Cauls - Extremely Average

Browsing Posts tagged Cauls

Creating the Cauls

February 9, 2010 Brian Meeks 4 comments

In Vol 28, No. 164, on page 6 of Woodsmith magazine is the article which describes the Adjustable Panels Cauls. It was sent in by George Johnson of Canton Oklahoma. They give the dimensions and I followed them somewhat closely. I visited my local Home Depot to buy the goodies I would need to make my cauls. I purchased (4) seven feet long, 1 x 2, in hard maple. I like hard maple. I also purchased (4) 36 inches long ½ x 3 inch pieces of Oak. I only needed one piece of the oak, but I wanted the other pieces for another project. So only buy 1 if you don’t want extra, and to be honest, I didn’t use the entire one piece either, I only used 18 inches.

As for the hardware, I came very close to making a tightening handle blunder, when I nearly bought a handle with the male threaded rod attached. This would have been a mistake. The handles need to be female which allow the threaded part of the 5/16^th carriage bolt to pass through. Which brings me to the quantities of stuff I needed, the plans required 4 handles, 4 washers (I bought 8 to allow for losing a few), (24) #8, 1 ¾ “flat head screws (I bought a box). I also bought a box of 1 1/4” flat head screw, because I didn’t believe the instructions. The 1 ¾ looked way too long. They were not too long and actually worked wonderfully.

Being new to woodworking, I lack confidence, so I bought extra stuff, which I didn’t need. I then reinforced my fears when I purchased (3) 5” 5/16” carriage bolts and (1) 5 ½” carriage bolt. I blindly trusted the little bin that told me I was buying 5 inch, and it was very sneaky in giving me a 5 ½ bolt. I fixed the problem by buying (3) 5 ½” and (1) 5” the next day. So I have an extra set that will allow for thicker boards to be in my glue up. In the photos I used the 5 ½ inch bolt. I may buy some longer ones too. The reason one can’t just buy really long bolts is that the threads don’t go all the way down the bolt. If I had bought a 7 inch, I wouldn’t have been able to tighten them all the way down.

So here is how I built my cauls. I cut (8) 36” pieces of hard maple, using my Japanese hand saw. I was amazed at how quickly it cut through each piece, and how beautiful the cuts turned out. It was definitely the right tool for the job.

I like sanding. I have read that many woodworkers don’t like sanding their projects. It is considered drudgery. I took 2 pieces and clamped them into my vice and sanded the top to a nice rounded edge on the outside edges on the top side of the two pieces. My reasoning was, it was a waste of time to sand the inside edges, so I didn’t. I also didn’t sand the bottom edges, because I wanted them to remain flat. So I sanded up each pair. I used 80, 120, 220 grit paper and my mouse sander.

The next step was to cut off 1 ½“blocks from the piece of oak. My Japanese hand saw handled this task as well. The blocks are used as spacers between the pieces of hard maple. There are 3 spacers per caul piece (top and bottom) and created the gap that allows the carriage bolts to be threaded up through the top and bottom. It means that one is able to move the clamping handles in to the edges of the wood when clamping, to apply the most pressure onto the wood being glued up.

So with 12 pieces of oak cut, I stacked them together and sanded the tops, rounding the edges. This was done for aesthetics.

The next step was to screw everything together. I placed a spacer in the middle, at 18 inches and one on each end, set in 1 ½ inches from the edge. I have no idea why they weren’t all the way out to the edge, but in the article, that is how George Johnson did it, and it looked good to me. I then flipped the pieces of wood upside down, with the rounded edges on the table, and placed my oak spacers in the correct positions. Next I clamped everything together, before drilling pilot holes. I then used a countersink bit to drill out a bit of space for the flat head screws to set into the wood. To make my life easier I got out both of my cordless drills, using one as a dedicated pilot holes driller and the other for the countersinking and the screwing in of the flat head screws. ( I am not sure all of the verbs in the last sentence really exist, but I digress)

Once all of this was done, I just needed to cut some blocks to hold the carriage bolts. The instructions called for 3 ½ inch blocks, but I had a lovely piece of hard maple that was 12 inches long, so I went with 3 inches for each block. Yes it was a daring move, but I am not afraid to live life on the edge. I sanded the 12 inch block before I made the cuts. I also drilled the holes, first with a Fostner bit, then with a regular bit. This meant that after I cut them into their 3 inch lengths, they were ready to go.

