Making Vice Jaws

I could not work on anything else much today. Outside it is still very windy and the workshop concrete floor was freezing cold even with the fire roaring in the stove. So I could not be there for more than two hours at a time and then I had to go inside to warm my feet for about the same. But I have managed to do something useful – three sets of jaws for my bench vice.

© Charly, all rights reserved. Click for full size.

© Charly, all rights reserved. Click for full size.

On the left aluminium, then beech wood and then spruce wood covered with an old carpet. I needed these for a long time and I had to do with impromptu padding the jaws of the vice with slabs of these three materials several times on each project. And impromptu padding leads to time loss each time you use it, not to mention the cussing. For a hobbyist making one – two knives per year it is not a big problem, but now…

The dark spots on the backside covered with masking tape are where a strong 6×3 mm neodymium magnets are hidden – they collect the magnetic dust in the shop very quickly. Thus the masking tape. I had eight these magnets for a long time and I had no use for them, so I have used them for this.

And the jaws work very well. The grooves on the alluminium ones might be a bit too shallow for stock thicker than 10 mm, but I am not going to do anything about them just yet, they do seem to work just fine as they are and I will probably need to hold even 3-4 mm stock in them more often than something bigger, so they cannot be too much deeper than they are.

© Charly, all rights reserved. Click for full size.

Working with aluminium is a bugger. Whenever I have an urge to file, cut or drill aluminium, I usually sit down quietly in the corner and wait until it passes. But sometimes there is no way around it.

Did I already mention that working aluminium is a bugger? It is worth repeating. It is soft but relatively strong in tension. It is an extremely good heat conductor. And it is also extremely prone to galling and cold-welding. The end result is that it blunts and overheats saws and drillbits and clogs-up files and abrasives.

A few years ago I got a useful tip from a machinist at my former workplace. I complained about how filing and cutting aluminium by hand is more difficult than steel because of the clogging of the tool teeth. I told him that I tried using powdered chalk to coat the file and clean it with a brass brush – a tip from another machinist – to prevent this, but it did not seem to work very well. And this machinist told me “wet your file with alcohol to keep it cool”.  And it does indeed help a lot. I still need to keep a brass brush at hand to clean the file from time to time, but the alcohol does prevent the shavings from sticking to it very strongly. And unlike oil, it dries off and does not make a mess, so I use it for drilling aluminium too.

Even so, it is worth repeating. Working aluminium is a bugger.

 

Bonsai for Beginners – Part 3 – Basics of Tree Physiology

Previous part.

Of those many books that I have read about the art of growing bonsai trees, only one goes sufficiently in-depth about this issue. Unfortunately, that one book is probably only available in Czech. I will not go too much into depth here, just the basics for your own research should you wish it.

The distinction between a tree and a bush/shrub is not clear-cut, but there are properties that some plants have that make them definitively shrubs – like roses – or definitively trees – like spruces. A rose, no matter how big and old will be unruly and bushy. Spruce, no matter how small, will be a tree, with a definitive main stem.

The most important factor in this is the absence or presence (and strength) of so-called apical dominance. In plants with strong apical dominance, the main stem produces hormones that regulate and/or inhibit the growth of secondary branches. That is the reason why spruces almost invariably have one upright stem with comparatively thin branches – they have very strong apical dominance like most conifers do. Roses, on the other hand, do not have apical dominance worth speaking of. They continuously sprout new twigs from the base of the stem near the roots. Common hazel is somewhere in between – at the start it has strong apical dominance, but the bigger the main stem gets the smaller inhibiting influence it has, it slows its growth and inevitably suckers start to sprout from the base even when the main stem is perfectly healthy and strong.

Apical dominance applies to roots too. Some plants tend to grow long, thing, non-branching roots, some have bushy ones.

It also changes during each season – in many plants with leaves the hormones are produced by the leaves, thus the more leaves there are on the branch/stem, the more it inhibits those below it. That can be used to your advantage for certain species – more on that when talking about them.

For a beginner, plants with strong apical dominance should be avoided, especially fast-growing ones. Many such plants when cut do not branch out but simply the bud nearest to the cut continues as the main stem. Some might even die. Best are plants with some apical dominance, but not a very strong one. But also not so weak as to tend to sprout suckers each season.

