Carved Fans: Frame for a Dancer

Posted on October 25, 2025 by woodworksbyjohn
Inspiration and trial piece
Lay out and starting technique

Those of you who follow my work know that I’m often inspired to create a frame when I go into Diane’s studio and see a work in progress. Well, recently I saw a dancer that she was painting and immediately thought Flamenco and visualized the fans I’ve seen Flamenco dancers use. Next thing you know I’m searching the net for pictures!! Once I found a picture of the fan to use the next hurdle was figuring out how to make a pattern and transfer that to each corner of the frame. Adding to the challenge is that the frame has a 15° slant to it so using a compass wasn’t an option. The frames size allowed for a circle with a 2″ radius so the first step was to use the Pages program and print off a couple of circles of that size, that’s the gray piece in the right photo. I’m a big fan of using plastic from lettuce containers to make my templates. The paper is attached to it with spray adhesive then cut to shape. For the circular piece in the center I used a 7/14mm gouge to not only cut the template but also the wood. The outside was carefully cut out with scissors and the location of the frame miter was marked on it as well.

Line the template up with the sight edge and the miter to draw the circle (3/4 of one actually). you need a way to divide the circumference into an even number of parts. The only way I know to do this is to use dividers , if you’re not familiar with these they’re the black tool in the right picture. Set up the dividers on paper, not your wood — you’ll be doing a lot of trial and error work to do this so paper is easier to erase! As a furniture maker I use them a lot to divide a given space into equal sized parts and layout dovetails. To use them you “guesstimate” a size you think would work, adjust the dividers to that size and then “step it off” from end to the other end. The goal is for the last step off to end exactly at the end of the piece. Until it does you’ll need to make very small adjustments spreading the legs more or less until you get equal sized fan blades. Keep the dividers at that setting, you’ll need them for each corner. Note: I’ve tried to explain this the best I could but it is confusing, here is a LINK for a short article I found on the net.

Here are the tools used. After using the template to draw the outer circle and the inner circle on the wood I first used a 7/14mm gouge to outline the inner circle. Start at the sight edge and use the dividers to divide the space, I’d suggest using a pencil rather than the point of the divider as it could show in the carving. Now, use a flexible straight edge lined up with the corner of the miter to draw a line to the marks you made using the divider. See the picture, top right. This line is the high point of the fan blade.

Use dividers to find center of fan blade
Draw arrows to show direction of slope

Once your corner looks like the left hand picture it’s time to divide the fans — I strongly suggest only doing two blades at a time to save confusion. Measure and make a mark at the center on one blade. Use the dividers to mark the centers of all of them, you may need to eyeball and adjust if it doesn’t look quite right to your eye. The right hand picture shows the arrows drawn to remind me which way the slope goes. Here’s the order that worked for me and the tools I used for this project:

  • Use 1F/8mm skew to cut angled line from outside to middle line at the bottom of 2 blades, draw your arrows to indicate slope direction
  • Use 3F/6 to cut to desired depth at end of the blade. I also used a 2/10mm and 2/14mm to blend the carving into the rest of the frame
  • I used what I call my golf ball skew, it’s an old Marples skew fitted with a golf ball which lets me make curved or straight free hand cuts. Make a straight cut down the middle line from the inner circle to the end of the fan blade
  • The goal is to have a tapered cut that slopes to the middle line and down to the end. For me, the best tool was a 3/4″ very sharp bench chisel. Take very light cuts and work from both sides trying to stop your cut before hitting the other side. Definitely practice these, you can’t put the wood back!
  • You will probably need to deepen the cut at the end of the fan blade to maintain a sharp edge.
  • The grain direction changes on every cut due to the miter and to add to the challenge my profile has a 15° angle too.

I needed a lot of practice before I got what I considered acceptable results. The profile is about 3″ wide and what I call my 15° profile. I plowed a 1/4″ bead on the sight edge for a detail and also to create a definite stopping point for the fan. The tool I started with at first was a 1/16mm double bevel skew since that’s a “carving chisel”. Wasn’t happy with how it worked, difficult to create that smooth slope I was after. Then tried a 3/4″ cabinet chisel and it gave a much smoother cut. Also easier to hold and control than the fishtail skew.

