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Behind the Scenes at Bridge City Tool Works
Updated: 1 hour 25 min ago

Holiday Shout Out – New Tool From Bridge City Tool Works!

Tue, 12/05/2017 - 12:23pm

Drivel Starved Nation-

I am please to share the latest edition to the HP-10 Convertible Plane, which will allow you to cut coves/flutes and cores in four sizes.

Cutting flutes is an essential element of decorative woodworking. The Greeks and Romans were masters at employing flutes in both their architecture and furniture. Why you ask?

Texture typically adds depth and shadows–both create visual interest. Here’s a pic of some of the cuts you can make with our Cove/Core kits, they include a corner cove, flutes and a core cut;

HP10 Cove Cuts 700

We have never offered soles and irons that are commonly referred to as “hollows” to the traditionalists. I actually do not know why other than something else must have been bugging to get made first. We now will be making the following diameters in four sizes: 1/4″, 3/8″, 1/2″ and 3/4″. All four of these sizes will allow you to make core cuts which is all the way to the diameter line.

The most common use for core cuts is the ability to create a cylindrical half diameter cut in two boards, regardless of length. When they are glued together, you have hole that would be impossible to drill. Projects that benefit from this technique include musical instruments, lamp making, and any other project where you need a hollow that cannot be drilled.

When combined with a guide fence, you can create 90 degree corner cove cuts which are a nice alternative to a square corner, which is often visually boring. I like corner cove cuts on simple picture frames, there is a cove on the inside corner and small chamfer on the outside edges of the frames below. (The little boy is now an executive expat in Mexico City and that little girl is about to bear her second child…)
Wall Array 700

Here’s a pic of the complete 4 size kit (you will be able to purchase singles too);
Cove_Core 700

The irons are really cool, you simply hone the entire beveled face. Fast, easy and the larger two sizes have been cored so you you only need to hone the periphery of the face.

The many uses of these profiles include;
Fluting
Veining
Grooving
Ornamentation where a round bottom is desired
Drawer pulls
Musical instruments,
and whatever your imagination can conjure!

I’m going to do something with the smallest size that I can’t tell you about but I think you will find it fascinating… and yes, it involves electricity, maybe magnets too.

The pre-order window will open later this week – time to plant a holiday gift idea with your partner!

-John

The post Holiday Shout Out – New Tool From Bridge City Tool Works! appeared first on John's Blog.

Categories: Hand Tools

The Woodworking Joint Used in the Arms of Ming Dynasty Chairs…

Thu, 11/16/2017 - 2:27pm

Drivel Starved Nation-

My latest trip to China was my favorite to date. When you are on an informative trip, fun is easy to find. When the weather is perfect, trips like this become magical.

The highlight for me was the gift Mr. Yang, the Hong Mu Master presented to me. It is a sample of the joinery used in his masterpiece pictured below;

As explained by Mr. Yang, his students are not allowed to build a chair until this joint is mastered;

Incredibly, mastering this joint can take up to a year. The rosewood supply he has is finite, so there is no tolerance for waste when it comes time to make a chair. And because there is no finish, the joints need to be perfect to become invisible. It truly is an amazing display of craftsmanship. The joint itself (I wish I would have asked if it had a name) is a thousand years old I am told.

Here is a short video by Academy Award Winning Cinematographer Wanna Be Consuelo;

Each chair arm has 6-8 of these joints. They are incredibly strong and could be completely functional without adhesive… they are that strong.

Pretty cool yes/no?

-John

The post The Woodworking Joint Used in the Arms of Ming Dynasty Chairs… appeared first on John's Blog.

Categories: Hand Tools

Bridge City China Trip and Charlie Manson…

Tue, 11/14/2017 - 3:45pm

Drivel Starved Nation!

After spending three weeks in China, my jet lag back here in Oregon is something else. I must be getting really old…

The day before I departed back to the States, my Chinese business associate Jack and his daughter Jessica accompanied me to Beijing for a special dinner.

It’s not a big secret that I am an Iowa son, born and raised until my graduation from Iowa State when I headed off to my teaching job in Oregon. Wow, that was 45 years ago! Ouch.

While living in Ames, I would occasionally get my hair cut–about once every three years. (I liked being a hippie where I learned that you could accomplish so much more in a day if you skipped bathing.) The place I frequented was called the Head Shop and it was owned by Al Thompson who was my barber. We have remained friends all these years and whenever he FaceTimes me he tells me my hair looks like it was cut with a Weed Eater…

Some things never change.