That, unfortunately, means that for a beginner or a small-scale grower, the most iconic of all bonsai trees – pines – are not suitable, as well as most of the coniferous trees overall. They are the most difficult to manage and to form, and some of them are downright snowflakes. Best suited are leafy plants, with moderate growth rate.

I will go into more detail when talking about specific species in due course.

New Forge Build – Start

The lining inside my portable mini forge is starting to fall apart, and instead of repairing it I have decided to build a completely new one. I have observed a few problems with the old one, how to achieve the best circulation of the hot gasses etc, and I think I can do a better job at it now than I did then.

I started with a rummage around my junk-pile. I thought about the hows and whats and I selected a few pieces of steel v-profile, a few treaded rods with matching nuts & washers and a long piece of stainless chimney duct. Then I made a sketch (sorry for the grime, it occurred to me to make the pictures only after  I have done all the work).

© Charly, all rights reserved. Click for full size.

It is slightly bigger than the previous one, but it should still be easily portable. And the fireclay bricks fixed at the front and back will save me some time preparing for my work. I hope. I see no reason why it should not work as expected, but proof of the pudding is always in the eating. In my previous job, I have always reminded engineers that reality, not their expectations, is the ultimate arbiter of what works and how.

After I was done with the sketch, I started to make a list of parts. I have decided to not weld it together, but to use screws. Partly because my welding sucks big time, partly because the fireclay bricks are all miss-shapen and of different sizes and I wanted to have a bit of room to play and partly I reasoned that if it all goes south, I will be able to disassemble it easier. This has meant however that I had to ad a lot of nuts, screws, and washers and that has proved to be a bit of a problem. A lot of the M8 nuts and screws in my junkpile were rusty beyond rescue and I had trouble getting all I need.

© Charly, all rights reserved. Click for full size.

However, I have managed to get everything I need without having to go shopping. I cut the steel profiles to size, wire-brushed them, drilled holes, then filed some of the holes to an oval shape in order to be able to adjust the size of the holders for fireclay bricks and I assembled it to try it out. It seemed to work alright, so today I disassembled it all again. Then I degreased every profile thoroughly with acetone and I spray-painted them with silver stove paint (not the duct, since that is already stainless and the paint would probably not hold on it anyway). When the paint dried, I could finally assemble the whole thing together.

Here it is.

© Charly, all rights reserved. Click for full size.

Today I have made the mold for the inside – the actual chamber and the in- and outlet. This time with my old trusty method “just wing it, mate”. Tomorrow I hope to fill it with refractory cement.

I will post about how that went.

A Knife for my Brother

I did not manage to finish a knife for my brother’s 50 birthday last year, for I nearly hacked off my finger with a hatchet. So I am rectifying the issue this year.

This is the blade that was hardened when I was working on the rondel dagger. It is not a perfect blade, aesthetic-vise. I messed up the polish a few times and I had to eventually stop trying to correct it otherwise the knife would turn into a small razor. It is a good universal kitchen knife, very good cutter, I am just not happy with the surface finish. But it is either this or nothing and this year I want to give my brother a knife I know he wants. He is going to appreciate it even with the flaws.

© Charly, all rights reserved. Click for full size.

I tried to make up for the flaws with the handle, so I have used a piece of partially rotten lilac branch that I have harvested last fall. It is just stunningly beautiful wood and this is probably the prettiest knife handle I have made so far. The wood is rock-hard with tiny pores (lilac is one of those woods that can take 1000 grit polish without dirtying) and would probably hold up well even without the boat lacquer coating. But it was partially rotten, so the outlying regions were not only discolored, but also softer, so I soaked it in boat lacquer to stabilize it. With the coating, it should be near indestructible.

The lilac-colored heartwood will probably age into dark brown over the years, but it might take a really long time since the branch was already several years dead when I cut it off.

© Charly, all rights reserved. Click for full size.

© Charly, all rights reserved. Click for full size.

© Charly, all rights reserved. Click for full size.

How to Make a Soft Buffing Brush Wheel

    1. Materials: Threaded rod or long screw, two matching nuts and at least two washers. The bigger the washers the better, to spread the load more evenly over a broader area. Further, you will need some sturdy paper and very sharp scissors or a razor. And the final ingredient is a lot of soft, thin string, at best some sort of linen or cotton.

      © Charly, all rights reserved. Click for full size.

    2. Cut several (in my case it was 24) identical semi-circles out of the sturdy paper, with the radius of the desired buffing wheel.

      © Charly, all rights reserved. Click for full size.

    3. Divide the semicircles into pairs and wrap each pair evenly with the thread so that approximately 60% of the paper is covered. It is good to wrap each pair in approximately the same amount of turns.

      © Charly, all rights reserved. Click for full size.

    4. Prepare one nut and one washer on the rod a few cms from the end.
    5. Pull string between the paper of one of the semicircles and tie it around the threaded rod as close to the washer as possible. You probably won’t be able to tighten it properly yet, but it is good to have it at least somewhat secured.

      © Charly, all rights reserved. Click for full size.

    6. Cut the string at the outer rim of the semicircles, remove the paper and tighten the thread around the metal rod properly. Twist carefully the threaded rod to pull the whole thing close to the washer.

      © Charly, all rights reserved. Click for full size.

    7. Repeat steps 5-6 for the rest, try to space the thread tassels around the rod as evenly as possible.
    8. Cap it with the second washer and nut and tighten the nuts. Be careful not to over-tighten them, it might shear the threads.
    9. Trim any threads exceeding the radius.
    10. Enjoy your soft buffing brush wheel.

      © Charly, all rights reserved. Click for full size.

I did not actually need to do this, but I had some rubbish thread that I have no better use for, I cannot spend too much time in my workshop yet for I would either freeze or burn through more wood than I can afford, and this was a fun way to spend an hour. It works a treat for buffing up lacquered or oiled handles, I will probably make several more to use with various grades of buffing compounds, but I need to buy or make the big washers, since I only had these two.

 

A Hunting Knife – Auction for FTB Legal Defense Fund

You can still donate, the damage Richard Carrier has done with his petulance is not undone yet. I cannot afford to donate any meaningful cash right now since I have no income. But I can afford to donate a bit of time. So I am giving this knife in exchange for the highest donation. Details see further.

© Charly, all rights reserved. Click for full size.

Technically it is a hunting & fishing knife since my first customer specifically requested it for angling, but you need not be a hunter for having a use for it. I am regularly using a knife like this when collecting mushrooms or just walking in the forest when it might come handy. It would also be useful as an all-purpose knife for camping. The false edge is sharp, but not cutting sharp. The blade is signed and numbered “2” in Glagolitic script.

© Charly, all rights reserved. Click for full size.

I made a simple leather scabbard, this time symmetrical so the knife can be conveniently fastened on either left or right side since the preference of its future owner is unknown.

© Charly, all rights reserved. Click for full size.

The handguard/bolster has a few dark spots. These are inclusions in the used material (see further).

© Charly, all rights reserved. Click for full size.

The endcap is fastened over an ornate stainless steel washer into which is the end of the tang peened.


If you are interested, write your bid in comments or per e-mail to affinity (note, I might not be able to post your e-mailed bids in the comments next two days, there is a huge storm coming our way and I might experience blackout).

If you bid from outside of the European Single Market, please make sure that you are allowed to import such things and be prepared to pay for any import/customs fees, duties or other taxes as may be relevant in your region/country/state. I will pay for the postage.

The knife will be sent to you after submitting proof of the promised donation. If the highest bidder reneges on their promise, it will go to the next one in line. The start is 10$ (the cost of materials), the sky is the limit.

The auction will run for two weeks until February 23. 2019 and this post will be pinned to the top of the page until then.

More info below the fold.


[Read more…]

Youtube Video: Is China’s Coronavirus the Next Pandemic?

My personal view of the coronavirus is that outside of China, the mortality rate might significantly rise above what it has now (which is already several times higher than influenza), just as it did with the swine flu pandemic in 2009 (which my sister barely survived, but luckily nobody else in the family got). My reasoning for this is – people in China were probably at least somewhat exposed to the said virus in its non-human-infectious form, or some of its less dangerous relatives, which would give them at least partial immunity. Once the virus spreads to populations that have no immunity to its or to viruses similar to it, it will become much worse.