Here’s one corner of the 18″ x 24″frame freshly finished with RMP finishes milk paint in Arabian Night Black. I’ve used their product on quite a few frames and like its appearance. You can mix up a small amount so there’s very little waste. To apply it they sell quality foam brushes which leave a nice finish. I usually apply 2 coats and then smooth them out with a 2500 grit nylon pad. To seal the milk paint my preference is OSMO 3043, satin. A thin coat is applied with a chip brush and then wiped dry with blue shop towels. Don’t rub it down too hard, some of the milk paint will come off and you’ll see it on the towel! After 24 hours or so, apply another light coat and since the first coat sealed the milk paint there won’t be any transfer. I’ll post a picture of the completed frame and painting on my Instagram once they’re both dry and assembled.

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Cutting Coves on Table Saw

Posted on October 10, 2025 by woodworksbyjohn
What you need
My cove cutting jig

Cutting coves seems like a job more suited to a shaper or perhaps a very large router. However; did you know your table saw is a great tool for this purpose? When building a piece of furniture you won’t find moldings to match the wood species you’re using so need to make your own. I use the same technique to create larger coved picture frame moldings — let me share it with you. As it happens all too often, an internet search will yield many methods, many of which contradict each other. My method simplifies the process, making it much easier to create coves whether it’s for a picture frame or molding for furniture.

All my jig requires is a straight, sturdy piece of material. Mine is Basswood 1″ thick x 2″ wide and 52″ long — cut-offs from frame making material. About 9″ from one end I centered a hole for a 1/4″ bolt. This is to attach a 3″x 6″ piece of wood; install a threaded insert for that. The purpose of the 3×6 piece is to let the cove cutting jig lay flat on the table; size yours to your saw, mine was a little over an inch thick. To keep it from slipping around while you clamp it down use double stick tape and apply a piece of sandpaper to it. This is the key part to simplify setting the angle for your cove. You will also need a block for the outfeed end of the jig to bridge the distance between the table top and the back rail.

Step 1:

Mark tooth where blade enters and exits
Setting angle with parallelogram

Your first step is to determine how deep your cove will be and set your blade at that height. I use a Tenryu Gold Medal 40 tooth combo blade. I’ve experimented using 8″ dado blades as well but the Tenryu works fine. For reference, these pictures are from the infeed side of the saw. Make a mark where the tooth of the blade enters and exits (I put down a piece of tape). After lowering the blade use a shop made parallelogram set for the width of your cove. Angle the parallelogram until it aligns with the marks you made on the throat plate. Draw a line on the inside as shown by the arrow. Note: a parallelogram is relatively simple to make. Make it from straight material, mine is 3/4″ square material and the pieces are 16″ and 6″ long. Set the measurement between the two long pieces and tighten the screws.

Step 2:

Adjust fence to angle and tighten down
Add the width of shoulder and move fence as required

What really simplifies this process is to using the jig I described above. Most methods have you try to place a clamp at either end of this long piece while keeping it aligned with the line you drew — no way; you’ll need another pair of hands. Align the fence to the line you drew on the inside of the parallelogram and tighten securely while putting pressure against the block to keep it tight against the table — this is where that piece of sandpaper comes in handy! My cove has a 3/8″ shoulder on one side so the fence needs to be shifted away from the blade. If you have set up blocks use them to draw that line then slide the fence to it and securely clamp it in place. You can also just make a mark.

Step 3:

Now it’s time to start the cutting. I always recommend having a short piece of stock to make trial cuts. Mark one edge of each board and make sure that all pieces are run in the same orientation each time. I put a couple of X’s on the edge facing me. For safety use a push stick and it also doesn’t hurt to have a feather board. This process creates a lot of dust so wear a dust mask. It’s safest to make very shallow cuts, 1/16″ or so. It’ll depend too on the species of wood you’re using, I’m using Basswood which is fairly easy to machine. Concentrate on having pressure above the blade to keep the board flat on the table. When you’re almost to depth take a light cut and use a slow feed to get your cove as smooth as possible.

Step: 4:

The final step is to sand your freshly cut cove! Which abrasive you need will depend on the smoothness of your cut and type of wood. For hardwoods a curved scraper might be your best choice but with the Basswood 150 and 220 grit sandpaper was all I needed. As a retired shop teacher I’ve found that old school, chalkboard erasers work the best, these are the last 2 that I have. I’d always ask other teachers for them and an untold number of students used them to sand lathe projects. You can also use round pieces of foam — whatever works!

Creating detail at sight edge
Final profile

The final steps to create this profile was to first use a Veritas skew rabbet plane to add a detail to the sight edge. This was followed by cutting the rabbet for the canvas to eventually fit into.