Al learned how to cut hair from a famed LA hair stylist and his Head Shop quickly became the most popular barber joint in central Iowa. Then he got a crazy idea…

In 1971, when hot pants and mini skirts were at their peak (did I just write that?), Al decided it was a good idea to shave ISU coeds legs for a buck. What do you think happened?

Back then, if a story was picked up on the AP wire, it went viral and yes it did! He has clippings of his exploits from around the world. The 1971 NPR radio story is now enshrined in their archives.

It wasn’t long before Al would make a monthly trip to Des Moines to cut the hair of the Governor. And now, whenever I go to Tennessee, or Al comes to Oregon, my haircuts are free. After each hair cut he proclaims, “Now, you no longer look like an idiot!” How cool is that?

So, what does this have to do with Charlie Manson? Al’s teacher in LA was Jay Sebring who was one of the seven people murdered by the Manson clan. But the crazy part is just beginning…

That Iowa Governor? Mr. Terry Branstad. Turns out he is the longest serving Governor in US history with 22 years of public service. He too stays in touch with Al from his new residence as the Ambassador to China in Beijing. See where this is headed?.

We were supposed to meet for dinner on Nov. 3rd, but got bumped by none other than Bill Gates. However, on Nov. 2rd, Jack, Jessica and your favorite tool Potentate took a cab over to the Ambassador’s residence where we were greeted at the gate by 4 or 5 Chinese army dudes. They asked, “What do you want?”

“We are here for dinner with the Branstads” I said.

“Who are you?”

“John” I replied.

About 5 minutes passed and the gate opened. It is about a 50 meter walk to the entry and awaiting us was Mr. Branstad’s wife Chris. We were there for almost 4 hours and had a great time (not once did politics get discussed). Here was our menu;
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For a Chinese business man and his daughter, this was an amazing life experience. I probably won’t be invited back (it’s a trend I have noticed over the years…) but really had a great time. Mrs. Branstad actually made the ice cream on the menu. How cool is that?

Our perfunctory parting pic is below;
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BUT WAIT–THERE IS MORE! I have even more crazy friends! Michael Hosaluk, one of the most famous woodturners in the world claims that he used to play hockey like me. No, not as bad as me, but hockey…. you get it. This dude won the Canadian equivalent of the the MacArthur Genius Award which means he got free money!

So I begged Michael to make me something special that I could give Mr. Yang the Hong Mu Master, Jack and the Branstads as a gift. He said sure, then in order to bring the price down (even though he got all this free money, he has to charge me because he is flippin’ famous, which is always expensive) I ordered ten sets of these;
Rice Bowls 800

They are ceremonial rice bowls, one with red lacquer, the other with gold leaf. And yes, that is actual rice you see. How cool! We will offer 5 of these limited edition sets in our upcoming holiday email.

The next day I walked over to the American Embassy because I have never been to an American Embassy before and was given a private tour by a docent. Not once did I spot a spy.

And that brings my latest China adventure to a close. It was a great trip… Until I received this email from Chris Branstad;

“John, are those rice bowls dishwasher safe?”

I knew it was a joke so now I have yet another crazy friend!

-John

The post Bridge City China Trip and Charlie Manson… appeared first on John's Blog.

Categories: Hand Tools

Bridge City Field Trip Report #4: The Hong Mu Arts Museum Tour

Tue, 11/14/2017 - 12:40pm

Drivel Starved Nation,

This is a long post, and it is full of pics. So there DSN, lots of Drivel! (If you have slow internet, you may have to wait a bit for all the pics to download).

Our last day together on the Epic Bridge City China Field Trip was spent at the Hong Mu Arts Museum. This 30,000 square meter facility was built specifically to honor Mr. Yang, the Hong Mu Master. He is China’s most famous woodworker and is a national treasure. The museum was privately funded (just under $40 million USD) by a wealthy real estate mogul who is living the giving chapter of his life. The museum is private and when complete next year, the grounds will include the now finished museum, a tea garden and a brand new private residence for Mr. Yang and his lovely wife. Attendance is by invitation only.

We were all warmly received as you can see here;
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Mr. Yang and I are the same age (old) and share a ready sense of humor. (While at dinner, he commented that when he visited New York city he had no money. I quickly gave him $2 bucks for his next trip which was a good for a long 5 minute laugh.) More important, his passion for his work is unrelenting and his productivity is actually unbelievable. He is one of “those guys” that does not have an enemy in the world, and it is really an honor to call him a friend.

All of his furniture is made out of an Asian dalbergia species (rosewood). All of it. And get this, in his pieces you are going to see below, NONE of them have a finish. That is not a typo, NO FINISH. It is simply the luster of the wood rubbed to a lacquer-like finish. Incredible.

When you first walk into the museum you see a large rosewood log on display and immediately to the left is an area of wood carvings from about 50 different countries. Here are a couple;
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If you turn to the right, there is an entire floor dedicated to student work.The pieces you see below are made from ONE piece of wood (no joinery). This is just a sample of the incredible work. The students spent one year on their projects.
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This is not one piece;
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What follows below are examples from the three floors of Mr. Yang’s work. Many of the pieces are grouped as they might appear in a residence. The “paintings” interspersed in the images below are all silk embroideries. They are all worth fortune! Even more amazing, this furniture was all crammed into his house on my visit last year!

Enjoy the images.

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This is a bookcase;
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This is a our equivalent of a “love seat”. The center section is for tea, and the couple sit cross-legged facing each other. The flexibility needed to sit like this does not exist in my body. Anywhere.
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I love the texture in this piece!
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This is Mr. Yang’s bed and it took him 5 years to make it. Most of the pieces you see here took over a year and the reason is simple, the rosewood was not kiln dried. He would work on a piece, let is sit for a month or two, do more work, repeat.
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The piece below is Mr. Yang’s masterpiece. It is an original variation of a Ming Dynasty chair using bamboo as a theme. It is exquisite.
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This tour-de-force of craftsmanship was unreal. This bird cage is made out of rosewood and it is all mortise and tenon joints;
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The lasting influence of Chinese furniture design is never more evident than Han’s Wagner’s tribute to furniture from the Ming Dynasty in his Wishbone Chair below;
Hans Wagner Wishbone Chair

I don’t know about you, but I feel really insignificant in the shadow of the Hong Mu Master. What an experience.

-John

The post Bridge City Field Trip Report #4: The Hong Mu Arts Museum Tour appeared first on John's Blog.

Categories: Hand Tools

Bridge City China Field Trip Report #3; Shanghai to Nanjing…

Tue, 11/14/2017 - 10:13am

Drivel Starved Nation;

Nothing quiets prejudice, hatred and biases more efficiently than travel. Only until one sees, smells, hears and learns from different cultures and their people can you intelligently grow as a citizen of planet Earth. Over the past 4 years, my 8-9 trips to China have been filled with wonderment, awe, disgust, dismay and joy. I thought this field trip idea would be an equally fun learning experience for Bridge City customers. And it was.

We all had a great time in Shanghai so it was time to see Nanjing! To get there, we took the bullet train.

The Chinese government is fully committed to connecting all corners of China with bullet train service. These sleek, all electric vehicles with bodies of extruded aluminum, shuttle passengers at an amazing 300 km/hr. (That is a Nascar speed of approx. 186 miles per hour!) The ride is incredibly smooth so of course I had to ask how that was possible.

In order to go that fast, and that smooth, the tracks need to be smooth. How smooth you ask? They are actually surface ground once in place and the tolerance is 1mm every 16 meters. How accurate is that you pesky knowledge seeker? 0.00075 inches per foot! That is crazy. How crazy? That is flatter than our precision straight edge!

I then inquired about heat and cold and expansion joints. I was told the rails are not welded but joined with a special alloy that keeps them “on track” during extreme temperature swings. There is no clickety clack, clickety clack, unlike my experiences on Amtrak here in the States. I would say that on average, the bullet train is smoother than air travel. That’s is simply amazing to me. It is also relatively inexpensive.

The train stations are nothing short of enormous. With the exception of the Boeing assembly building in Everett, WA (do put that on your bucket list of places to see), these train stations are the largest buildings I have ever been in. They are sleek, modern, and so damn big they disguise the fact that at any given moment, there are thousands of people waiting to catch a train. Here’s a pic of the Nanjing station;

Nanjing train station

This pic was taken in the middle of the station, and those windows down yonder are at least three football fields away. It is the same going the other direction. The place is huge, shiney, new and unbelievably impressive. AND, this is just the UPSTAIRS! You take an escalator down to the train terminal to an equally large space to catch one of the many trains, which like German trains, operate to the minute. I was also told that this year, for the first time, bullet train travel was profitable.

Here’s a little video of a train coming into the station;

What 180 mph looks like from a window seat…

Once in Nanjing we had a guided tour of the Harvey Industries facility, and were able to see the new Gyro Air Dust Collector in production as well as the Bridge City Tool Works assembly area. We had a fascinating time culminating that evening with a BCTW hosted dinner, our last dinner together.

The next day was the highlight of the trip…

… To Be Continued.

-John

The post Bridge City China Field Trip Report #3; Shanghai to Nanjing… appeared first on John's Blog.