Since it is a pulmonary disease, our whole family is especially susceptible and in danger, since all of us have asthma, my parents are elderly, my sister has already damaged lungs and my brother is a heavy smoker. I certainly hope not to encounter it, I already had viral bronchitis this year for two weeks and I did not enjoy it in the least.

Making Kitchen Knives – Part 14 – Straightening Curls

Last time I was working on this project, I had some very bad results from quench. This week I have finally managed to test one idea of correcting the problem and maybe prevent it from ever happening again in the future. And I am glad to say that it did work. Not perfectly, but the new process is definitively worth to use instead of the old one.

Here is first the comparison of the three worst blades before and after. As you can see, there are still some curls in there, but they are noticeably less pronounced and one blade is almost completely straight. They will still come smaller than intended out of the polishing process, I will still have to remove some material from the edge until I get to the straight part, but I estimate it to be about 1/2-1/3 of what it was before. On the worst blade, the curls went about 10-15 mm from the edge towards the spine, whilst now it is about 3-5 mm. That is a significant improvement, and I think that had the blades been quenched from a straight form, they would never have curled in the first place.

As I alluded to previously, the process that I wanted to use for correcting the blades is called plate-quench. It cannot be used for simple carbon steels. Only so-called deep hardening steels can be thus quenched, and N690 is such steel, according to some articles I found on the internet. Nevertheless, it is better to not have the internet at all than to believe everything you can read on it – the manufacturer recommends oil quenching.

So I have tested the process first on one blade that I accidentally broke when correcting an ever so slight banana-bend. When the broken blade hardened properly – which I have confirmed not only by scratching with my gauges, but also by breaking off a tiny piece of it – I went on with the curly ones. On one of these, I confirmed the hardening too by breaking off a tiny piece of the tip, with the remaining two I was satisfied with the scratch test only.

For the plate-quench are used two flat plates from either alluminium or copper. These two metals have very high heat conductivity and thus can cool down some steels fast enough for them to turn into martensite. Luckily I got quite a few nice slabs of alluminium on hand. And because I wanted to make the process a bit faster (despite not making time-measurements this time), I have made a simple prototype quench-jig.

It consists of two identical pieces of alluminium with a small hinge, and locking pliers. The hot blade went out of the forge between the plates with the edge towards the hinge. Then it was firmly clamped by the pliers to hold it straight. When it stopped glowing near the tang – indicating a temperature well bellow 600 °C – I dunked the whole thing in a bucket of cold water just to be sure. And just as last time, because it costs nothing, I have put the blades into a freezer straightway for a few hours before tempering them. None of the three blades cracked.

Not an actual quench, staged photo – sometimes I miss having third hand greatly. © Charly, all rights reserved. Click for full

It worked reasonably well and quick. I will definitively improve it and build a proper jig when the weather is nicer and I do not freeze my nuts off in my workshop. I will add a more stable hinge(s) and maybe even screw one of the plates to the pliers.


Another advantage of this process is no burnt oil gunk on the blade, no flames and no stinking oil fumes.

Yellowhammers Visit.

I had this visitor a few weeks ago, but the light was bad and I was unable to identify the species. Luckily my biologist friend was able to forward it to an ornithologist who was so very kind and identified the bird for me. So when yesterday they returned in good light, I knew what I am looking at.

The ornithologist also sent some bad news with the identification. He confirmed my subjective observation that there are significantly fewer birds. Some species are actually becoming rare – the whole genus Carduelis for example (greenfinches, goldfinches, siskins). This winter I have not seen a single specimen of these three species, whereas in previous years greenfinches and siskins came in flocks counting dozens.

© Charly, all rights reserved. Click for full

© Charly, all rights reserved. Click for full

© Charly, all rights reserved. Click for full

And yes, we finally had a few cms of snow. This week seems to have been the actual winter, what we had before was merely agonizingly long and dark fall.

Bonsai for Beginners – Part 2 – Necessary Tools

I hope I will finally be able to do this series justice since I am starting to re-pot my trees this year. Part one was here.

You do not actually need some very sophimasticated or expensive tools to start growing bonsai trees, but even if you only aspire to have one, these are the essentials that you will need. If you have a garden or potted plants, you probably already have some or even most of them.

