I buy what I would call “used” lumber (even though it may not have been actually used) on a somewhat regular basis. Most of my purchases have come from barn finds because I like to buy in larger quantities and lots of barns are sitting out there with big stacks of lumber in them. I make sure to only purchase if the price is right because I have learned the hard way that the lumber is never as good as everyone thinks it is or wants it to be. And, there are many reasons for this:
- Not cut from high-grade logs: The lumber is cut from whatever logs were available at the time. There may have been some high-grade logs (from the bottom of the tree) in the mix, but there were definitely also low-grade logs (from higher up in the tree). This means the lumber will have more knots and other defects. In the hardwood industry, logs are sorted by grade. Low-grade logs are milled to make low-grade products, like railroad ties and pallets. They aren’t even milled at grade sawmills.
- Wood is more precious to the owner: Wood that should be trimmed off was kept simply because they weren’t ready to let it go and it didn’t hurt anything to keep it.
- People involved in the lumber production are not professionally trained: Usually the owner of the logs and the sawyer they employeed do not know enough about sawmilling to produce the highest quality lumber. Many sawmill owners do not understand how to cut for grade lumber, and even if they do, they are often given direction from the log owner to maximize yield and not grade. Beyond that, cutting for grade involves flipping the log in the sawmill many times, requiring more work and more time, so those steps are often skipped.
- Lumber hidden in a stack is always lower grade than everyone remembers: After the lumber is cut and tucked into a stack, it looks higher grade. It’s too easy to forget about defects and only remember the perfect boards.
- Lumber is cut thin and inconsistent: Often (almost always) barn find lumber is cut a little thin and inconsistent. People ask for 1″ thick lumber and the sawyer delivers, even though commercially produced 1″ thick (4/4) lumber is cut at 1-1/16″ to 1-1/8″ thick. Lumber rough cut right at 1″ thick often doesn’t dry, joint flat and plane entirely to 3/4″ or more in thickness. As well as being cut thin, the lumber is usually cut inconsistently – a result of inexperienced sawyers, poor-performing equipment and no real need to worry about consistency of cutting. It’s not easy (and more work) to make sure all of the lumber coming off of a sawmill is the same thickness from end to end of each and every board.
- Best boards already used: This one is self-explanatory and obvious. You would use the best boards first too. It just makes sense that the lumber which remains may not be the best boards out of a log.
All of these reasons explain why the lumber won’t be as good as you would hope, but it is also helpful to see examples of what makes lower grade lumber. Click on the video link to see a recent batch of walnut I purchased and what I found in the stack. And, remember when purchasing used lumber, just don’t pay too much.
About two years ago we started using Festool Domino connectors in the shop because we were working on a trade show display which needed to pack flat for shipping. The metal connectors are made specifically for this occasion, and if you have ever put together a piece of breakdown furniture (think Ikea), you have probably used something similar.
The connectors work great, fit into a normal Domino slot and are easy to use, but since they do require an access hole to tighten the lockscrew, they can’t be used everywhere. And, just like a Kreg screw connection, there will be never-ending discussions about whether or not this is “real woodworking”. Regardless of how real they are, the connectors have found a place in our shop and recently we found another great use for them.
Jeff, our building and finishing extraordinaire (he can do it all), was working on a desk which came together at some funky angles and decided to try the Domino connectors for alignment and clamping, and it worked great. The corner joint, which he glued together, lined up perfectly and pulled together tightly. Previously, we used other variations of under counter hardware an/or wacky clamping setups to pull the joint together and they always seemed a bit amateurish, like we were just making it up as we went, and often we were. But, not now.
Now, we are using the Festool Domino connectors not only for pieces which need to breakdown, but also for connecting and clamping those hard-to-clamp joints. And, just recently, we built a big walnut bar which required both, in the same piece. We had several joints which needed to clamp together permanently, and since the bar was very big and U-shaped, it needed to come apart in the corner to be assembled on site. The Domino connectors worked perfectly in this case, and I am sure you will be seeing more of them in the future.
Click on the video below to see how the project came together and how the connectors made it all possible.