The last step was to check the flatness of the bottoms of each caul section. I had focused on making sure that the tops were flat, because I intended to flatten any that needed it, using my router. There was only one that needed flattening, so I used my 2 inch flush trim bit. It is a really nice bit, made by Amana. I spent $128.00 on this bit. That seems like a lot, but I have already used it a bunch of times. And it cuts like a hot knife through brie.

When I finally assembled the cauls, they looked even better than I had hoped. Now I just need to find a project that requires a glue up.

Tutorial Cauls, Tutorial, Woodworking

Henry Wood Detective Agency: Tommy ‘The Knife’ Ch 8

February 8, 2010 Brian Meeks No comments

Henry took a couple of pictures of the cauls. He told Luna that he needed to head into his office and made her promise not to leave the house. She said she would read a book. Henry took the paper with him, he turned on the shower, and only then did he read the ‘Big News’

The headline read ‘Missing’.

An accountant with the prominent Manhattan law firm of Smith, Havershome and Blickstein is missing, and the Police commissioner Jonathan O’Rourke has indicated that the entire department is scouring the city. Mr. Alexander is wanted in connection with the racketeering and money laundering case against famous mobster Tommy ‘The Knife’. He has crucial evidence in the case and the commissioner has asked the entire community to be on the lookout for the missing accountant.

The article went on to provide a bunch of conjecture regarding the case, most of which wasn’t at all accurate, but did fill out a fairly thin story. At least now, Henry knew which mobster was after Mr. Alexander. Tommy ‘The Knife’ was a ruthless thug who preferred to use a barber’s straight edge to a gun. He had risen up through the ranks by collecting for the most powerful loan shark in the city and now ran a veritable army, made up of the dregs of society. Henry took a shower and shaved. He told Luna that he was off to the office and made her promise to stay inside, again. She did.

The snow had ceased to fall. The streets were wet, but traffic was light, as most had taken off work and stayed home. The drive was easy and Henry’s thoughts turned to the case. What could be the next clue? He thought about the journal. He needed to get it to the DA, but first he wanted to go to the office and see if anyone had been around to see him. He also wanted to go meet Miss Culberson, as it appears the Journal doesn’t have anything to do with her father, and he wanted to find out who put her up to hiring him.

Henry parked his car in the alley down the street from his building. He rounded the corner and immediately saw the crowd gathered around the front of the charred building that used to hold his office. He didn’t stop to ask what had happened. He knew the answer. He went to his apartment, which was only 5 blocks away. He kept the apartment in the city as his official residence. Henry made sure that he spent at least one night a week in the place, just to keep up appearances.

He was careful. He used the back entrance. There wasn’t anyone around. The back stairs were empty, but Henry was extra careful. He listened for anything out of the ordinary. It was quiet, except for the baby crying in 5B. When he stepped onto the landing he didn’t see anyone. Henry pressed his ear carefully against the door and again he heard nothing, not so much as a mouse in the house. It turned out that there weren’t any mice, only rats. He opened the door and walked in. The door closed behind him.

“Mr. Wood, you owe me two tires.” came from the man sitting in his comfy chair.

Before Henry could come up with a clever response, the man to his right, welcomed him with a sock to the gut.

“It seems youz been sticking your nose where it don’t belong, Mr. Wood.” said the man in the chair.

Henry was about to say answer, when he got another greeting to the midsection.

“You tell your buddy Big Mike that he messed with the wrong guy. If he wants a war then we will give him one.”

The thug behind Henry brought something down on the back of Henry’s head and he dropped to the floor. The knocking at the door caused Henry to come to. He moaned and said, “Come in.”

Big Mike walked in as Henry was trying to sit up. He looked around the apartment. “They tossed your place pretty good, eh buddy?”

