Repetition.

I was out of town for a couple of weeks recently; down in Cincinnati for Woodworking in America (peddling my wares) and then in Pennsylvania for a short visit with my family.  WIA was a blast.  I met too many good people to mention here, and had the opportunity to let other people put the new adze through its paces.  Between the adzing, turning demonstrations for the Galbert caliper, and travisher demonstrations, our booth was a mess for the entire show.
 
As much fun as I had traveling, it felt great coming home to Maine.  I stopped by my workshop as I drove into town to drop off some tools.  After I set down the boxes I stopped and felt my body completely relax for the first time in two weeks.  Home, sweet home.

Reamers in progress.

It is fair to say that for the month leading up to WIA I was basically living in the workshop.  My goal was to finally catch up with the reamer wait list and build a supply of reamers to take with me to the show.  I was also finalizing the adze design and making finished prototypes to take along, but mostly I was cranking out reamers like the little one man factory that I am.

It might sound crazy, but I love the repetition of making the reamers.  I pull ten air dried hickory rounds from the rack above my bandsaw, rough turn, drill, duplicate, turn the top, sand, finish, saw the blade slot, drill for the adjuster screw, cut the shaving reliefs, drill and install the brass tip, ream for the handle, and fit the blade.  It's not really as fast as that description made it sound, but at the end of the process I have ten reamers. I love watching them take shape.  The process is controlled, but it still takes awareness and skill to move through it without losing a few blanks.  That's what keeps it fun.

I started a new batch last week which will take me over 150 reamers so far this year.  You would think that I would have the process figured out and nailed down in every way by now, but I learn a few new things each time I make a batch.  Early on, the lathe duplicator taught me a lot about vibration.  More recently, I've been learning how to find a rhythm in the order of operations that carries me through the process a little faster.

Complete.

It's funny but my two weeks out of the shop completely throw off my rhythm.  I had to think more about everything that I was doing and I even did a couple of steps out of my normal sequence.  That gives me a couple more things to work on when I make the next batch, and that is what keeps it interesting.

Reamer Blade Sharpening

This past fall and winter Pete Galbert and I collaborated in designing a tapered reamer for making round tapered mortise and tenon joints.  It can be used for other things, but my primary use for this tool is in creating the joints used in windsor chairmaking.  Since we made the tool available my workshop has switched over from primarily a chair shop to primarily a reamer shop.  I'm very pleased with the reamers, and I continue to minutely refine both the reamers and the processes I use to make them.

I recently finished a batch of eight reamers and thought that I would share the techniques I use to sharpen the blades before I send the tools out.  The short description is that I use an angled block clamped to a granite plate with 600 grit wet/dry sandpaper adhered to it.  It is important to maintain the 6 degree flat taper along the length of the blade so that it continues to perform well in the reamer body.  The combination of the angled block and the sandpaper on granite makes maintaining these blades fast and simple.

The blades are ground to a 70 degree bevel, so I cut my angled block at 75 degrees.  This produces a five degree microbevel which takes me straight to the edge and brings up a burr in 5-10 strokes.  My granite plate is a 3" wide strip cut from a 12"x12" granite tile.  The 600 grit sandpaper is attached with spray adhesive.  The dimensions of the angled block aren't the least bit critical.  It should be as long as your stone, wide enough to clamp securely, and have an angle that produces a slight microbevel.  Nothing fancy.  Mine is a scrap of spruce lumber that I made in five minutes.

 As I slide the blade against the angled block I also apply downward pressure to the blade.  This produces a burr quickly.  Once I have a burr the clamps come off and I lay the face of the blade against the stone to polish that portion and to begin to remove the burr.  When polishing the faces of the blade I use my thumbs to apply downward pressure and I walk them up the blade making about ten back and forth motions with my thumbs in each position as they move down the blade.  It is important to keep the downward pressure from your thumbs directly above the edge you are trying to polish. 

 Polish both faces and then return to the angled block for a few more light passes.  Alternate light passes on the faces of the blade and the bevel until there is no longer evidence of a burr.  When the burr is gone insert the blade back into the reamer body and ream away.

For more information about this reamer check out Pete Galbert's blog here.