Categories: Hand Tools

Bridge City China Field Trip Report #2: Shanghai, the Largest City in the World…

Tue, 11/07/2017 - 3:20pm

Drivel Starved Nation;

After our kick-off dinner, we all took a nice walk along the Bund which was a block or two from our hotel. Here is how it looks to my cell phone at night;

The Bund

After this spectacular view, we retired for the evening. Well not all of us… but that is another story.

Early Saturday morning we were picked up in a 15 passenger van and our first stop was the Oriental Pearl Tower. Until 2007 it was the tallest structure in China at 468 m (1,535 feet) high. It is memorable for the glass floor on the observation deck. Here are the shoes I wore that day;

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What a fun people watching place! Yes, it is a bit unnerving to walk out onto a glass floor that high in the air, but for some people, it is outright terrifying. I was terrified at first, but then remembered there is nothing more terrifying than running Bridge City Tool Works…

TRIVIA: As of 2017, China is home to 5 of the top 10 towers in the world. #2, #5, #7, #8, & #10. You can look them up, I have jet lag.

After circumnavigating the glass floor a couple of times, we headed off to an old part of Shanghai where the streets were narrow and filled with the most awful smell imaginable, and it emanated from a food booth! It’s called 1,000 year old tofu and apparently it is delicious. NO ONE in our group tried this which is the strangest source of pride I suppose. Here’s a pic from a similar booth in Guangzhou;
IMG_1166

The motto for this stuff is, “Smells like hell (understatement of humankind), tastes great!”

We then were chauffeured over to a part of Shanghai that reminded me of upper Manhattan. It was a walking tour with stops at a couple of famous residences that now serve as museums. I, of course, went around and checked out the woodworking. Wow, Chinese woodworkers are really good at making miter joints. We then had a great meal that was sponsored by our host company, Harvey Industries.

According to 2017 data, Shanghai is the most populous city in the world with approximately 35 million people. That DSN members is within a million or so of the entire population of Canada. It’s also within a couple million of the entire population of California. It’s also one of the safest places I have ever been. These people do not seem to have the anger gene found in western societies, which I find fascinating. People are happy, healthy and know how to enjoy themselves, and they are way more family centric than what I have observed in America. Again, these are simply my observations.

THIS IS JUST PLAIN STUPID DEPT.
Lastly, I forgot to share in my previous post the dumbest product I have EVER seen. I spotted this at the Canton Fair in Guangzhou;
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I asked the guy “Who buys this?” His response, “Only Americans”.

This left me totally depressed for an hour or so. Incredible. And embarrassing.

Just think, somebody got paid to come up with “The Potty Putter”. I also wondered how much the male model was paid for that image. And why male… ? So many questions!

Next report features our bullet train ride to Nanjing.

-John

The post Bridge City China Field Trip Report #2: Shanghai, the Largest City in the World… appeared first on John's Blog.

Categories: Hand Tools

Bridge City China Field Trip Report #1: Adventures in Eating…

Mon, 11/06/2017 - 2:53pm

Drivel Starved Nation-

Your favorite Tool Potentate just returned from three weeks in China. I spent a week in Guangzhou, 3 days in Shanghai, a week in Nanjing, and 3 days in Beijing.

While in Shanghai I met up with the Bridge City China field trip participants. And while in Beijing we had the privilege of a private dinner with the American ambassador of China and his wife in their private residence followed by a private tour the next day of the American embassy, the largest American embassy in the world. In short, this experience was more than any of us expected and will take multiple posts to share all that we explored.

TRIVIA #1: “Jing” means capital. “Bei” means north. “Nan” means south. Nanjing is the old capital of China and Beijing is the current capital.

Before I dive into the details I am reporting that what is happening in China (over the past 20 years) is the largest renaissance in human history. The scale, the speed, and the importance of what is happening in China cannot be ignored. It is almost beyond imagination. It is also beyond my intelligence grade to judge, comment, disagree or approve of what is happening in China, this post is to simply share what I observed from my limited perspective. That means no politics in this safe space I call my Totally Awesome and Worthless Blog.

The Canton Fair is held in Guangzhou every October over a three week period and is the largest trade show on the planet. If you have ever been to a woodworking show in America, the attendance ranges from 1,000 to 5,000 and around 25,000 for the two big shows that alternate between Atlanta and Las Vegas. The week I was there the attendance was around 500,000. That is insane.

We were showing the Chopstick Master and other assorted Bridge City Tools but honestly, my jet lag was so bad I had a hard time staying awake. I did find it fascinating that several attendees asked me about Pencil Perfection which is crazy because we just released it for pre-order two days before I left for the exhibition. The speed of the digital world still amazes this old guy.