“I was thinking of having a decorator in anyway.” Henry said.

“I told you that they were some bad guys.” said Mike, while helping his friend to his feet, and continued, “Maybe you best tell your buddy what you have been up to?”

Henry and Mike turned the kitchen table back upright and got a couple of chairs. He grabbed the bottle of bourbon from the counter and two glasses. “Was there anybody hurt in the fire?” Henry asked.

“No, it must have started around 3 am; we don’t know the cause yet. You think it was your new friends?” Mike asked.

“I don’t believe in coincidences.” Henry threw back the shot.

“Now what have you found out, that has gotten Tommy’s people on your back?” Mike asked as he poured Henry another one.

Henry filled in Mike on the details, including the message they left for him. Mike promised to look into Miss Culberson for Henry. Henry told Mike about the journal and explained that he had it hidden and that they needed to get it to the DA. They each had another shot and sat without saying a word.

Henry Wood Detective Agency Cauls, Henry Wood Detective Agency

Henry Wood Detective Agency: Bad News Ch 7

February 7, 2010 Brian Meeks No comments

The note simply said, “Went to the store for bacon, eggs, juice, and bread.” Luna wiped the sleep out of her eyes and looked around. The house was small but cozy. She hadn’t paid much attention the night before; she was too overwhelmed. On one wall was half a dozen photos of Washington DC. They were nicely framed and were quite nice. The other walls were mostly covered by book shelves. She ran her finger along the spines and read some of the titles, “Candide”, “Father’s and Children”, a collection of short stories by Rudyard Kipling, a book of haiku, and various tomes on chess.

She went into the bathroom and splashed some water on her face. The sound of the front door startled her, but she immediately heard Henry calling out. Henry had also picked up the morning paper, the headline was disturbing, and he wasn’t sure if she was ready. He hid it behind the credenza and headed into the kitchen. He heard the sink running in bathroom as he unpacked the groceries. Henry was an extraordinarily average cook, mostly he could keep himself alive, but he did make a pretty good breakfast. He hoped she liked bacon and eggs, and thought to himself, “Everyone likes bacon and eggs!”

Luna walked into the kitchen and said, “That smells delightful. Here let me help.” She took the spatula out of Henry’s hand and took over. He wasn’t use to being taken care of, and it made him a little bit uncomfortable, but she looked really happy, so he sat down at the kitchen table, trying not to think about the paper.

“Luna, you really don’t need to do that, I can make breakfast.” Henry said.

“You aren’t used to being taken care of, are you?” Luna said with a little smile, and then continued, “Why haven’t you found yourself a Mrs. Wood?”

Henry chuckled. He could tell she was feeling much better after a good night’s sleep. He liked seeing her like this. He also felt that a subject change was a good idea. “So, how long have you been working at the bakery?”

Her eyes got big, “I love baking, cooking is fun, but making cookies and cakes is the most wonderful thing in the world. I have been there for about 10 years. I make the best chocolate chip cookies in the world.” She said, sticking out her chest as she pointed to herself with her thumb. “Since I came to see you, I haven’t been into work though. I have been too worried.” Suddenly she was sad again.

Henry thought another subject change was in order. “What else do you like to do?”

She flipped the bacon over and cocked her head to the side, “I like books. I like books a bunch, they are swell. I have a degree in literature from Oberlin College. Did you know that the first woman to ever attend college went to Oberlin?”

“I didn’t know that.”

“Her name was Lucy Stone and she graduated in 1847. I wrote a paper about her relationship with Susan B. Anthony. It got an A.”

“I bet it did. Do you like to write?” Henry asked, seeing that her mood was on the upswing again.

Luna cracked an egg into the skillet. It didn’t even look like she was thinking about it, she was a machine in the kitchen. Henry just sat and watched her precise movements; it must be an Alexander trait. Another egg hit the skillet and she said, “I do like to write. I keep a journal and I write some stories, but I would never want to be a writer.”

“Oh, why is that?”

“Because when you get done writing a story, you can’t eat it!” She said giggling.

Henry laughed too.

They sat at the table and ate breakfast, telling stories and laughing about Henry’s college days. He had a thousand stories and she loved them. Her days at Oberlin were much tamer. Henry was exciting and he made her feel safe.

Henry told her that he was almost done with his cauls, and asked if she would like to come downstairs while he finished them. She said she would be down after the dishes. Henry tried to object, but she would have none of it, and sent him down to the basement to play.

When Luna came downstairs she sat next to the workbench and asked him about his project. Henry loved talking about woodworking, and wasn’t ready to tell her about the Headline.

“Cauls are helpful in gluing up boards. You apply the glue to the edges, lay some wax paper over both sides, clamp them lightly together, and then put a caul over each end.” He said, while he sanded a small block of wood, and continued, “Once you tighten it down, they keep the boards from popping up when you tighten the clamps, and the wax paper keeps the glue from sticking to the caul.”

“That is quite clever. I use wax paper for cooking.” She said, and then asked, “How did you learn how to build a caul?”

“I read an article in a magazine. It described what I needed.” He answered, and then proceeded to list off the components, “8 pieces of 2 inch maple, cut to 36 inches long, and twelve 2 inch by 3 inch spacer block, plus some 5 inch bolts and knobs.”

“They look lovely.”

“Thanks, the directions didn’t call for it, but I spent a lot of time sanding each piece, so it will feel nice and I won’t get splinters.” He said with pride.

The rest of the morning was spent talking in the basement. Henry didn’t know that Big Mike was looking for him. He didn’t know that his phone at his apartment in the city had been ringing off the hook. He didn’t know about the fire.

Henry Wood Detective Agency Cauls, Henry Wood Detective Agency

Henry Wood Detective Agency: Thursday Afternoon Ch 6

February 6, 2010 Brian Meeks No comments

The falling snow painted a layer of clean on the city. Henry didn’t have time to take in the loveliness of it all. He did notice the two children holding hands and spinning around, mouths open, laughing as they drank in the flakes. Their parents watched with the pride. He assumed they were tourists from Florida, real New Yorkers, just hunkered down and got on with their day.

Henry walked down the street towards his car. He had his eyes open for the thugs, though he couldn’t imagine that they would have guessed where he was heading. His pace was brisk, but not so much so, that it looked out of place. It was still early enough that rush hour hadn’t started, so Henry expected that he might be able to get out of the city without too much fuss. He was right. He headed north and ninety minutes later he was pulling up the lane at the Alexander house. It was a modest, but elegant place, set back in the woods.

Henry’s tracks were the only ones in the snow. He felt a bit better. He still couldn’t be sure though. All he knew for sure is that nobody had driven up the dive in the last hour or so. There didn’t seem to be any lights on. He got out of the car, turned up his collar, and with one hand on his hat, used the other to knock. He waited. No sound, no movement, just silence and the feeling of dread welling up deep inside of him. He knocked louder. When he began pounding his fists on the door, his mind was racing, and fear was replacing the dread.

There wasn’t any sound, no wind, no storm, just the millions of flakes streaming down, narrowing the world to a space of about 20 feet. If it got any worse, Henry wouldn’t even be able to see his car. He didn’t know what he should do next. The barely audible creek of the door handle was deafening. Harry spun around to see the door open just enough for him to see two eyes peering out. As soon as Luna saw who it was, she flung the door open and yelped, “Henry”. He was so relieved. She waved for him to come in and as soon as he crossed the threshold, she threw her arms around him.

“Henry! I have been so alone and afraid. I am so glad you are here. Have you found daddy?”

Henry returned the hug. He couldn’t help but notice how warm she was and how nice it felt to hold her. It was a good hug. “I haven’t found him yet, but I have found another clue. I will tell you all about it. But right now we need to leave.”

“In this storm?” she said, looking up at him. Her eyes were warm, but there was a bit of fear around the edges.

“Yes, I am afraid so. I have a house. Nobody knows about it. My neighbors don’t know who I really am. It is a good place. You will be safe there.