This is the method I use all of the time and certainly not the only way to go about it. For me, it’s relatively easy and quick for creating the occasional coves I need in my work. To do production runs of this process you may want to consider a more complex set-up. Appreciate any comments if you use this and it works out for you too.

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Wood or Plastic: What’s your Choice?

Posted on September 27, 2025 by woodworksbyjohn
Plastic molded tray (probably imported!) or hand made Steamed Beech?

I’m sure I’m not the only woodworker who enjoys creating something that’s relatively simple and challenging that will serve a purpose. I love the challenge of making furniture and picture frames but this had some techniques not usually used and would be useful — enter the bathroom drawer tray! I have some leftover Beech which was resawn from furniture projects that required 8/4 material, the pieces were approximately 3/8″ and 3/16″ thick.

The first step was making the tray, it measures about 1 1/2″ x 7″ x 12″ and is 3/8″ thick. Hand cut, dovetailed construction and the bottom was rabbeted for a 1/4″ plywood bottom which was glued into place. No pictures on that but same process I always use. To house the lapped dividers the first step is making mitered pieces that fit snugly; these will eventually be slotted for the dividers. Begin by cutting them on the miter saw but slightly over-sized. They are fine tuned for a snug fit with my Donkey Ear miter jig. If you’ve never seen or used one of these I really like it. Unlike a typical miter shooting board this allows you to hold the piece on either edge so that should there be any tearout you can plan for it to be on the bottom. Some time ago I posted a blog about it — here’s a link to that post.

After those mitered pieces fit snugly on the inside of the tray it’s time to cut the slots and ends so the dividers slot together. To figure out how to space them I made a full size drawing and laid the items out on the drawing and took the measurements from that. This picture shows the tools I used. First off was a Japanese Dozuki saw that has an adjustable depth. I used that during my Kumiko building phase — much cleaner. accurate, and quieter than a tablesaw! The depth gauge was set to the thickness of the wood which is slightly less than 3/16″. The 1/8″ chisel was used to remove the waste. A line was first drawn to locate the divider. Next, a scrap of the divider material was lined up to the line with a small square so the other side could be penciled in. Those lines were cut to the depth set on the Dozuki saw and the waste was chiseled out, any needed fine tuning was done with chisels.

Holding and cutting these thin and small pieces isn’t easy. I took a scrap piece of wood and cut in a notch. The notch is slightly deeper than the needed depth and is wide enough so the the depth stop has room. It was clamped between bench dogs and the pieces are held firmly while sawing. As you can see, adjoining divider members are taped together to be as accurate as possible. After all the pieces were cut and dry fit they were lightly sanded and given a coat of Osmo #3043.

There’s a number of parts and they need to be assembled in a specific order. I don’t use glue, if your mitered perimeter pieces are tight it’ll hold together without any problem. To start place #1 in first and lock it into position with #2. Next, slide the short divider #3 into #2 and lock them in place with #4. The #5 piece locks across #1 and now the mitered piece #6 locks everything into place. Follow this with #7 and finally #8 is what could be called the Keystone which locks the entire assembly into the tray. When you put in numbers 6,7, and 8 you’ll find you need to push them into the tray evenly. This is where getting a good tight fit with the miters is important.

That’s about it, fun project to make and helps to maintain my hand tool skills. Used the table saw and planer to rip to width and surface to thickness. I aways use hand planes to remove planer chatter marks. The miters began with a miter saw but were fine tuned with the Donkey Ear shooting board.

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Two Frames: #270 & #271

Posted on September 3, 2025 by woodworksbyjohn

Things have been somewhat disorganized in the shop lately! I needed to replicate a previous frame (#256) to send to Diane’s gallery in Carmel to replace a painting sold there, somewhat confusing but it involved a commission Diane received through the gallery so a frame was needed. Diane sent the commissioned painting separately since making the frame required time, it was shipped last week. We are also getting ready to send 9 paintings to her Charleston, SC gallery so I’m busy with the packing of those. In the meantime these are the two frames recently completed.

Frame # 271

This frame is for a 24″ square, stretched canvas for another painting by Diane. The frame is of Basswood and about 3″ wide. I wanted to carve some type of floral design in the corners so searched the internet for it and this is what I came up with. My process is to screen grab and then use the pages program to size the design to fit the frame. The next step is to glue the pattern onto a piece of plastic; salad containers work great! They are flexible and can be flipped over to duplicate the opposite corners.

