjust, when sneaking up on a final depth.
A couple of years ago a friend of mine showed me a gift he received from his kids, and it was one of the Lee Valley mini planes, which got some chuckles from everyone around. He went on to share that it was truly completely functional, which I know it says on the website, but it was still hard for me to wrap my head around. Ok, shift back to present time, and I decided to take a chance and ordered one of the Lee Valley Mini Router Planes (shown above in the lower portion of the photo), hoping my results might surprise me.
I opened the packaging and my heart sort of sunk. The presentation box this little router plane comes in is so tiny, almost to the point where I was afraid I’d made a mistake. I opened the box and the plane was so amazingly small, but all of the parts worked super smooth. I took the blade out of the plane and took it to my Shapton 1000-grit Glass Stone (as this blade is quite narrow, the Glass series stone is one of the few stones I trust will not create a long dado in the stone in rapid order) and worked the bottom of the blade. This blade is made from A2 steel, and it took a fair amount of time to work so it showed a consistent scratch pattern.
This wasn’t because the blade was out of square or warped, just because the steel was so hard! It felt like I was working a super high Rc valued Japanese iron, or something on that magnitude. I followed doing the same on the bevel side of the blade, but since this is such a small blade, I could only make short back and forth movements. All of the sharpening was freehand, as no guides that I have would work with this blade. After both mating surfaces were complete on the 1000-grit, and I had a small burr, I very lightly worked both surfaces on my Norton 8000-grit water stone. This stone is much softer and I was very cautious not to stay in one spot for too long. I brought in my Glass Stone 16000-grit to finish up the blade, and brought both edges to a razor sharpness.
While I had the mini Router Plane apart, I noticed it’s sole still had mill marks from manufacturing, so I put some sandpaper down on my flat granite plate and worked it until all of the milling marks were gone. I applied some wax to the sole, which is what I do to the sole on all of my hand planes, so the friction between the wood and plane is almost nil. There is no good reason to leave the sole unworked, and basically fight against the wood.
After re-assembling the mini router plane, I took it to a knife handle where I’d already cut along the shape of the tang, with an Exacto knife, and removed a fair amount with a very sharp chisel. When I set the mini router plane onto the handle blank, it looked like this might actually work. The size of the little router plane just looked like it was the proper scale for the work needed. I was so pleasantly amazed when I started removing wood, as the blade in the router plane was cutting through the wood like it was butter. And this feeling didn’t stop anytime soon. I finished both inside areas of the handle for this knife blade, and it was still going strong. Part of this is the small cross-section of area it is cutting, but still, the A2 in this blade is really holding its edge like a champ!
I hope you enjoyed the read and perhaps will test the same for yourself. Please let me know if you have any questions or comments.
@LeeLairdWoodworking – IG
@LeeLairdWW – Twitter
We have an old dresser that is almost 30 years old, that was purchased just before our son was born. It has some nice looking maple/curly maple on it and is fairly heavy, which lead us to believe it was well made. Unfortunately, this was around the time I was just cutting my teeth on some basic woodworking, so I didn’t dig into it as I would today.
I became aware that the top drawer was twisting in it’s track and it was a struggle to get the drawer in or out. As I was going through all of the excess stuff in the room, I pulled the drawer to see what exactly was happening. The drawers, which are each approximately 30″ wide, have one “T” shaped runner in the dead center of each level. The front end of the runners are screwed to the face frame, and initially it looked like the rear swung into what looked like a dado, with perhaps a dab of glue securing it. After completely removing the top runner, I saw there was a hole in the rear of the case, in the “dado section”, as well as signs a screw was driven into the rear end of the runner. The actions of the drawer must have created enough vibration to cause the rear screw to back out of the runner. Sure enough, I pulled the dresser away from the wall and there was one screw lying on the ground and it fit perfectly into the hole in the runner.
The second part of the dresser issues is the fact that they installed a plastic guide on the rear of each drawer, to fit over the runner’s “T” shape. I know not all plastic is bad, but in this type of usage, it just doesn’t seem like it matches the drawer sizing, nor the level of the dresser’s original cost. The plastic guide on the problematic top drawer, had split at some point and one side section was gone.
I can’t tell if the screw popped out of the back first, and the ability of the rear section of the runner to swing from side to side applied extra side force to break the guide, or if the guide went first. I suppose at this point it really doesn’t make much difference.
With the runner from the top drawer already out, I took it to the shop as a template for a replacement guide. I found some cherry that looked like it would potentially work nicely.
I started with a piece of cherry that was about 6″ long, marked out the guide’s overall length, and marked a centerline to align with the center of the runner. I clamped the cherry in the face vise on my bench, and set my small square so the bottom of the runner was just slightly proud of the guide. I needed the bottom of the guide to just clear the face frame when installing the drawer. So with the rear of the runner sitting on the cherry, and the top of the runner against the square, I traced around the shape of the runner.
With the necessary opening of the guide defined, I used my Lie-Nielsen Crosscut saw to saw straight down at the two narrow vertical lines, until I reached the top of the intended opening. Shifting to my Knew Concepts saw, I cut along the horizontal lines, leaving only the the narrow vertical sections uncut. I used my small 1/4″ palm chisel from Czeck Edge Tools to methodically remove the remaining wood.
I tested the fit and it was too tight widthwise, for the runner to completely enter the created opening in the guide. I used a small file to carefully remove wood, testing every so often, until the desired fit was established. All of the sharp edges were gently rounded to provide the best opportunity for the guide and runner to interact well together. Lastly I applied my Lie-Nielsen stick of paraffin to the mating surfaces of the guide and runner, and rubbed them in to help obtain the best performance.
I’ll include the installation information in one of my next blog entries. Thank you for stopping by and checking out the article. Please let me know if you have any questions, comments, or suggestions.
@LeeLairdWoodworking – Instagram
@LeeLairdWW – Twitter
I recently wrote another article for Highland Woodworking, for their Christmas idea special, and here is a link so you can check it out.
I’ve written many articles for Highland Woodworking since 2010 and you can search their Blog using my first and last name, which will locate the majority. As info, most of those articles are unique, while focusing on hand tools, and are not duplicated here on my personal blog.
More content to come here on my site soon.
Thank you for stopping by and let me know if you have any questions or comments.
@LeeLairdWoodworking – Instagram
@LeeLairdWW – Twitter