First – not depicted – flower pot(s). Bonsai are typically grown and shown in beautiful elaborate glazed bowls, proportioned to the tree. But ordinary flowerpot will do in a pinch – important is the plant, not the pot. Some trees can also be grown on a flat stone or a hollowed-out piece of wood etc. Anything that holds the substrate together will work, but if you intend to display the tree anywhere, the pot should be chosen accordingly. An ugly pot detracts from a beautiful plant. If you get your first bonsai tree in the form of one of the mass-produced little ones, you will probably get a passable pot with it. If you start your bonsai from a cutting or a seed, it will take several years before you need something more ornate than an ordinary flower pot. However, from the start you should keep one thing always in mind – for most bonsai styles the roots need enough space to grow to the sides, so wider and shallower pots are better than narrow deep ones.

And now for the tools on the picture, from left to right, top to bottom.

A container for storing all your tools. Whether you have one tree or many, you will usually need more than one tool at one time, so it is good to have them packed in such a way that you can take them all with you when needed, and neatly put them away when not, since they will not have any other use.

A tree balm. Either acrylic or wax/resin-based. You need something to dress cutting wounds. Acrylic-based balms are the best and some sort of ordinary acrylic paint will do too if nothing better is available. Wax/resin-based balms are perfectly OK for most conifers and for big trees, but some deciduous bonsai trees do not respond to them well, it seeps deep into the wood and can kill buds, even branches.

A mesh (plastic, glass) or pottery shards to cover the holes in the pot.

A wire. For holding the mesh over the hole and for forming the tree. Depicted here is thin steel binding wire, PVC coated. Alluminium or copper wires are better but more expensive and harder to get. A string will do in many cases, but it is more difficult to work with.

Root growth stimulator. You will need to cut roots, and in some instances, you will need to encourage the plant to grow new ones.

Charcoal. Best is low-quality charcoal from soft or rotten wood, even better one that was already lit and water-quenched several times. The reason for this is that such charcoal is very brittle and porous and can be easily crushed in fingers to a fine powder and applied to the cutting wounds. It is important for dressing bigger root wounds of all trees – it prevents fungal spores and microbes from entering them. For trees that excrete latex from wounds, it can also be applied to dry the latex quickly and seal the wound on branches and twigs too.

Bamboo BBQ skewers and chopsticks. To tease apart fine roots and comb out old substrate from the root ball when re-potting the plant.

Two pairs of pruning shears. They should be visually different, since one pair you will use for roots only, and one pair will be exclusively for branches. That is not only to prevent dragging spores from the dirt into the branches but mainly because the shears for roots will blunt faster and would tear the branches instead of cutting them neatly.

Pliers. The combination pliers will suffice since they can cut the wire too. But I have dedicated wire cutters as well.

Ordinary shears. You may need to cut leaves or very thin and fine twigs. Pruning shears are too coarse for that kind of job. Some very old shears are fine, and if you are able, grind the bevels to a steep knife-like angle.

A knife. Not only for grafting, that is improbable for a beginner, but it gets used also for cutting f.e. a piece of wood into a temporary spatula to apply tree balm.

A flat brush. To carefully clean the surface of the tree trunk without damaging the bark, to sweep away needles/leaves from exposed roots, and to tidy the surface of the substrate.

A flat hook. Or a very blunt knife or a spike or something similar to soften old hardened soil in the pot, to cut it away from the sides where it often gets stuck and to pry away more difficult root-tangles.

A trowel. Enuff said.

A substrate. Ideal substrate depends on the plant(s) you intend to grow – more on that when I will write about individual species – but most plants will survive in a substrate consisting of equal parts of coarse sand, high-quality topsoil (f.e. collected from molehills) and peat/compost. Bought substrates are OK, but I would recommend to mix them with soil and sand anyway, they contain a tad too much organic material. It is also recommended to heat any substrate, whether bought or self-made, to at least 70°C prior to planting to kill any germs it might contain. For that, you might need a tin pan and a baking oven, or a plastic bowl and a microwave.

If you start growing more trees, your toolbox will expand and no doubt you will buy some of the more beautiful and specialized ones. But all these will fit into a little bag and they are all you need to start. All the tools in the picture are ones that I am consistently using for over a decade by now, some even for several decades. None of them are expensive or difficult to get. Why buy a fancy tool, when an old one does the job just as well?