It may seem like more work than what is needed but for consistency I make a cutting diagram and annotate the exact chisel/gouge used to cut out the design. It helps me to make a left and right side since the design will be flipped and for me it’s real easy to get confused. At the bench I have the pattern clipped to the tool holder, after doing 3 or 4 of them I start to remember which tool to use but at 75 I like having that pattern to keep on track. For me, using specific tools for each curve helps to keep the design consistent. These pictures below show some of the progress, my goal was to have a consistent flow of the design on all sides. This frame started with what I refer to as my 15° profile and has 1/4″ beads that border the carving.

Plow plane for 1/4″ beads
Beginning carve, small tools needed to remove waste
Progress being made

After the basic design had been carved all around the frame it was time to detail it. You can see the original drawing I found was quite detailed with lots of flourishes. Diane’s work is more contemporary so that wouldn’t be appropriate. My take is more modern and “flat”. The finish is Real Milk Paint’s Blue Spruce, top coated with OSMO #3043 satin finish. The picture shows how the top coat really enhances the color and also seals the milk paint. I experimented with the social media “stuff” and created this instagram Reel to show off this frame — Enjoy! You may be prompted to sign in to an Instagram account but if you X out that box the reel should open.

Frame #270

This profile is for a 1/4″ panel so it can be made from material that is 1″+ thick. The width could be whatever you want but I generally stay about 3″ wide. The first step is to cut a 1/4″ bead on the outside edge which, cut #3. You could use a router but I prefer my Veritas small plow plane with a 1/4″ beading bit. Once that’s done use a 1/2″ dado head to make cuts #2. The depth is roughly 5/16″ and the technique is to leave an area wide enough to support the board when using the dado, it will be removed by setting the board on edge against the fence and creating the recess on the face; cut #1. The final table saw work required is cutting the rabbet. Please note: when creating a profile I always cut one or two test pieces about 12″ long for doing the setups. Lay out both ends of the test piece. After each cut is correct I orient the frame pieces the same way and cut them all before going on to the next setup.

Once the profile is cut it needs to be mitered and joined. I use biscuits and allow glue to fully dry overnight. I used a 8/6 mm gouge to form the peas and the tools shown are needed to lay them out evenly on all sides. I did go into quite a bit more detail in my about initially making this frame. Here is a LINK to that one. The finish for this frame is identical to the original #256; composition gold with my Iced Gold finish.

Hope this blog helps any of you who are discovering new ways to make custom, closed corner frames. When I first started writing these many years ago it came about because of the frustration I had then trying to find information about how to do this “stuff”. Appreciate those of you that read this and the occasional comments and question you ask.

Keep making Sawdust (and chips!) — John

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Have you missed me? I’m Back!

Posted on August 16, 2025 by woodworksbyjohn

Due to some technological mishaps my blog has been “incognito” for the last 3-4 weeks! I didn’t realize it until a couple of my followers told me about it. The problem was with my domain registry but happy to say it’s been resolved — I do have a love/hate relationship with technology for sure!

What you may have missed is the latest project which was my Danish inspired love seat, here’s the link for the first blog about it: https://woodworksbyjohn.com/2025/06/07/danish-inspired-loveseat/

….. and here’s the link showing the completed project : https://woodworksbyjohn.com/2025/06/28/danish-loveseat-finished/

Hope these come through for you; if you feel so inclined I would appreciate a quick note to confirm the the technical issues have been resolved, thanks — John

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Danish Loveseat Finished

Posted on June 28, 2025 by woodworksbyjohn

Here we have the results of my latest challenge; the loveseat is in the room! It’s been over a month of work to meet this challenge but well worth it. The entrance to this room is such that it wasn’t possible to get a piece of furniture like this into it. This piece is about 50″ long and a total of 34″ tall and 30″ deep. One aspect of this challenge was to use barrel connectors and threaded brass inserts so that the piece could be assembled in the room. I covered that process in my first blog. Six pieces in all; 2 leg and armrest, 2 stretchers, the seat, and the back. A common question is always how much money and how much time! For the 8/4 Birch (30 bf), hardware, and seat webbing I spent about $375.00. The foam and material came to roughly $400.00 which includes the work done by a local shop since Diane’s sewing machine couldn’t handle the thickness of the material.