“I feel safe with you.” She hugged him again.

“Ok, now go pack a bag. Do it quickly, the storm is not going to let up, and we need to get on our way.”

Henry watched her walk up the stairs and he stood in front of the fire to knock the chill off. He was trying to think one step ahead. It seemed like a run of good luck that nobody had gone after Luna yet. He wondered if they were on their way. He put out the fire after lighting a couple candles. Luna had been napping on the couch. He folded the blanket and put it on the arm of the sofa. Henry walked to the front door and peered out the window. He could barely see the car. He heard Lulu coming down the stairs when he saw the headlights. He stepped away from the window, and instinctively felt for the six shot cobra under his jacket. He didn’t want to get in a shoot out though. He was certain that they would have a lot more firepower. Their car pulled up behind Henrys. Henry grinned and put the chain across the door.

He whispered to Luna, “There are some dangerous people outside. Soon they will be inside. We need another way out?”

“Who’s out there?” She sounded frightened.

“I will tell you when we are safe. Now where are the doors?”

There was a pounding at the front door, someone was trying the handle.

“There is a back door to the patio, and the side door by the kitchen.”

“Side door will do.” Henry said, taking her by the hand.

It was dark inside; there were only the candles that Henry had lit. The door erupted as one of the thugs kicked it open. As soon as he heard the front door being kicked in, Henry opened the side door in the kitchen, and he and Luna were out into the storm.

Inside the thugs were spreading out. One had run upstairs; the other was checking the cellar, while the third one was in the family room and heading towards the kitchen. Luna rushed to the passenger side and Henry stopped long enough to shoot out both the tires on the left side of the other car. He hopped into the car and fired it up. His car didn’t do great on the snow, but it would do better than one with two flat tires car. They were gone before the thugs made it back outside.

Over the next two hours they crept back to Henry’s place, he had explained how he had found the journal and told her about the trouble her father was in at the firm. When they got home, Luna was tired and looked like she was about to drop. Henry grabbed her bag and showed her inside. A quick tour ended at the bedroom and Henry grabbed a blanket and pillow. He would sleep on the couch. Normally she would have objected, but she was too tired. Henry said he would be downstairs if she needed anything.

Twenty minutes later Henry had pulled out some 1 x 2 maple he had lying around. He hadn’t gotten back to the lumber yard, so he would just have to use some scraps to make something. He didn’t care what he made, he just needed to create. He had seen an article by George Johnson of Canton Oklahoma, where George had made a set of adjustable panel cauls. He measured each one carefully and then used his Japanese hand saw to cut them. The spacers for the cauls needed to be one and one half inches, and he needed 12 of them. The hand saw worked fine for those as well. He was really happy with how good he was getting with hand tools.

Henry was really in the zone, he didn’t even notice Luna sitting on the stair watching. She had her hair pulled back, wore a big wool sweater, and had her legs pulled up to her chest. She was a tiny ball of quiet, but she felt safe. Henry’s precision and attention to detail reminded her of her father. She thought about him. She wondered where he was and if he was ok.

Henry finished the half of the first caul when he looked up and saw her sitting there. She was peeking out over her knees. He saw the corner of her eyes go up and he knew she was smiling. “Are you hungry?” he asked.

She nodded.

“Do you like Chinese?” He said, walking around to the stairs.

“I love Chinese food, but can we get it, with the storm?” Luna said, poking her head up over her knees.

“Mr. Wong fears nothing! And it is only 2 blocks. So I think we are ok.” Henry said with a wink. Luna gave a little clap.

They ate and talked. Luna fell asleep on the couch; Henry pulled the blanket up over her shoulder and then got a blanket for himself. A few minutes later he was asleep in the chair next to the couch.

Henry Wood Detective Agency Cauls, Henry Wood Detective Agency

Extremely Average

Browsing Posts tagged Cauls

Creating the Cauls

Henry Wood Detective Agency: Tommy ‘The Knife’ Ch 8

Henry Wood Detective Agency: Bad News Ch 7

Henry Wood Detective Agency: Thursday Afternoon Ch 6

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