Our Chinese host and I arrived in Shanghai on Friday and that evening Bridge City hosted a get acquainted dinner for our field trip participants. We had several cancellations at the last minute so the group totaled 10 or so for the duration. The dinner was fun and I enjoyed watching Americans push the limits of their palette with the various Chinese dishes that have been perfected over their 5,000 years of cooking. My limits were pushed too — check out these menu items…IMG_1172

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I asked our Chinese host if there was anything the Chinese would not eat. His response;

“People”.

The next report will be the sights and sounds of Shanghai.

Now, go get a snack.

-John

The post Bridge City China Field Trip Report #1: Adventures in Eating… appeared first on John's Blog.

Categories: Hand Tools

Pencil Precision Video, China Field Trip, Other Bridge City News

Tue, 10/17/2017 - 4:16pm

Drivel Starved Nation-

Here’s the latest news regarding your favorite Tool Potentate…

JOHN OUT OF THE OFFICE DEPT.
This Thursday I depart for China, first stop is Guangzhou. A week later, I will meet up with the BCTW field trip participants in Shanghai for a couple of days of food and tourist attractions–this should be really fun. We then will all board the bullet train (over 300 km/hr and smoother than flying!) for Nanjing. More great food and a visit to the museum of China’s greatest living woodworker. This will be an incredible experience, and I will be sure to take lots of pics and videos for you.

On November 3, I will be taking the bullet train to Beijing and that evening we are meeting the American ambassador to China (Mr. Terry Brandstad) and his wife Chris for dinner, and chopstick making! (Did you know that they extrude the bodies of the bullet train out of aluminium? It’s the largest extrusion in the history of the planet!)

NEW PRODUCT DEPT.
This week we will open the pre-order window for Pencil Precision™. I think you will thoroughly enjoy making pencils–I’m an old guy and not easily amused (except at my own mistakes) and this thing is just a blast to use.

Many of you own an HP6v2 plane so we are offering two kits, one without the plane and the other with an HP-6v2. This is a globally sourced project with components made in the USA, China, Germany, to name a few. Without question, this is the best value tool making kit we have ever produced – Here’s a pic of the kit without the HP-6v2…
PPGroup without HP6 PP Version
This kit includes two sole kits for the HP-6, the planing fixture, the extrusion fixture, and enough blanks and ferrules to make 12 pencils. It will allow you to make round pencils. The extrusion die kits for beaded and Reuleaux pencils will be sold ala carte and are $89 per set. This way you can buy just what you want. This kit is under $450!

The kit with the plane is only about $100 more.
PPGroup with HP6 PP Version 700 Yes, the orange crank is removeable to reveal a 1/4″ hex… do the math on that one you power freaks!

In both kits you will receive a sample of six ferrules with erasers and six without. This will allow you to explore both pencil making options. The ferrules come in eight colors and you will understand why when you make your first pencil with child or grandchild assistant. Watching the look on their faces when it is their turn to pick which color is priceless.
Ferrule wo Eraser Black.70
Red Ferrules with Eraser 700

We will announce the spectrum of colored pencil options at a later date as we are in negotiations with potential suppliers. The kit comes with 12 2H leads and we will offer black lead options in the following hardness: 4H, 2H, H, HB, B, 2B and 4B and Red and Blue. We recommend H and HB for little kids.

AND, all pencil component options, whether it is 12 leads, 6 plain ferrules, 6 ferrule/erasers or 12 cedar blanks are all under $9.00. The material costs for making beautiful custom pencils will be right around $2.50 each. Combine that with the fun of involving your entire family is simply unbeatable.

When I return from China we will begin filming the HOW-TO video tutorial but to wet your whistle, here is a short video peak at one of our prototypes in the skunk lab. I removed the crank and I am using a Dewalt power screwdriver (I love this tool) with an almost dead battery. Each die is really a circular plane iron and serves as not only the cutting edge, but the chip breaker as well. It doesn’t get any easier than this!

Pencil Precision is a complete hobby/factory in a box and this is what it isn’t: a toy. This is a professionally made tool that will last generations–which is a whole lot longer than a smart phone.

Just sayin’.

 

-John

The post Pencil Precision Video, China Field Trip, Other Bridge City News appeared first on John's Blog.

Categories: Hand Tools

Introducing Pencil Precision from Bridge City Tool Works

Tue, 10/10/2017 - 4:13pm

Drivel Starved Nation!

