Building Some Chevalets, a Class Action #2: Making Hand Tools with Power Tools

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Blog entry by shipwright posted 07-19-2015 12:15 AM 2180 reads 0 times favorited 19 comments Add to Favorites Watch
« Part 1: Wood Gloat and a Little Glueing Part 2 of Building Some Chevalets, a Class Action series Part 3: Lots of Parts,Lots of Joinery »

I would love to have the time to work on these chevys with hand tools without the noise, dust, and sharp whirly things but I’m on a mission here and time is of the essence. In that light, this morning started out (after cleaning up the glue-ups) with dadoing the recesses in the columns to match those made in the face plates yesterday. I am pleased to say I can still count to ten without using any toes.

Next I laid out the mortises in the bases and moved on to the mortiser (sorry, no photo). In order to organize the process I first made sure that all bases were the same width and then cut the mortises with the same fence settings, first with one side and then the other against the fence. This meant that the remaining centre piece was the same width in each piece, I then set the dado for that width and cut the space between the tenons in one pass.

I finished them up with passes on all four sides cut with the column flat on the table saw.

I want these really tight because I will have to knock them down for storage (or possibly shipping). I’m hoping to be able to fit a few of the joints tight and fasten them with bolts. To that end I machined them snug and fitted with a sharp chisel.

It seems that I have accomplished the tight fits as these needed to be assembled with the assistance of my four pound pin maul. They are (right to left) a tall (23”-25”), two mediums 21 1/2”-23 1/2”, and a short (20-23”). This should allow me to fit most students up with a comfortable size.

In order to be ready to go tomorrow I then got out the parts necessary for the glue-ups of the arms, carriage posts, and carriage logs. (my terms)

...... and glued them up

I now have eight hours in them and have used four and a half ten foot 2×6’s and two ten foot 2×8’s.

They should take on chevy looking shapes tomorrow.

Thanks for looking in.


-- Paul M ..............the early bird may get the worm but it’s the second mouse that gets the cheese!

19 comments so far

View Mathew Nedeljko's profile

Mathew Nedeljko

715 posts in 4436 days

#1 posted 07-19-2015 12:37 AM

Paul you are a man on a mission… you work so fast! Looks great so far.

Have you thought about a name for your new marquetry school? CSFM perhaps?

-- Aim high. Ride easy. Trust God. Neale Donald Walsch

View a1Jim's profile


117908 posts in 4183 days

#2 posted 07-19-2015 12:38 AM

Interesting Paul I”m looking forward to the next step.


View Joe Lyddon's profile

Joe Lyddon

10864 posts in 4658 days

#3 posted 07-19-2015 01:00 AM

Paul, You’re really FLYING along!

Be Careful… Speed Kills… :)

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:

View DocSavage45's profile


8881 posts in 3448 days

#4 posted 07-19-2015 01:19 AM

Looking good Paul!

Question? Did you cut the tenons with one pass? Or is that the last cut with a full dado?

-- Cau Haus Designs, Thomas J. Tieffenbacher

View sras's profile


5288 posts in 3735 days

#5 posted 07-19-2015 01:25 AM

Wow – talk about a whirlwind blog! Fun to watch!

-- Steve - Impatience is Expensive

View SPalm's profile


5334 posts in 4488 days

#6 posted 07-19-2015 02:49 AM

Wow. This is so much fun to watch.
Good for you Paul, this is going to be quite something.


-- -- I'm no rocket surgeon

View shipwright's profile


8453 posts in 3404 days

#7 posted 07-19-2015 03:00 AM

Thanks all.

Tom, I cut the space between the tenons with the tenon jig and the measured setup. The rest I finished off with the mitre gauge, flat on the table.

-- Paul M ..............the early bird may get the worm but it’s the second mouse that gets the cheese!

View Boxguy's profile


2864 posts in 2873 days

#8 posted 07-19-2015 03:57 AM

Paul, thanks for letting us peek over your back fence and see what you are doing. Good luck on the next steps.

-- Big Al in IN

View TheFridge's profile


10859 posts in 2092 days

#9 posted 07-19-2015 04:27 AM

Thank you for buying me more shop time. Whenever the wife questions it I show her your “box”. Then I tell her i can do that one day for her (yeah right) and I need to practice. So thank you and I thoroughly enjoy your blogs and projects.

-- Shooting down the walls of heartache. Bang bang. I am. The warrior.

View stefang's profile


17039 posts in 3940 days

#10 posted 07-19-2015 12:14 PM

It looks like you are well on your way Paul. I think the foot and post and clamp was the most work of my chevalet project. The rest is smaller pieces and easier to work with even though some are a bit more complex. The fir you have looks like quite good quality. I guess you must be feeling a little like Henry Ford right now with your impressive mass production. With the varying sizes you shouldn’t have to choose your students based on their heights. Will you be teaching in Arizona, Canada or both?

-- Mike, an American living in Norway.

View Woodbridge's profile


3710 posts in 3024 days

#11 posted 07-19-2015 01:59 PM

Looks like you are making great progress. Thanks for sharing this ambitious project with us. I noticed the golf clubs in the background. All this and you still have time for a round of golf!

-- Peter, Woodbridge, Ontario

View shipwright's profile


8453 posts in 3404 days

#12 posted 07-19-2015 02:18 PM

Mike, just in Canada. I can’t work in the USA without a visa or green card. Anyway I don’t have room there.

Peter if the photos were good enough you could see a fair bit of sawust on the golf clubs. :-)

-- Paul M ..............the early bird may get the worm but it’s the second mouse that gets the cheese!

View Roger's profile


21030 posts in 3410 days

#13 posted 07-19-2015 04:17 PM

You are a busy busy man Paul. “Git-er-done”!

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

View grizzman's profile


7836 posts in 3909 days

#14 posted 07-19-2015 05:00 PM

you certianly were all reved up to make these, its a great idea, i hope there is interest and you get some students, thats the main thing here….

-- GRIZZMAN ...[''''']

View Philip's profile


1277 posts in 3145 days

#15 posted 07-19-2015 05:09 PM

Wow Paul, you are a production shop right now. I’m slowly getting a frame/shadow box done. Nice work

-- I never finish anyth

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