The Birch was resawn so I have quite a bit of it left over which yielded 3/8″ and 1/2″ material which will probably be used for future drawers or boxes. The side pieces and armrests were selected for their grain and coloration. The finish is Osmo 3043 which I apply with Mirka Mirlon abrasive pads. A glass like finish was achieved with two coats using the 1500 and 2500 grit pads. This is the fourth blog on this piece so if you’d like to see more about it check those out as well. This slide show illustrates the process, as always; if you have a question or comment feel free to reach out to me, thanks — John

  • Barrel connectors for stretchers
  • Bolt into brass inserts for seat which is supported by stretchers
  • Bolts on inside of back to leg assembly
  • Assembled without upholstery
  • Right side view
  • Left side view
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Danish Loveseat: Part 3

Posted on June 23, 2025 by woodworksbyjohn

Backrest and Seat

In my last post the parts and pieces were completed for the seat frame and the backrest. Since that time the slats were finished (Osmo 3043 using Mirlon abrasive pads). The top and bottom rails were finished as well but their tenons were taped off. The final step was to form the sides of the backrest with spokeshaves then glue the entire piece together and finish it completely. Before assembling that though the through mortise and tenons for the arm rests had to be fitted.

  • Trial fit for armrests
  • Backrest pieces prefinished
  • Backrest glued up — 6′ Jorgensen clamps

The process for making the seat assembly was similar. It consists of two end pieces which are supported by the stretchers between the two legs. The front rail is attached with a haunched mortise and tenon joint and the back and center support use mortise and tenons as well. To accommodate the webbing from House2Home, a 1/8 slot is routed for the clips. Kind of tricky, it’s best to remove about 1/8 of material so the webbing lays flat. This was done on the tablesaw with a rip blade which requires dropping the wood onto the blade and then lifting it off — care required on this operation. The recess is then squared off before I assembled and finished the entire seat.

  • Haunched tenon on front rail
  • Material removed for webbing, rip blade
  • Squared off and chiseled smooth
  • Glued and clamped
  • Finished with 2″ webbing installed

Armrest to Leg Assembly

While designing this piece I looked at so many Danish Modern pieces on Pinterest it made my head spin! I wanted something graceful and not just a machined, routed piece. I had set aside a piece that had some interesting grain for the armrests so that determined how wide they could be. Even though they’re about 4′ apart it’s important to me that the grain matches. The bottom has a simple, long chamfer while the top has a slight radius. Sculpting began with my old Stanley 151 and finished up with a Bogg’s style Lie-Nielsen . The antique Stanley removes material quickly without clogging while the L-N does a beautiful job of finishing. After drawing in the “limit” lines of the bottom chamfer work began with the spokeshave, shaving to the lines. Once the cut was close a sliding bevel was set to make the chamfer uniform on the edges and the ends formed to match.

Beginning of end
Checking chamfer angle

The armrests are attached with wedged, through mortise and tenon joints. The method that Mike Pekovich from Fine Woodworking Magazine uses is what I prefer too. Here’s a LINK to it but you may need to be a Fine Woodworking member. He utilizes a spacer to get the width just right, this way you only need to set your marking gauge one time. Only variation I did was to use a 3/8″ drill on the drill press to remove the bulk of the material. He uses a smaller bit and makes more holes; either way works. I could do this because my tenon is 7/16″ wide. I also used this method on the Japanese toolboxes for laying out both the mortise and the tenon. I’ve been presenting my work in a slide show format to simplify the blog — let me know if I succeeded!

  • Lay out on tape using spacer
  • Drill press to remove bulk
  • Chisel work to scribed lines
  • 2° angle for outer walls
  • 4° wedges
  • Kerfs and relief holes
  • Assembled armrest to legs

At this point this project is almost ready for final assembly. The last thing that needs to be done is to apply the Osmo to the leg and armrest assemblies. We get our foam at Galaxy Foam and Upholstery Supply here in Las Vegas. They have foams of all densities and wrap batting around it which makes for a better cushion. Also bought the material there and unfortunately it’s too thick for Diane’s machine so they are currently being sewn at Oscars Upholstery. I’ll do a final blog on this when the cushions are done and the love seat is ready. I’ve been told my blogs can get long winded but appreciate any comments or questions you may have, thanks — John

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Danish Loveseat: Part 2

Posted on June 9, 2025 by woodworksbyjohn

Now that the knockdown fittings are in place I’ll turn my attention to the seat and back assemblies. The seat assembly is made of 1″ x 2 5/8″ pieces of Birch and joined with mortise and tenons. The seat is 46″ wide so a brace was added at the center, it’s lowered so the webbing will lay across it. Webbing is installed with clips (from House2Home) and I learned that the “professional” way to do this is to remove a 1/8″ area so the clips and webbing lay flat in the frame. You can see better pictures of it in this my previous blog. It’s now ready to go and the next step on it will be to radius the edges, finish sand, and then rub in at least 2 coats of Osmo 3043. After that the webbing will be installed.