Recently, I got a call about a walnut tree which fell in a storm. The homeowner knew it was a walnut and gave me a call to see about doing something with it, hoping to sell it. I get these calls regularly, especially for walnuts, and I always follow up so I don’t miss the good ones.
Even though most of the calls are about walnuts, most of the walnuts aren’t much to talk about. I’ll ask questions about the diameter, where they and their tree live and why they took it down, and though these questions will get answered, the overwhelming theme is, “It’s a walnut”.
Well, just because it is a walnut doesn’t mean it is a good walnut. I have received plenty of calls where I never bothered to pick up the tree because I could tell that the tree wasn’t great and the owner was way too attached, and often, they want me to take down the tree.
I only pay for a few trees a year. I don’t really mill that many logs overall, and they are readily available just for the asking, so there isn’t much incentive for me to spend money on them (really, almost all of the logs I get are free). But, this one was different. It met all of my criteria for a tree to both spend the time and effort to retrieve it and to also pay the homeowner.
So, what makes a tree stand out from the rest and why is this one worth paying for?
First off, yes, it is walnut. You now have my attention. Species does matter and walnut is at the top of the food chain for our local trees here in the St. Louis area. For example, walnut currently sells for $12 bf. while other hardwoods like hard maple, white oak and cherry are in the $4-$7 bf. range. But that doesn’t make it a good tree, that just makes it worth a good close look.
Diameter is currently the biggest driver for me deciding how bad I need a log. The bigger the diameter, the more options there are and the more wood overall. I draw the line at 24″ in diameter on the skinny end of the log, inside the bark. Any smaller than that is a tree which I can easily find and usually procure without spending money. Though smaller logs do still have value, they don’t have enough value and I will not pay for a log under this size. The 24″ size gives me the option to make bookmatched dining room tables (usually 42″ wide) out of only two pieces. If we end up going to a three-piece table top, I only really need an 18″ diameter log and those are widely available at no cost. This walnut was over 24″ in diameter at 30′ from the ground, so it was the perfect size for what we do. Length isn’t usually a problem, but I do sometimes get calls about big diameter trees with very short trunks which branch off close to the ground. The longer the main trunk the better and this tree had a super long trunk.
Location is the second thing I ask about when discussing a tree because it affects so many aspects of the growth and my ability to process it. First off, the location affects the way the tree grows overall. A tree which grew in the open is usually short, wide and branchy. This one obviously, started its life with trees around it and reached up, producing a nice long trunk. I am cutting this tree into slabs, but it would also produce very nice, straight-grained, knot-free lumber.
Location also affects what is in the tree, specifically metal like nails, screws, hooks, chains and wire. Trees which grew in a bad neighborhood, in a small yard usually have a tough life and are full of problem-causing metal. This walnut spent its life in a nice, big front yard in a happy neighborhood on a street which I know has produced a lot of nice trees and shows no signs of metal.
Location also affects how easy it is to access. I get a lot of calls about trees at the bottom of a hill in a back yard with a little gate and no way to get to the log. This tree was in the level front yard right next to the driveway with nothing around it. Access couldn’t be easier.
Overall health of the tree and quality of the logs is the last thing I look at. In this tree I looked for scarring from lightning strikes, busted branches, possible hollow spots and rot. The roots showed a little bit of decay, which could have led to some hollowness in the bottom of the tree, but it was minimal and ended up not affecting the logs. There were some busted branches from the fall, but all of the main pieces showed no signs of breakage. It was entirely solid and sound. On walnuts, the speed of growth also affects how wide the sapwood (white outer layer of wood) is on the log. If it grows very slow, the sapwood may only be 1/4″ wide, while on super-fast-growing trees in a wet, wide open yard might have sapwood which is over 3″ wide. I’m looking for a good balance for live edge tabletops with the sapwood about 1″ to 1-1/2″ wide, and again, this tree was perfect.