It’s always exciting when we have something new to share… which I suppose makes this post news. (I did that math all by myself – FYI)

Since 1983, (that’s 34 human years, but 311 tool maker years), we have been producing impeccably crafted bench tools primarily for avocational woodworkers. It’s been mostly fun, but not as fun as it could have been knowing what I know now…

Three years ago, I experienced a life changing happening in China that I cannot get out of my head. If you missed my original post, you can read it here.

What I learned over the previous three years is the enthusiastic joy the Chopstick Master™ has brought to people’s lives the world around  is something I hope to duplicate with future offers from Bridge City.

I believe the thrill of using the Chopstick Master is not the pair of chopsticks (yes, they are beautiful and function perfectly), but the self-esteem boost one experiences from the making process. Learning something new is always its own reward (good and bad) but there is another aspect in play here that is noteworthy. And that is the power of gesture.

To make a pair of chopsticks takes about 15 minutes. Giving them away as a gesture creates a feeling that lasts way beyond those fleeting 15 minutes.  It is simply about as good as one can feel about themselves. And it is contagious, as in Quality is Contagious™.

Last January I met with the lawyers that manage our patents and trademarks and we were discussing the improbable success of the Chopstick Master when one of them blurted, ”What’s next, a gizmo to make pencils?” This unintended comment, meant as a joke, was simply a great idea in my mind.  Why?  Because I felt that making pencils would be 10 times more fun than making chopsticks! And having fun, is a big deal to me.  I now love lawyer humor too!

I left on my annual work retreat in February and immediately jumped head first into the rabbit hole of pencil making (when the Muse talks you listen). I have been doing almost nothing since.  So yes, your fearless Tool Potentate has yet again “bet the farm” on this improbable idea. It worked with the Jointmaker Pro and I sure do hope it works here…

The patent and trademark has been filed so here’s an overview of how  Pencil Precision™  works;

Using our venerable HP-6v2 Plane (any version with locking dovetail nuts), you attach the pencil groove soles, insert the iron and adjust for a whisper cut, attach the fixed purpose acetyl depth skids, and plane the supplied 170mm cedar blank until the plane quits cutting. This process creates two 1mm radius channels and dimensions the blank stock to exactly 4mm in thickness. Repeat this for the second blank. The blue knob tightens the red clamp jaw which freezes the blank in place. The unit was designed to work on a kitchen counter or workbench. This step for both halves is less than 5 minutes.
Cutting Pencil Lead Channels 700

Once the two halves are complete, you put a thin film of wood glue on one side, position the 2mm dia lead blanks in place and use the fixture to clamp the blanks for at least 1 hour. No other tools are required (OK, a small hammer will help later…) but this device is literally a factory in a box.
Glue Up Image 700

You next place the pencil sandwich back into the fixture using the orange index clamp pads. These keep the pencil blank centered while you plane 1/2 the diameter of a round pencil blank. All pencils shapes emanate from this round pencil blank. When the plane quits cutting (the depth skids control everything so you cannot screw up), flip the blank and repeat. The result will be two round pencils! Again, about 5 minutes for this step.
Round Pencil Pass 700

Next, you decide what pencil profile you would like to make, your choices are to stay with round (perfect for colored pencils) or hex, or beaded or our modified Reuleaux profile. In the image below, we are making a beaded pencil. Put in fixture and crank away. You are literally extruding wood through a series of progressive dies (think circular plane irons). The results will almost make you scream with joy the first time, the second and third… it is that much fun! This takes about 1 minute.
Extruding a Pencil 700

With a completed blank, you have to decide now how to finish your pencil. You can paint, or go natural, the many choices are yours. (I will post later why making a pencil out of cocobolo/ebony/rosewood is a stupid idea). With a piece of cardboard under the fixture, your paint set-up looks like this;
Paint Setup 700

Painting will require at least 3 coats, so you need to plan accordingly. We will provide detailed painting tips (I have an airbrush which is awesome) but in the shop we are painting with a brush using acrylics and a top gloss coat. Once the finish is dry, it is now time to cut the tenon to receive the ferrule. This is strikingly easy for anybody regardless of skill. First, you put the pencil blank in the hole and lower the guillotine. Spin the pencil with the cutter engaged to score the shoulder. This takes 15 seconds.
Ferrule Shoulder 700


Once the pencil blank has been scored, you remove the excess wood by repeatedly pushing the ferrule end of the pencil into the hole at the end of the fixture, rotate and repeat. This shaves the pencil to the proper diameter. The other cutter you see is the built in pencil sharpener.
Cutters 700

The supplied ferrules (we have not decided on all the colors yet, but we really like the champagne color, works for everything) are beautiful. Plop one in the the fixture, raise the guillotine to the fixed 90 degree position (no, the blade is not exposed, it just looks that way) and with the pencil resting against the guillotine and the orange body, tap the pencil home. Without this setup it is way too easy to get the ferrule on crooked. All that is left is sharpening and inserting the supplied eraser.
inserting the ferrule 700

What’s not to like?
Beaded Pencil 1 700

Yes, we have a way to identify the lead types and we will offer colored pencil leads for the adult coloring book market.

Imagine making a pencil for your child’s SAT test? Your grandchild’s first pencil? The gesture opportunities are endless. This “pencil factory in a box” can be enjoyed by your entire family on the kitchen counter!

I will give a report on the crazy way our contest was won in my next post. And, we are still working on pricing.

-John

PP_Logo_and_type_Page_2

The post Introducing Pencil Precision from Bridge City Tool Works appeared first on John's Blog.

Categories: Hand Tools

New Tool from Bridge City… Clue #6

Thu, 09/28/2017 - 2:07am

Drivel Starved Nation!

I know, this is hard!

This part is 210mm in length. And, it serves several purposes, one of which is in conjunction with an earlier clue…

For those of you who follow this Totally Awesome and Worthless Blog (about 4.2 billion people when I last didn’t check) you know that when we use the color red in our products, there is a reason…

-John

The post New Tool from Bridge City… Clue #6 appeared first on John's Blog.

Categories: Hand Tools

New Tool from Bridge City Tool Works Identified!

Wed, 09/27/2017 - 2:36pm

Drivel Starved Nation!

We have our two winners who identified what I have been working on over the past 7 months. Now watch it make me the laughing stock of the internet.

It’s called Pencil Perfection and here is what you can do with it;

I have some commitments that will keep me out of the office until next Monday, but when I return, I will share the story behind our winners, this project and what it means to me and hopefully you too.

-John

The post New Tool from Bridge City Tool Works Identified! appeared first on John's Blog.

Categories: Hand Tools

Bridge City New Tool Clue#5

Tue, 09/26/2017 - 10:00pm

Drivel Starved Nation,

Keep thinking!

This milled and anodized aluminum part looks similar yes/no?

I am happy to share it is exactly 300mm in length.

-John

The post Bridge City New Tool Clue#5 appeared first on John's Blog.

Categories: Hand Tools

Clue # 4 for New Bridge City Tool…

Tue, 09/26/2017 - 12:51am

Drivel Starved Nation,

Got a headache yet? I would if I were you. Think about this, I’ve spent 7 months of my life figuring out how to become the laughing stock of the internet. This is my way of sharing the pain headed my way.

Here’s clue #4, this component is 77mm in length. Milled from aluminum and it is known internally as “the rack”.

-John

The post Clue # 4 for New Bridge City Tool… appeared first on John's Blog.

Categories: Hand Tools

Clue #3 for New Bridge City Gizmo….

Mon, 09/25/2017 - 10:11am

Drivel Starved Nation!

Before I share the next clue, I am informing all that we have a winner! NO! You say. Me too! So, why clue 3?

Well, it’s my contest, my rules, and our fun. It’s just too early to stop my ability to insult our customers. I do promise however to share this story and why we are going to have TWO winners for this contest. That’s fair, don’t you think?

Oh, one more thing… both winners will receive this thing whether they want it or not. How cool is that?

OK, now back to the mystery–What you see below is 350mm in overall length. And yes, those are acme threads.

-John

The post Clue #3 for New Bridge City Gizmo…. appeared first on John's Blog.

Categories: Hand Tools

Clue # 2 for New Bridge City Thingamajig….

Fri, 09/22/2017 - 12:59pm

Drivel Starved Nation-

Here’s your second clue to the thing that will make Bridge City the laughing stock of the internet…

If you guessed bent stainless steel wire you are correct! The longer version is about 90mm in length.

-John

The post Clue # 2 for New Bridge City Thingamajig…. appeared first on John's Blog.

Categories: Hand Tools

New Tool Coming from Bridge City! Here’s Clue #1…

Thu, 09/21/2017 - 1:33pm

Driveled Starved Nation!

Over the past several months I have alluded to a project I began on my work retreat last February. Today is September 21st and it is finished! I’ve been playing with the last physical prototype for about 3 weeks and I am pleased to share that we are going into our pre-production routine next week which includes sourcing and pricing. The pre-order window is still several weeks away.

Before I share our first clue, I am admitting that this project very well may make us the laughing stock of the internet–maybe you too. And if so, I could care less, this thing is so MUCH FUN! Actually, it is so much fun I will give you TWO clues today (isn’t that nice?), one a word and the other an image:

1) “Gesture”

2) Here is a little sub-assembly to keep your brain occupied until the next clue;

See the little red aluminum part? It is 47mm long. And the threaded shaft that is driving it is M6x1.0, Left-hand threads too. From those clues, you can size the rest of the assembly. (We have converted completely to metric here, so don’t read anything into this other than the Imperial measuring system is SO inefficient.)

The subassembly pictured also contains the following (not all are visible);
2 steel washers
1 retaining ring
1 spring washer
1 nylon washer
1 set screw

My only response to your comments will come from this short list;

warm
cold
really warm
moronic
What meds you on?
bingo!
nice try.
Who gave you insider information?

I haven’t decided what the prize is going to be for guessing this invention… maybe a copy of the letter from my patent lawyer questioning my sensibilities…

-John

The post New Tool Coming from Bridge City! Here’s Clue #1… appeared first on John's Blog.

Categories: Hand Tools

Bridge City Tool Works Introduces New KM-2 Kerfmaker…

Thu, 09/07/2017 - 11:53am

Drivel Starved Nation!

You talked and we listened. Over the past couple of years we have received numerous requests for a larger KM-1 Kerfmaker. I am pleased to announce that I finally got around to designing one. And in the process, we have made it better!

If you are new to our Kerfmaker tool, we conceived and patented this device several years ago and over this time it is our number one selling tool. Here’s a video of how the original KM-1 works–the KM-2 Kerfmaker is no different;


The KM-1 Kerfmaker is limited to a maximum stock width of 2 inches. The KM-2 Kerfmaker will allow you to make cross laps and other joints with stock up to 100mm (4 inches) in width. Here’s a pic;
KM2 700

It is a scaled up version of the KM-1 with the exception of the two magnets you see embedded in the end of the two referenced faces. These magnets firmly hold the the KM-2 in place so you do not need to by hand. This is incredibly handy. Here’s a pic of the setup using our new magnetic reference stop (you clamp this in place). As you can see, the KM-2 can be used with this stop either in the vertical or horizontal position;
KM2.12 700

KM2.13 700

With a wider capacity, you can now use the KM-2 with a dado head and the KM-2 can be calibrated to any kerf size up to 25mm in width. Pretty cool. Hey wait, there is more! The magnets allow you to stick the KM-1, and the stop, directly to your saw. Pretty cool again.

So, what does this mean for the KM-1? I really don’t know as of this writing but I am entertaining the thought of adding the magnets to the KM-1 with a magnetic stop that fits that tool the next time we make them. The magnetic base really is a huge benefit in use. The KM-2 closed is 182 mm in length, 44 mm tall and 16mm thick and gauges stock width up to 100 mm with a maximum kerf of 25 mm. FYI.

We will open up pre-orders for the KM-2 the second week of September with delivery in early December. The whole set-up will be around $100 bucks.

JOHN IS STUPID DEPARTMENT…
In other news, we are making an incredible new tool that has caused some confusion, mainly because I did a crappy job of explaining how it is used. I actually explained my reasoning to my two dogs and they looked at me like I was an idiot. Let’s try round two…

Pictured below is our new Universal Gauge;
UG_L and UG_R.1 700

The tool at the top is the LEFT version of this tool (UG-L) and the unit on the board is the RIGHT (UG-R). If you are using this tool to set-up a table saw, you would use the RIGHT version if your blade tilts to the left, and the LEFT version if your blade tilts to the right. The confusion we created is for those woodworkers who want this tool but will not use it on a table saw, so here is the definitive answer to “Which one?”

See the unit on the piece of wood? It is the UG-R (R for Right). If you were going to scribe a line along the bevel arm, which hand would you use. If you said LEFT… BINGO! If you are right handed you will want to order the unit in the top of the image. Make sense? Regardless, this may up being my most favorite layout tool, my shop at home is really small.

LASTLY
Look for an email soon regarding our FREE SHIPING OFFER on the Gyro Air Dust Collector that runs through October 15th.
GYRO AIR_EN _Web

LASTLY AGAIN
Some 15 year old kid with illegal fireworks deliberately (through ignorance I presume) started a forest fire in the beautiful Columbia Gorge east of Portland last weekend. You cannot imagine how bad the air quality is here, the worst I have ever seen and I was here when Mt. St. Helens blew. I mention this because if you are a parent or a grandparent, this is great teaching moment to inform those you love that their lives can change in an instant and that every action has an unintended consequence. This fire is unbelievably tragic and right now it is about 40,000 acres and is 5% contained. Ugh!

-John

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Categories: Hand Tools