  • Rip blade in tablesaw to create 1/8″ recess for webbing
  • Groove for clips and initial chiseling
  • Chiseling complete and sanded
  • Haunched tenon for front rail
  • Seat platform glued up

The seat back was built next. At this point the uprights for this are straight so that I have a reference point for the mortises. Once it’s complete they will be tapered and I plan to do some spokeshave work to sculpt them. The slats are 5/8″ x 1 1/2″ wide and will fit between the top and bottom pieces in 1/4″ x 3/4″ mortises. Figuring the spacing was first done on masking tape using dividers and a 1 1/2″ shim; took some time but much easier than trying to do the math required. One important consideration was that I needed at least 2″ of space at the ends to install the connecting hardware. There are 13 slats so that meant 26 mortises and 26 tenons — hollow chisel mortiser and dado head on the tablesaw made this go much quicker. For these, the slats won’t be glued in; matter of fact I think it’s better that there is some allowance so they can move freely with seasonal changes in humidity.

  • Mortising top and bottom rails
  • 3/8″ dado set up for tenons
  • Double checking slat length
  • Dialing in thickness with rabbet block plane
  • Scribing width and cutting
  • Removing waste
  • Squaring shoulders and easing end of tenon
  • Roundover bit to radius all edges

It’s been a hot summer so far in the desert so finishing is probably best done in the morning, by early afternoon it’s been as high as 104° in the shop! The Osmo should be fine at those temps but the Old Brown Glue I like to use may set up before I can get it clamped. Pre-finishing all of the slats makes sense, it’s always a hassle trying to dry the finish around all of those. I’ll tape off the tenons and wait to apply the finish to the sides of the backrest until it’s been assembled. It’s taken quite a bit of time to make all of these parts from 8/4 Birch but I’m sure it’ll be worth it when done.

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Danish Inspired Loveseat

Posted on June 7, 2025 by woodworksbyjohn

I’m not so sure I like the term “loveseat” but that seems to be the proper name for a small couch/sofa built for two people so that’s what I’ll go with! If you’re a follower of my work you may recall my interpration of the famous Z-chair which I completed a year of so ago. Well, now it’s on to another project for the front bedroom of our home. The room currently has a queen size bed but is rarely used by overnight guests. We’ve decided to make that room a more useable space for us and use a blowup bed on those occasions where it may be needed. Making this smaller loveseat will leave plenty of room for that and allow us to use that room as part of the house. One problem with this room is the way the door opens and the configuration of the walls makes it impossible to get large furniture in the room. That means I get to challenge myself to use knockdown joints with threaded inserts, cross dowel nuts, and through bolts — hey, I love a challenge!

The only real furnishing in this room is the Birch cabinet I made previously. I decided to make this loveseat from Birch as well and who knows, maybe a table is in the future too. As the picture shows, I prefer to draw my plans out full size once the design has been worked out; and then cut pieces of Masonite to give me a true representation of the piece. There will be 6 pieces; the seat, right and left sides, front and rear stretchers, and the back. I plan to use brass inserts and black 1/4×20 hardware to assemble it.

After creating my cut list I purchased about 31 board feet of 8/4 Birch from Peterman Lumber here in Las Vegas. Since you have to buy whatever boards they have it’s challenging to get the right amount. The boards I bought were all 7″ or so in width and 8′ long. After cutting pieces to rough size I planed a working edge on them so they could be ripped and resawn as needed. The side frames are 1 1/8″ thick while the seat assembly and back are 1″ in thickness.

Resawing after establishing a working edge
Smooth plane after running through power planer

The stretcher between the legs has a single tenon at the front and a double at the rear. The stretcher was kept square so it lines up on the sliding arm and then tapered after the tenons were cut. The mortises are 3/8″ x 1 1/4″ deep and 90° to the leg. The tenons are angled at 15° and were cut using a flat top rip blade and my Sawstop sliding table. It was easy to set the opposite angle by adjusting the arm to the end of the board while keeping the fence set at the same location — much easier than using a wedge.

At this point, my main goal is to get the leg assemblies put together so they can be used to locate where the threaded brass inserts need to be installed the relationship of all of the pieces. The front and rear stretchers attach to the leg sections with connector bolts and cross dowel nuts — this was a challenge to drill a straight 1/4″ hole about three inches long! To add to the challenge the tops are angled to allow the seat to sit lower in the rear than in the front. The seat and back sections use threaded brass inserts and connector bolts and that too was a process. Started with 1/16″ pilot holes on the drill press to insure they are straight and then the loveseat was reassembled to line everything up. More complicated than I can write up so these pictures will help — if you want more details feel free to contact me.

  • Pilot hole from drill press in back rest, located on frame
  • Transferred to frame, ready for insert on drill press hole
  • 3/8″ hole for threaded insert, seat rail
  • Insert hole at top, pilot hole for connector bolt
  • Hand pressure only, hex driver for insert

To summarize the slide show basically the first hole drilled is 1/16″ and done on the drill press to get it as straight as possible. Then the parts were clamped in position so that I could use a hand drill through that hole to mark the location on the adjoining piece. Threaded insert holes were 3/8″ and connector holes were 1/4″ it all worked! In this picture you’re looking at the inside of the loveseat. Number 1 are the tenons for the eventual armrests; Number 2 is the seat frame, and Number 3 is the backrest. The piece of masonite represents the foam for the seat.

This is what the piece looks like at this point. No rush on this project, just taking my time and trying to avoid making mistakes which is easy to do — I’ll do separate blogs as work progresses.

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Crazy Challenge: Hexagon Box with Hinged Lid!

Posted on May 16, 2025 by woodworksbyjohn

Beginnings — it started out easy enough but that soon changed! I decided to see if I could construct a hexagon box that had a hinged lid. Why, just because I’d never done it or see it done! I wanted a better place to keep my Lie-Nielsen spokeshave than the cardboard box it came in. Since I had some Poplar in my shop decided to use that. Started by cutting 6 pieces at 30° and assembled them using packing tape, even book matched them– easy ’nuff!!

Now that I had a hexagon cylinder it needed the end pieces. Used a scrap of MDF to play with the sizing to match the outside of the hexagon. Once the miter saw was set with a stop block and the MDF fit well I cut the Poplar. The blade angel is 30°.

First cuts
Second cuts

I’m a tails first dovetailer and this took a bit of thinking and planning ahead. The first step was scribing the thickness of the box on both sides of the end pieces. The tails are at the and marked off with a pencil. Removal of the waste began by first deepening the scribed marks with a chisel. After cutting closely to the line those deeper lines made it easier to chop the shoulders square. Transferring to the hexagon began by scribing the thickness of the end pieces all around, both inside and outside of the hexagon. Then the end piece was positioned and the tails were transferred to the hexagon. Not much room to move a dovetail saw but that was the easier part. The waste can only be removed from the outside of the hexagon so I got creative in how to hold the hexagon. At this point, I think a slideshow will illustrate better than anything I write!

  • Tails laid out, scribing shoulders
  • Making scribe lines deeper made final chisel work easier
  • Fitting and scribing onto hexagon
  • Awkward position but able to chisel waste out
  • Used body weight to hold hexagon on scrap and chiseled out waste
  • Almost ready to glue

Once the box was glued up, I separated the lid on the bandsaw, I correctly assumed that cutting it would change the size so the lid was a bit smaller than the box. Another unforeseen problem is the the screws for the hinges were too long since they sit on a 30° angel — cut them shorter so there’s not a lot of purchase with them. I had a small piece of curly Spanish Cedar so used that for a lid lift and also the French fit insert to hold the spokeshave. Sorry, didn’t take any pictures of that process but it’s secured inside of the hexagon with silicone seal. The hinges and the lid lift are mortised in, quite different cutting a mortise on an angled piece of wood!

  • Cutting off the lid lift
  • Stanley #271 scribes depth of mortise
  • Mortise laid out
  • Progress on mortise
  • Mortise done!

All things considered, this was an interesting challenge and glad I took it on. I enjoy these types of projects, let me know if you too decide to try making one of these. Here’s a short video I posted to YouTube of the finished project, enjoy — John.

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