Everything about this tree was as I would have specified and the fact that it was already down and most of the top cleaned up made my assessment easy. It was nice to be able to get a look at the cut branches at the top and the busted roots at the bottom to get an idea of the quality of the inside. I could have only had a better look at the inside of the log if it was cut to length, but I told the homeowner that I wanted to decide where to cut it and do that myself. Besides getting my chainsaw stuck and my crane giving up at the end, this experience and this tree was as good as it gets in my business.
After 10 years in St. Charles, MO we are moving a bit west to 821 Midpoint in O’fallon, MO. We started moving in earnest last week, and this past weekend I officially pulled the plug on the tools in the old shop. There is no turning back now! The new building is a 12 minute drive west of the old location on Highway 70. It is a nice stand-alone building which can easily be found by just Googling the address. No need to aimlessly wander around a giant building trying to find the wood shop buried in the back corner. We don’t have a sign yet at the new location (of course), but you won’t need it.
This Saturday will start our conversion to the new shop. By then, all of the wood and most of the slabs will be at the new location. So, if you are planning to visit on Saturday morning (open 8-12), please report to the new shop. From then on, 821 Midpoint will be our official location.
To kick it off, I put together an announcement video so you can see the outside of the shop (that was the day I got the keys) and our first moving video. Click on the video below to check out the progress.
Years ago, I posted a video of me installing a mantel which was shot by my daughter Mira, who was nine years old at the time. The video did a fine job of covering how to install a mantel and has gotten a lot of views through the years, but it has also been heckled quite a bit. Most of the criticisms (which I have since deleted) revolved around the lack of a tripod and the poor videographer.
I was attempting to get my daughter involved in the business even though she had no interest in woodworking, so I thought shooting video with the big camera might do the trick. Though the video is indeed shaky, we had a fun time doing it and it has served its purpose, allowing customers to have a reference to watch so they can see for themselves how to install a mantel.
Ever since the negative comments started rolling in, I have wanted to reshoot a mantel install video and now I have finally done it. This time, I used a tripod and Mira wasn’t involved, so if anyone has a problem with the video, they probably just have a problem with me.
This install video is specific to the piece of spalted sycamore I used and the fireplace it went on, but all of the techniques are the same ones I use on most mantel installs. If you are installing a mantel and have any specific questions on how to do it, feel free to ask. I will respond and add it to my next mantel video. In the meantime, check out the video below to see how I do it and the small changes I’ve made through the years.
It’s official. I’m going to end up with three installments about quartersawing. In an effort to not bore everyone to death in this video, I had to keep out all the important details, like why are we even bothering to do all of this extra work? There are a couple short answers (it’s pretty, it’s more stable) but since I like to give long answers, I’m going to need more time.
My focus for the last video was to show how I deal with oversized logs and this week I show how to actually quartersaw. I think it will help a lot for everyone to see, in a video, how riftsawn and quartersawn lumber are produced from the quartersawing process and see how I tackle the task.
Quartersawing a log takes much more time because each log essentially produces four individual logs (quarters) and each one needs to be processed separately. Throughout the process, lots of decisions need to be made to produce the most and best lumber.
Click on the video link below to see how the quartersawn lumber is cut and to see some really pretty boards.
I spend a lot of time talking about quartersawn lumber with customers and have always wanted to get my thoughts about it into one place. Turns out, it is probably going to be in at least two places when I get done covering it. There is just too much to know and the more I try to explain it, the deeper in the weeds I get, and staying out of the weeds is not my forte.
Since I have spent over twenty years discussing it with customers, studying it on my own and generally just worrying about if I am producing the best quarter sawn lumber as efficiently as possible, I have come up with a lot of talking points. Luckily, for you, I am not going to get too deep into it until the second installment, when I finish producing the quarter sawn lumber.
In this first video, I was most excited to show how I get a log which won’t fit on the sawmill prepared for quartersawing and to get a chance to use my chainsaw (which I do whenever I can). Click the link below to see how I get the large logs ready to be milled.
I just finished installing a barn door to cap off a bar area of a basement remodel. During its construction everyone visiting the shop talked about how pretty it was, and I agree. It’s weird because I didn’t imagine I would like it so much or get so wrapped up in terms like “pretty”, especially since I prefer to use the word “cute”.
Originally, we thought we might add some color to the individual boards, like maybe some washes of blue to go with the cabinets, but it turned out to be unnecessary. We wrangled up some wood in the shop from several different barns, and all of them stood on their own with no paint necessary. They were different enough that Tom, who built the door, even named them to keep them separated. The most textured gray pieces, which were sycamore, he called “dragon skin” and the smoother brown ones he named “Douggie Fir”. I think getting to know the wood really helped Tom pass the time at the chop saw.
The door is extra wide and turned out to be quite heavy, with two layers of hardwoods and a core of 1/2″ thick MDF, which required the wall hardware to be custom made and beefed up a bit. I got to visit one of my favorite places, Shapiro Metal Supply, to get the material and browse for a bit. The video below was shot just days before their recent fire.
While I did need extra muscle to get the door in the house (luckily they had a walkout basement), I was able to hang the door on my own. Click on the video below to see how it came together and see just how “pretty” it is.
In a couple of my latest videos I showed a little snippet of filling voids with a hot glue gun. And, while I was quick to gloss over it, many viewers asked what in the heck I was doing with a hot glue gun on the fancy wood. The short answer is filling voids, mostly from knots, but also from cracks and any other imperfections which show up naturally while processing solid wood.
We started using the system (we purchased it from Rangate) about a year ago, and it has won us over in the shop for its speed, while producing great results. It has been taking over for epoxy in more and more situations as we gain more confidence in its ability to perform.
The knot filler sticks are basically hot glue sticks and we call them hot glue sticks. However, they are definitely different. I can tell you from experience that actual hot glue sticks aren’t sandable like the knot filler sticks made to fill wood. I attribute it to a lower melting temperature of the hot glue sticks, which almost immediately gum up sandpaper and just get pushed around on the surface like old chewing gum. YOU HAVE TO USE KNOT FILLER STICKS.
We have been using the sticks purchased from Knottec because they are more reasonably priced than the options from Rangate and seem to work equally well. Overall, I feel like the Rangate system is overpriced based on the fact that in the end it is really just a 300 watt hot glue gun and a couple of simple accessories, which are available for much less money than we paid.
The knot filler sticks are available in several different colors, but we mostly use black. It seems to look the best in almost all occasions. Only on white woods, like maple, do we deviate from the black, but there are many times even in those white woods, where the black looks great. If you only get one color, get black.
Overall, using the hot glue gun is super simple. Just squirt some in the defect, squish it in with an aluminum block (which also quickly cools the glue), and then cut off the extra. Click the video below to see just how quick and easy it is.
Well, I finally did it. After endless comments from customers about not being able to find the shop and a recent encounter with a customer that went quite poorly due to the lack of signage, I broke down and decided to make some directional signs for the shop. We have a sign on our door, but it is hidden from the street and doesn’t really do much except to confirm that you are indeed in the right place just before you actually enter the shop. Everyone finds the building without a problem, but we need to help them find the door.
First, let me address why this took so long. All of our work has always been word of mouth. I built the business slowly, starting by working from my home shop, so I never really needed a sign. I usually visited customers at their house and very few visited the shop. As the business has grown, more customers find us on their own, and I would rather them not be mad at me before they get to the shop (or don’t get to the shop as the case may be).
In St. Charles, any directional signs 2 square feet and under, do not require a sign permit, so I am making that the size limit for my signs. Hopefully, that way I can put up the signs at multiple entrances without causing any problems.
I decided to use the cnc router to make the signs and mix in a little artwork in the design and construction, which is the perfect mix for me. Plus, I used some salvaged wood for the project, which makes me feel even that much better about it. The boards came from a set of bleachers I salvaged from an old gym. Most of them were straight-grained Douglas fir with a clear coat on them. Those boards were super nice and didn’t stay around the shop long. The boards I used for the signs were some replacement boards made from southern yellow pine, which were painted and were never going to be purchased in the shop, so they were the perfect pick for this job.
I still have a few signs to finish up, but click the link below to see how the first one was made: