WOODWORKER CREATES BEAUTIFUL MUSIC

Posted on December 1, 2015 by EdwardsDirect.net

“I made this jumbo-body guitar from Flamed Honduran mahogany with rosewood binding,” says John.

“This guitar has a Sitka spruce top,” John tells us. “I trimmed the sound hold with Abalone shell.”

John Mannino is a skilled, self-taught Pennsylvania artisan who builds high quality acoustic guitars. “I always wanted to make guitars,” he told us. “I want to make as many as I can, of the highest quality I can.”

“Here’s a detail of a sound port on a dreadnaught-style guitar I made of local walnut with paduk trim.”

“I worked in construction for many years, hanging drywall and painting. I injured my back it gave me time to try what I’d always wanted to do, build acoustic guitars. Growing up, a friend’s father made violins. Maybe that inspired me.

Trial and error, and error, and error

I started making guitars about 14 years ago. I bought cheap equipment — a bandsaw, jointer, drill press, and so on at Lowe’s. I got a book on building guitars and started on this journey. I’m completely self-taught. I call it trial and error, and error, and error! It’s taken me a long time but my instruments are getting better and better. I’m getting good reactions from musicians.

Of course I play guitar myself — folk music, blues, jazz. A little bit of everything. But I don’t get that much time to play. I’m in the shop building guitars eight or ten hours a day. This is an avocation, something I want to do. And building quality guitars is a real challenge.

John makes them light and strong

Here’s John with one of many guitars he’s made, and the Woodmaster Drum Sander he uses to make them.

Flamed Hondouran mahogany guitar with Sitka spruce top.

Unlike an electric guitar, you have to build the sound into an acoustic guitar. You really have to know your wood. Different woods have different sounds, and you have to know how thin you can make the wood without having it collapse on you. You want a guitar to be light enough to be responsive but not so thin that they collapse.

East Indian rosewood OM (Orchestra Model) guitar by John Mannino

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I build every part of my guitars entirely by hand. Each guitar takes me a couple months to build. I made four this winter. I build the guitar itself then lacquer it, then let it set for two weeks to a month, then sand it down and buff it. Then I string it and let it set some more. Then I do the final setup, put strings on it, and play it. Of course while I’m waiting on one I can work on other ones.

When you’re into guitar making, there’s no such thing as too much wood. I buy wood all over. On the internet, at shows, at symposiums put on by ‘ASIA’ — the Association of Stringed Instrument Artisans. I work a lot with East Indian Rosewood, Honduran Mahogany, padauk, lacewood, ebony, and many more woods.

“This would be impossible without my Woodmaster Drum Sander.”

My Woodmaster Drum Sander is my most important piece of equipment. I couldn’t build guitars without it. It would be impossible to do what I do without my Woodmaster Drum Sander. When I started out, I got a Delta sander. It was $1,100 or so and was a big piece of junk. It kept breaking down, it was in the repair shop more than in my wood shop. My son did some research and learned about Woodmaster. The Woodmaster Drum Sander is built like a tank and is not that much more than Delta® and Grizzly® equipment that’s made in China.

I’m very satisfied and happy with my Woodmaster. It’s well used; I’ve had it four or five years and it’s never broken down. It’s very precise; I can sand wood down as thin as 80 thousandths of an inch. I make the backs of my guitars 100 thousandths. The sides are 80 to 90 thousandths.

For anybody doing delicate woodworking…

Toby, John's Old English Sheepdog, keeps watch as he prepares to play.

Toby, John’s Old English Sheepdog, keeps watch as John prepares to play.

My goal in all this is to make as many guitars of the highest quality I can before they put me in the ground. Building a quality guitar is a real challenge! For anybody else who wants to make guitars, or anybody doing delicate work like this, I’d highly recommend getting a Woodmaster Drum Sander.”

— John Mannino, Woodmaster Drum Sander Owner, Lumber City Guitars, Reedsville PA

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MAKING ADIRONDACK STYLE FURNITURE with a Woodmaster Drum Sander

Posted on September 29, 2015 by EdwardsDirect.net

Established in 1892, the Adirondack Park in northeastern New York State is over 6 million acres of pristine, mountainous wilderness with dozens of mountains, over 3,000 crystal clear lakes, and more than 30,000 miles of sparkling waterways. It’s twice as big as Yellowstone, Yosemite, and Grand Canyon National Parks…combined!

It’s also the birthplace of rustic, decorative Adirondack Style furniture made of native woods, saplings, birch bark, and more. Distinctive and ruggedly handsome, Adirondack Style was created by early 1800’s settlers who built and furnished their cabins with what was available. Today, the style is perfected and popularized by skilled craftsmen like Richard Vega, woodworker, artisan, and Woodmaster Drum Sander owner.

“I build high quality, rustic, Adirondack Style furniture — tables, cabinets, chairs, and more. I use different grades of woods; red oak, white oak, curly maple, pine, cherry, and exotic woods, too. We’re a small, mom-and-pop, internet-based business but my customers are hotels, restaurants, and celebrities including a major movie director. I’ve built a lot of furniture for a big hotel at a Six Flags amusement park. We do business with decorators in New York City, California, the Midwest. We have a big project coming up in Lake Tahoe.

My tables are often very big, from 36” to 48” wide — sometimes up to 60” wide — and 7’ to 24’ long! When you’re doing large projects or large orders, you want to save time and the Woodmaster does the trick for us. It saves is a lot of time.

Creating flat faces on round saplings

I use a lot of hickory saplings in my furniture. I get them from specialized tree farms. Some of our tables have trim made of hickory saplings that are split lengthwise. I found a way I could smooth the split faces on the Woodmaster. I put them, split side up, between two rails and run them through the sander. That evens out the faces so they fit nice and tight to the table edges.

I’ve owned and used Woodmaster Drum Sanders for many years. I have two of them — a 38” 3875 and a 50” 5075. I keep them well maintained and they do exactly what they’re supposed to do, create perfect surfaces. They’re very powerful and I’ve had no trouble. I’ve had other drum sanders and changing sandpaper on them was very time consuming. They had steel drums with clips to hold the paper. It’s hard to get your fingers in there with the clips and paper changes take too much time. Woodmaster’s Velcro® system makes paper changes easy. It takes less than 5 minutes.

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1/4 turn equals 1/16 of an inch sanding depth

We use my Woodmasters to do some restoration work, too. People bring in beautiful red oak doors from 1800’s homes and ‘Great Camps’ in the area and we put them through one of the Woodmasters. It’s very precise so I can sand off the gloss finish and the stain, right down to the oak, then refinish them. I take off only a little at a time using 180 or even 220 grit. The Woodmaster’s very precise — 1/4 turn of the handle equals 1/64th of an inch sanding depth.

I chose Woodmaster for several reasons. First, it’s made in the USA. Also, it came with a very good warranty, especially on the motor. It’s a very powerful motor compared to other sanders. And of course the price — you can’t beat the price and the quality. The customer service is right on the money, too. They have technicians there who will handle all your questions.

60” wide tabletops

I got the ‘big daddy’ 50” model because many of my tabletops are as wide as 48”. And I added the 38” model to handle 36” tabletops and end tables. I’ve built tops as wide as 60”. In those cases, I make two, 30” wide halves and glue them together.

Woodmaster’s affordable, high quality

I’m absolutely happy with my Woodmasters. You really get quality, at a good price, and you couldn’t get a better machine. You can’t beat the Woodmaster Drum Sander for low price and high accuracy.

My only advice for anybody thinking about getting a Woodmaster Drum Sander is this: if you’re going to buy a drum sander, go with Woodmaster. You won’t regret it.”

— Richard Vega, Adirondack Rustic Designs, Woodmaster Drum Sander owner

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“CAN I FACE-SAND ALUMINUM CASTINGS on the Woodmaster Drum Sander?” — Woodmaster’s not just for woodworkers!

Posted on August 31, 2015 by EdwardsDirect.net

Drum sanding’s not just for woodworkers! Art Blackwelder has a nice business creating cast aluminum markers for golf courses. He paints the castings then removes the paint from the high spots to highlight the lettering and design. What’s the best way he’s found to do this? His Woodmaster Drum Sander.

Drum sanders are for woodworkers, right? Well, not always. Art Blackwelder is a Woodmaster Drum Sander owner who uses his Woodmaster to face aluminum castings.

Besides wood, what do YOU sand that a drum sander would sand better? (Take our SPECIAL SANDING CHALLENGE, below)

OK, now think about it: what are YOU building, making, or manufacturing that could be done faster, easier, and better with a high-precision, tough as nails, Made in America Woodmaster Drum Sander?

PAINTED PLAQUES GO IN — Art mounts his painted castings on a jig and runs them through his Woodmaster Drum Sander.

$FINISHED PLAQUES COME OUT — One pass through the Woodmaster Drum Sander shaves the paint off the surface of the plaques' lettering and design details. The result? A perfect, professional finish in a fraction of the time it used to take.$

FINISHED PLAQUES COME OUT — One pass through the Woodmaster Drum Sander shaves the paint off the surface of the plaques’ lettering and design details. The result? A perfect, professional finish in a fraction of the time it used to take.

“I owned a pattern shop for 24 years, now I own Eagle Golf Products. We were the first company to make custom cast golf course equipment like tee markers and yardage markers. We make patterns using a golf club’s logo and lettering, then cast the markers out of aluminum.

3 sanding problems, 1 Woodmaster solution

SWIRL MARKS — PROBLEM SOLVED

We paint the finished castings then sand the paint off the faces of the lettering and logo so they stand out. I had a big, 30” disk sander but it would always leave swirl marks. We sell through dealers and they didn’t like that. The Woodmaster Drum Sander sands straight across without swirl marks.

SANDING HEAT — PROBLEM SOLVED

Our disk sander would heat up the casting. The paint would get gummy, then dust particles would mix in with the paint and we’d have to redo everything. Now we sand the faces with the Woodmaster Drum Sander. It doesn’t heat up the castings so the paint doesn’t get gummy.

SANDING DEPTH — PROBLEM SOLVED

Some club logos are intricate. When we used a disk sander, if you held a disk sander on it too long, it would remove all the detail in an instant. With the Woodmaster, we have control over sanding depth, over what we take off. We take off just 1/32” — it does what we need it to.

The Woodmaster’s self-feeding feature makes production simple. The rated of feed can be adjusted to the workpiece. And the sanding depth can be fine tuned to the thousandth of an inch.

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Time Saver, Money Maker

Some of the many plaques Art’s turned out in his shop. Very nice!

Grinding our markers always took a lot of time. The Woodmaster Drum Sander’s saving us a lot of time. With my old disk sander, it would take a minute and a half to sand each marker. With my Woodmaster, we can sand six or eight markers in the same amount of time. We made a jig to hold our castings, a piece of plywood with six holes cut in it hold 6 castings so you can simply run them all through at once.

Actually, we can now finish 6 or 8 markers in less time than it took to sand one. It really works great. Our Woodmaster’s been making us money, that’s what counts!

Deal Sealer: Risk Free Trial, Financing, no payments for 3 months

Other companies have drum sanders but I like Woodmaster best. I like that I can reverse the variable-rate feed belt and bring the workpiece back to me. I just think the machine is super.

The Woodmaster paid for itself in under a year. I saw a Woodmaster ad and called for the information on it. What sealed the deal was I didn’t have to pay for it all at once. They gave me 3 months to try it before I had to pay.

Brass, bronze, aluminum — Art surfaces many metals with his Woodmaster Drum Sander. What are YOU sanding that a Woodmaster could handle faster, easier, better?

“Hello, Woodmaster? Will this machine do what I want it to do?”

I called Woodmaster before I tried grinding aluminum on it and they assured me it would do what I wanted it to do, like face bronze or aluminum castings. They said just take a light cut on the face of the marker. Works great.

We always need it yesterday — Woodmaster ships fast

You’re always running out of something when you run a shop, and you always need it at the last minute. We call Woodmaster when we need something and I haven’t had a problem. We get our order quickly, they ship well.

— Art Blackwelder, Woodmaster Drum Sander Owner, North Carolina

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Take our SPECIAL SANDING CHALLENGE:

If the Woodmaster Drum Sander will handle Art Blackwelder’s cast aluminum markers, what else will it sand? Well, what have you got? Call 1-800-821-6651 or email and challenge us. Tell us what you’re sanding and we’ll tell you how our Drum Sander will create a perfect finish faster, easier, and better than your current sanding method!

QUESTIONS? COMMENTS?

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BUILD A POOL TABLE – Mesquite and a Woodmaster Drum Sander

Posted on July 23, 2015 by EdwardsDirect.net

Charles (Chuck) Phelps tells us he’s a self-taught woodworker. Well, he obviously a good teacher and a good student. He recently completed his “dream project,” a regulation-size pool table. His strong math background played a big part, as did his Woodmaster Drum Sander. Here’s Chuck’s story…

“I was an economics and math major in college and I use geometry to plan many of my projects, figuring out what angles to cut and how to achieve them repeatedly. I’m a self-taught woodworker, I never had woodworking training. I work by trial and error, trying things out on scrap wood. And I use a lot of scrap wood!

Chuck’s pool table is a beauty. His Woodmater Drum Sander and Woodmaster Molder/Planer helped him turn a long-time dream project into a reality.

I recently built my biggest, most difficult woodworking project, a regulation-size, 4’ x 8’ pool table. I couldn’t have built this pool table without my 38” Woodmaster Drum Sander.

Mesquite’s very stable — doesn’t shrink or expand with moisture

Chuck runs one of his solid wood backgammon boards through his 38″ Woodmaster Drum Sander to get a perfectly smooth, even, perfect surface.

I’d had a slate pool table bed for years just waiting for this project. I found plans on the internet and chose to build my pool table it from mesquite. It’s a pest tree in the south where huge areas are overgrown with it. They just bulldoze it out. But it’s a great wood to work with because it is very stable and doesn’t shrink or expand with moisture. I found a woodworker who salvages, saws, and sells it. Besides my Woodmaster Drum Sander, I have a Woodmaster Molder/Planer. I ran the wood through it to get it all to uniform thickness.

It was really crucial to have the Woodmaster Drum Sander for this project because it gives you extremely precise, repeatable thicknessing. For example, the pool table’s rail height must be exactly 63% of the diameter of the ball so the rail’s ‘nose’ is just above the ball’s center. If the rail hits below center, the ball will fly off the table! The rail height works out to a very odd and precise measurement and you can’t create that height by stacking commercially made lumber.

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1/6 turn equals 1/100″ sanding depth adjustment

The Woodmaster Drum Sander is extremely precise. When I turn the height adjustment crank one full turn, it changes the sanding depth exactly 1/16”. To change the depth just 1/100” I turn the crank just 1/6 of a turn, the equivalent of 10 minutes on a clock face. This drum sander’s precision is really quite amazing.

For the side panels, I chose highly figured wood and it needed a lot of attention from my drum sander. The legs are all glue-ups. I have a Woodmaster Molder/Planer, too, and I used it to get really smooth surfaces.

Anyone for backgammon? Commercial boards’ diamond-shaped pieces are laminated to a substrate. Chuck makes his of solid wood. It takes real precision to do this kind of work!

I make backgammon boards, too. The design is very elaborate with lots of diamond shapes. Commercial backgammon boards are laminated but I make them from solid wood. I use three woods and put them through the drum sander. I cut all the diamond shapes and pieces, glue them up, and put them through the Drum Sander again to get a perfectly even surface. This would be impossible to do without the Woodmaster Drum Sander.

“Woodmaster’s obviously the best on the market”

I do lots of research before I buy tools and I try to buy the best. Woodmaster equipment is obviously the best on the market. You can’t get Woodmaster’s throat width on equipment from Home Depot. I looked at a drum sander that had a cantilever head — it was attached only on one side. I rejected it simply because of that design.

I’d advise others to not skimp on inferior equipment. If you get a machine that doesn’t work well, it’ll drive you crazy. It’s simply a mistake to start with imprecise tools. The Woodmaster Drum Sander has tremendous durability, strength, and it’s very safe to use. I have no ambiguity at all – it’s by far the best drum sander available.”

— Charles Phelps, Woodmaster Owner, Gualala CA

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“WOODMASTER JOBS KEEP COMING AND WE CAN’T SAY NO” — Woodworking couple’s happy & BUSY in retirement

Posted on June 30, 2015 by EdwardsDirect.net

Here’s a happy couple who’ve found the secret of a full and rewarding retirement. John and Kaye Lepien are woodworking partners. “We work together and design things together,” says John.

“It gives us both a creative outlet so we don’t just sit around as so many retirees do.” And how’s business? “We’re almost busier than we’d like but it’s awfully hard to turn jobs down.”

“I taught Industrial Arts for 36 years. I retired in 1997 at 57. Today, my wife, Kaye, and I run our own woodworking business, J & K Creations, and have a Woodmaster Drum Sander. Business is great. In fact, we’re busier than we’d like to be. It’s awfully hard to turn jobs down.

It’s not about the money

John and Kaye’s daughter sells the work her parents do with their Woodmaster. Her online catalog describes this piece, “Handcrafted in Michigan. Colonial Pipebox. Distressed Olde Forge Mustard paint by Olde Centry Colors with brown stain. Box measures 17.5″h x 6″w x 4.25″d. Sorry pick not included.”

Money is not the object of our business at all. It’s not about the money. Our business keeps us active and busy. So many people retire and have nothing to do. They just sit around and they die! I see it all the time.

This business is something Kaye and I can do together. We’re here in the shop together all day long and that’s great. We work together and we design things together. It gives us both a creative outlet.

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Every day’s different

I once worked in a factory at the same machine for 8 or 10 hours a day and I said ‘I’m just not going to do this for the rest of my life. It’s boring!’ Today, in our business, every day’s different and I love it.

Kaye and I started out selling what we made at craft shows. Then our daughter bought a store in downtown Iona, Michigan, ‘Keeper of the Crows,’ where she sells primitive home décor and antiques. We supply over 50 primitive-style wooden items to her store.

We make ‘primitives’ and antique-style items of pine and poplar. We round the edges and corners and mar the surfaces a little. Then Kaye paints them and we sand off the corners to give a ‘distressed’ look. Kaye adds stain and we finish it with Crystalac. It acts like a lacquer but it’s water-based and dries in no time.

Folding cutting boards and more, every kind you can imagine

Online, John & Kaye’s “Colonial Candlebox” is described and sold as, “Distressed redish/orange with dark brown stain. Box measures 14″h x 8.5″ w x 4.75″ d. Sorry does not include flower pick.”

We make custom furniture, too. I use walnut, cherry, maple, hickory and more. There’s no waste: I save all the cutoffs and leftover pieces of hardwood from other projects and make every kind of cutting board you can think of. They sell like crazy, especially at the Holidays. This is where our Woodmaster Drum Sander comes in so handy. We make 40 or 50 cutting boards at a time. We glue them up and send them through the Woodmaster and they come out perfect.

“We use our Woodmaster Drum Sander 4 to 5 hours every day.”

“Colonial Shelf” by John and Kaye. Their daughter sells their work online. She writes, “Love this little shelf/setter. Distressed sage green. Shelf measures 16 1/2″h x 12″w x 5 3/8″d. Sorry crock not included.”

Our 38” Woodmaster Drum Sander works like crazy. I use it every day, four or five hours a day. We use it to make all kinds of things — fancy little boxes; mahogany cribbage boards; furniture; shelving; kitchen islands; cabinets; US flag boxes; all kinds of things. We designed and make a folding cribbage board. I did a kitchen and bathroom out of white pine for a retired state trooper. I make a lot of things that have drawers so I make 50 drawers at a time with the drum sander. We’re very diversified and we’re always making new designs. I’d be lost without my Woodmaster Drum Sander.

Also, I do custom sanding. A lot of people come in asking me to sand things for them. A young man just brought in 10 walnut boards he wanted sanded. I just made a 6’ by 34” wooden floor panel for a fellow who’s turning a Cadillac hearse into a limousine. The word gets out and I get calls. I don’t advertise, the word just spreads. I got three calls yesterday!

I’d never used a wide drum sander until I made a big project for myself using a friend’s drum sander. I got a Grizzly® drum sander but I hated it and practically gave the damn thing away. After that bad experience, I shopped around and got my Woodmaster. I used it every day. All the time.

He sets sanding depth by ear

I got the 38” Woodmaster Drum Sander because I wanted to run doors. I just ran more than 30 doors for one job! Here’s how I set the sanding depth: I set it so the drum doesn’t quite touch the workpiece. I turn the Woodmaster’s handle until I can hear the drum just kiss the wood. Then I turn it just a touch more — that’s my setting.

In 36 years as an Industrial Arts teacher, I’ve seen all kinds of equipment and, yes, that experience influenced my decision to buy a Woodmaster. I’d buy another one in a minute. The people at Woodmaster are great, too. You can call and talk to them. I call them a lot when I have technical questions. I get on the phone with Woodmaster and I get people who know what the hell they’re talking about!”

— John Lepien, Woodmaster Owner, J & K Creations, Saranac MI

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HOW TO DO A DAY’S WORTH OF HAND-SANDING IN 15 MINUTES (Hint: Woodmaster Drum Sander)

Posted on June 1, 2015 by EdwardsDirect.net

Besides cabinetry, Jeff builds handsome Adirondack chairs with his Woodmaster Drum Sander. This style chair, with slanted seat and back, is both handsome and comfortable.

OK, woodworkers, which would you rather do: spend an 8-hour day pushing a hand-sander around, or zip your work through a Woodmaster Drum Sander in 15 minutes? Or let’s put it another way: how’d you like to reduce the time you spend hand-sanding by 97%?

For cabinetmaker/furniture maker, Jeff Rhone, those time-saving numbers are real, and those questions are no-brainers. But the time Jeff saves is just one of four reasons he chose the Woodmaster Drum Sander. Please read on…

Jeff Rhone’s running a great business from a small wood shop — just 600 sq. ft. He put his Woodmaster on casters so he can tuck it out of the way between sanding tasks.

“I run a one-man custom cabinetry shop. Most of the work I do is custom cabinets and furniture. I specialize in small cabinetry jobs, kitchens, pantries, mudrooms, closets, entertainment centers, and so on. I started woodworking in a small custom cabinet shop. We’d take on anything — furniture, refinishing, everything. Our main bread and butter work was custom cabinets. Eventually, I went out on my own.

Everything from face frames to furniture parts — saves literally days of hand sanding

I first ran into the Woodmaster Drum Sander in trade school. The school had a Woodmaster and I thought it worked great. I ended up getting a Woodmaster 38” Drum Sander and I’ve used it on every project I’ve built since I got it — everything from sanding down face frames to sanding all the pieces for the Adirondack chairs I build. This sander has saved me literally days of hand sanding. It is a Godsend.

“The cart in this photo is a gun cart,” Jeff tells us. ” The gentleman who asked me to built it uses it in old style Western shooting competitions. It has a gun rack and room in the box for ammo.”

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My current shop is just 600 sq. ft.. I have a lot of big tools like shapers and so on but the Woodmaster fits right in. It has a small footprint and it’s on casters so I can move it where I want it. My Woodmaster works out perfectly.

I do everything myself, I don’t send anything out. I do one project at a time, anything from cutting boards to kitchens. I make a lot of Adirondack-style chairs and the sanding the Woodmaster does is remarkable. It does in 15 minutes what would take me a full day to do by hand.

Slashes sanding time 90%

Here's a handsome entertainment center ready for installation. Jeff does all manner of cabinetry — kitchens, bathrooms, closets, more.

Here’s one of Jeff’s handsome entertainment centers ready for installation. He builds all manner of cabinetry — kitchens, bathrooms, closets, more.

Woodmaster says a cabinetmaker spends 60% of his time hand-sanding, and that the Woodmaster saves 90% of that time. I agree with that 100%. For example, making chairs. When I was hand-sanding, it would take me a whole day to hand-sand all the parts for just two chairs. Today I just sent all the parts for four chairs through my Woodmaster in under half an hour. And the surface quality the Woodmaster creates is great. (Note: when we did the math, Jeff’s Woodmaster actually saves him 97% of the time he spent hand-sanding.)

Between sanding jobs, Jeff’s Woodmaster rolls out of the way so he’s able to maximize the utility of his 600 sq. ft. shop.

I chose the 38” Woodmaster Drum Sander so I could run 36” cabinet doors and face frames without any issue. I can do entry doors up to 36”. This size works great for butcher block counter tops I make, too. They’re 25” wide — a 24” sander’s not quite wide enough for that.

The other Woodmaster advantage is the ease of sanding a lot of small parts. I just send them through side by side. They come out the other end and drop onto a table I have set up to catch them on the outfeed side.

Jeff chose Woodmaster for 4 reasons: Affordability, Made in America, Small Footprint, Saves Time

I chose Woodmaster for several reasons. First, it’s affordable. It’s cost effective — you’d pay twice as much for a Powermatic. Second, it’s made in America. That’s important, keeping jobs in the USA. USA tools are better made than imports. Third, it has a small footprint. I’ve got it on optional casters and I can move it out, use it, and move it back. Other sanders didn’t work like that.

And fourth, it saves time and everybody knows time is money. For somebody like me, a small shop woodworker, it’s saved me literally days and days of hand sanding. It paid for itself a year ago. I’d give this machine a 10. It’s one of my most-used machine in my shop, right after my table saw and my chop saw.

Booked 3 months ahead — no regrets

I don’t advertise and don’t want to. Right now, I’m booked out three months or more. I’d recommend it to other woodworkers and I’d do it again myself. I researched drum sanders for almost 10 months. I don’t regret my decision at all.

I can’t ask for a better drum sander. It’s a quality machine. The way it’s made, I could use it all day long and never have an issue. I love it, wouldn’t get rid of it. Woodmaster, keep up the good work!”

— Jeff Rhone, cabinetmaker, Woodmaster Drum Sander Owner, South Dakota

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HOW TO MAKE LAMINATED “WIGGLE CANES” with a Woodmaster Drum Sander

Posted on May 6, 2015 by EdwardsDirect.net

Here’s retired engineer and dedicated woodworker, Dennis Westphal, with his Woodmaster Drum Sander. Thanks, Dennis, for sharing your secrets for creating your exceptional “Wiggle Canes!”

Dennis Westphal is a woodworker who loves a challenge. Maybe his decades in engineering inspire him to take on highly complex projects. He certainly has a knack for merging two exacting disciplines — woodworking and engineering — in the production of his extraordinary “Wiggle Canes.”

Dennis has been kind enough to share specific “how-to” detail on his entire production procedure and we’re happy to pass it all along to you. Note he stresses the importance of the precision it takes to produce his 15-layer, laminated Wiggle Canes — the kind of precision he achieves with his Woodmaster Drum Sander.

“I like to make unique woodworking projects, things that are a little different, things not a lot of people make. That’s why I make what I call ‘Wiggle Canes,’ functional walking canes with a definite wiggle in them. I like making them and I just like the way they look.

I’ve made Wiggle Canes as gift for people who need walking assistance, people we know who’ve moved into assisted living homes. People wouldn’t want to pay me for the time it takes — maybe 25 hours apiece between sawing, sanding, soaking, gluing, and finishing.

I like this 2675 Woodmster Drum Sander. I use it almost every day. I don’t know what I’d do if I didn’t have it. I guess I’d have to get another one! Thanks for the opportunity to show some of my projects to other woodworkers.

Precision Sanding is ESSENTIAL

I got the Woodmaster Drum Sander because I wanted a machine that would give me precision and speed for the kind of work I do. I knew the precision this Drum Sander would give me. I did a lot of online research and read comments from Woodmaster owners. I asked questions and got pretty positive results. I chose the 26” 2675 because it’s big enough to handle any project I’d want to make.

Each cane is made of 15 layers of wood, each layer 1/16 of an inch thick. I glue up strips in five sections, with three layers in each section, and then glue the sections together.

I make them with different patterns. Some have layers of walnut on the outer layers and maple in the middle. Some have maple outer layers and walnut middle layers. I’ve made them of all walnut, and all oak. I build them extra long so they can be cut to the right length for the person who’s using them.

Dennis reveals how he does it…so you can make Wiggle Canes, too!

Ripping Strips

Here’s how I cut the strips on my table saw. The curved fixture behind the blade allows the strip to curve away from the stock piece to avoid binding.

Precision Thickness Control

To control the thickness of the strips being cut, I use this dial indicator set-up. It is mounted on a magnetic base that sits on the top face of the saw on the right side of the fence. The plunger on this indicator moves in or out 0.100” per one full turn of the indicator pointer. This works well for what I need for the strips.

I make an initial skim cut on the stock to make sure the two edges of the stock are parallel, and to set up the cutting of the strip. After the skim cut is complete, without moving the fence, I place the indicator fixture in place by putting the indicator plunger against the right side of the fence and pushing it toward the fence for most of the available travel of the plunger. I stop the fixture with the indicator pointer at zero on the gauge. This zeros the gauge.

Next I move the fence toward the blade two full turns of the indicator pointer, stopping again at zero. Since this indicator moves 0.100” per turn, I have moved the fence 0.200”. This also moves the stock the same 0.200” from its zeroed position after the skim cut. Since I am using a 1/8” (0.125”) kerf ripping blade, the stock is now 0.075” (0.200” – 0.125”) to the left of the blade resulting in a nominal thickness of 0.075” for strip as it is cut.

Due to the blade not cutting exactly 0.125” and possibly some slight side-to-side movement of the stock as it is being pushed through, the actual stock thickness comes out in the 0.065” to 0.070” range.

This makes it ideal for one or two passes through the Woodmaster, with a very small amount being removed per pass. I end up with the desired 0.062” (1/16”) thickness. I always use scrap stock to cut some strips, both to confirm the thickness of the strip coming off the saw and to set the Woodmaster to the proper height and to know when that proper height is set, and if one or two passes are required.

Sand to precise thickness with the Woodmaster Drum Sander

Here’s an MDF board with double stick tape that’ll hold the strips as I run them through my Woodmaster Drum Sander.

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Gang-Sand Several Wood Strips for Uniform Thickness

I’ve attached six strips to the MDF board with double stick tape. This photo shows them feeding through my Woodmaster.

Soak Strips in Water for 24 Hours

I soak strips in water for 24 hours after I sand them to the required thickness (1/16” or .062) in this water-filled PVC pipe fixture. I place small pieces of scraps between the strips to allow better contact between the water and strips. Then I hold the bundle together with rubber bands

Clamp Strips in a Drying Rack to Shape Them & Form the “Wiggle”

After the strips are soaked in water for 24 hours, all fifteen strips are placed in the clamping/gluing fixture, clamped to form the Wiggle and the curved handle. They’re allowed to dry for a minimum of 24 hours. They are then removed and placed (in proper order) into this drying rack to fully dry. The way it is made, it holds the curves as the strips dry because, if the strips were to just dry loose, they would lose most of the curves — they’d tend to go back to their initial flat shape. As noted above, since only five strips are glued at one time, this holds the remaining pieces in the proper shape until they can be glued.

Apply Glue to Strips Mounted on a Gluing Fixture

This fixture holds each strip as I add the glue using a roller. Due to the shape of the strips, it is very difficult to roll on the glue with one hand while trying to hold it with the other hand, so I came up with this.

Glue Strips & Clamp Tightly

This photo shows an overhead view of my clamping/gluing fixture in place with the first five strips in place. Due to the complexity of putting the glue on the strips, putting them together, putting them into the fixture, properly aligning everything, and adding the clamps, you only have time for five strips before the glue starts to set up. To hold everything in place, a spacer equal to the thickness of the other 10 strips is added. After 24 hours, the spacer and the five glued up strips are removed from the fixture. The spacer is replaced by a thinner one that is equal to the thickness of five strips. Next, the second five strips are glued to the first five and placed back into the fixture with the thinner spacer, clamped and allowed to sit again for 24 hours. This is repeated a third time with the final five strips and no spacer, again for 24 hours. Then sand and apply a finish.

Notes from Dennis…

I’m a retired engineer and I enjoy making Wiggle Canes because they’re a blend of engineering and woodworking. I’ve got a CAD application on my computer and I lay out everything with it. I figure out all the ‘what ifs’ and see what each can would look like. I make half a dozen drawings then draw the individual pieces and parts.

Giving credit where it’s due, the concept of the Wiggle Cane is not mine. I picked up the idea from a woodworking site from a woodworker who goes by the name “Nimrod.” The fixtures and procedures noted above are all mine but Nimrod gave me the idea to develop them and make the canes. Nimrod’s canes were the curved handle version, but the “Gentleman’s” cane with the different handle that is added to the Wiggle portion is my idea and development.”

— Dennis Westphal, Woodmaster Drum Sander owner, Galva, Kansas

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“WE’RE JUST AVERAGE AMERICANS, starting a business with a Woodmaster Drum Sander”

Posted on April 1, 2015 by EdwardsDirect.net

Meet Russell and Beverly Yanney with their Woodmater Drum Sander!

“My wife and I have owned a 50” Woodmaster Drum Sander for 5 years. When you do precision wood working like we do, FLAT is essential.” — Russell and Beverly Yanney, Green Forest, Arkansas

The Yanneys may have started with no woodworking experience but they certainly have it now. They used their CNC router to carve the Marine Corps logo, “But the wood must be flat first,” says Russell. “Getting wood truly flat without the Woodmaster Drum Sander is impossible.”

“My wife, Beverly, and I got started in woodworking in about 2009 when we were renovating a house we purchased. We’re just average Americans, not trained woodworkers. Our backgrounds are in the medical field. We started woodworking from zero and didn’t even know the difference between different types of wood.

Here's a closeup of inlaid lettering. The Yanneys create a perfectly flat surface with their Woodmaster Drum Sander, then use their laser cutter to cut both the letters and the spaces they'll fit into.

Here’s a closeup of the Yanney’s inlaid lettering skill. The Yanneys create a perfectly flat surface with their Woodmaster Drum Sander, then use their laser cutter to cut both the letters and the spaces they’ll fit into.

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Building a viable woodworking business

We’re now expanding our scope and developing our work into a viable woodworking business. We already do craft fairs and have a small storefront in our town. My wife is already full time at it and I’m part time. She does the design work and I do the engineering. We’re making custom cedar benches, jewelry boxes, custom chests, fireplace mantles, chopping block tables, and more.

Wildlfe scenes like these are popular among the Yanney’s customers. After sanding the wood perfectly flat and smooth with the Woodmaster, they carved this outdoor scene with their CNC router.

We got started with a small planer, a table saw, and a chop saw. One thing led to another and I found a CNC router and a 50-watt laser cutter I couldn’t pass up. That led us to purchase our Woodmaster Drum Sander. The CNC router and the laser cutter have such high precision and low tolerance, the workpiece must be flat.

“Woodmaster holds tolerances to 0.0001 — that’s ONE HUNDRED THOUSANDTHS of an inch!”

Flatness and precision are essential in our work because we work in thousandths of an inch. The Woodmaster Drum Sander holds tolerances to 0.00001 – that’s 100 thousandths of an inch – side to side and end to end. Without our Woodmaster Drum Sander, getting wood flat is just impossible.

A beautiful jewelry box by the Yanneys. Woodmaster created the flat surfaces; their laser cutter created the floral designs.

We use the Drum Sander in our inlay work. We sand the workpieces flat with the Woodmaster then use the laser to cut the inlaid pieces and the recesses they fit into. Then we sand the surface flat, even, and smooth with the Woodmaster. We do our bas relief carving work with the CNC router. Here, too, flatness is key and we prepare our workpieces on the Drum Sander.

The Yanneys own a Woodmaster Molder/Planer, too.

Quality, versatility, affordability

We actually got an Woodmaster Molder/Planer before the Drum Sander. I chose Woodmaster because it’s American made. I wanted good quality, versatility, and it didn’t cost $10,000 like some machines do.

We’re both perfectionists. When we say ‘perfect’ we mean it and Woodmaster helps us achieve it.

“Write the check”

I’d tell anybody who’s thinking about getting a Woodmaster, ‘Write the check!’ It’s American made, easy to use, and you don’t have to be a mechanic to maintain it. You can definitely make money with a Woodmaster. It does what you ask it to do.”

— Russell Yanney, Woodmaster Drum Sander & Molder Planer Owner, Arkansas

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TRUE PRECISION ARTISTRY IN WOOD — He makes extraordinary 1,000-piece end grain cutting boards with his Woodmaster Drum Sander

Posted on March 3, 2015 by EdwardsDirect.net

Dennis gave this creation the name “Impossible” because it’s impossible for 3-D forms to do what he’s made them do. In our view, doing the precision work Dennis does is darn near impossible!

Here’s Dennis in his show with his 2675 Woodmaster Drum Sander. That’s where you’ll often find him — some of his creations take 200 hours of shop time. Design time not included!

A lot of retired folks just while the days away watching TV. That would never do for dedicated do-it-yourselfers like Woodmaster Owner, Dennis Westphal. “I’d go nuts just sitting around,” he says. Once he made all the furniture his home could hold, he started making his amazing end grain cutting boards. Some are for use in the kitchen but others are made for display. Dennis calls them “decorative cutting boards.” We call them true artistry in wood.

“I’m a retired engineer who’s been doing woodworking for close to 60 years. I spend a lot of time in my shop. I use my Woodmaster Drum Sander almost every day.

Dennis’s “Expansion” cutting board seems to expand from the center outward but it’s an illusion — it’s actually perfectly flat.

Dennis’s “Contraction” cutting board appears to bulge in the center and contract at the edges. But this is a clever illusion, too!

Over the years, I’ve built a lot of furniture for our home — china cabinets, tables, TV stands, and more. After awhile, there was no more room. So I started making end grain cutting boards made up of precisely made little pieces of solid wood, all standing on end with the end grain running right straight through from top to bottom.

Thousands of individual pieces — true artistry in wood

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I give them as gifts — Christmas, weddings, and so on. I make a lot of them, both functional and decorative. The decorative ones are artworks rather than ‘working’ cutting boards. I make all of them with my 26″ Woodmaster Drum Sander.

All are made from end grain cherry, maple, and walnut. Some have over 1,000 individual pieces of wood, some as small as one-quarter inch square.

“Here’s how I make them.”

Here’s how I make them. First, I dream up some kind of pattern. I have a picture in my head of what I want to do, then I lay it out using a CAD program on my computer so I can see what they’re going to look like. The nice thing about CAD drawings is I can modify them easily. Sometimes I make a dozen versions. Then I print out dimension drawings.

Tolerances to ten-thousandths of an inch

I rough-cut wood on my table saw, then put it through my Woodmaster Drum Sander. I can get the wood down to a few thousandths of an inch with my Woodmaster. I can control the thickness to 0.010, that’s ten thousandths of an inch! I really enjoy the Woodmaster Drum Sander for the precision it gives me.

A curved-line design creates the illusion of an undulating surface in one of Mr. Westphal’s creations. But it’s an illusion — the surface is flat as a board.

When the pieces are particularly small, I use double stick tape to attach them to a piece of MDF and I run that through the sander. I tape down and sand as many pieces at one time as I can. When I sand the pieces to size, I take them off.

Then I glue up the pieces. I use Tightbond 3 because it has a long ‘open’ or setup time. I can’t glue very many pieces together at once so I make a series of separate glued-up subsets of maybe 10 blocks at a time, then glue the subsets together.

Here’s a CAD drawing Dennis sent us – his precision plan for one of his decorative cutting boards…

…and here’s the finished cutting board. Guess Dennis believes in the old saying, “Plan the work and work the plan!” Sure works for him.

200 hours work — “And I love doing it.”

Some of my decorative cutting boards take 200 hours of shop time, and that’s not counting design time. And I love doing it. I’m retired, but my brain doesn’t shut off. I’d go nuts if I all I did was sit and watch TV.

“I wanted a machine that would give me the speed and precision I need.”

I got the Woodmaster Drum Sander because I wanted a machine that would give me precision and speed for the kind of work I do. I knew the precision this Drum Sander would give me, and it handles end grain wood more safely than other machines. I did a lot of online research and read reviews and comments from Woodmaster owners. I asked questions and got pretty positive results. I chose the 26” 2675 because it’s big enough to handle any project I’d want to make. After all, I’m not making full-size doors.

Here’s Dennis’s workshop, neat as a pin with his Woodmaster front and center. He told us his biggest project recently was, “getting my shop cleaned up so I could take photos!”

That’s what I tell people who ask me about Woodmaster. Think of what you want to use your sander for, what you want to make. Get a machine that’s big enough to handle it. But remember a big drum sander will sand small things but a small drum sander won’t do big things.

I like this Woodmaster Drum Sander. I use it almost every day. I don’t know what I’d do if I didn’t have it. I guess I’d have to get another one! Thanks for the opportunity to show some of my projects to other woodworkers.”

— Dennis Westphal, Woodmaster Drum Sander Owner, Galva, Kansas

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EXTREME HOMEBUILDING with a 50” Woodmaster Drum Sander

Posted on January 29, 2015 by EdwardsDirect.net

THIS IS THE HOUSE THAT CHARLES BUILT with help from his 50″ Woodmaster Drum Sander and a 25″ Woodmaster Molder/Planer: almost 18,000 sq. ft. of living space…76 interior doors…4 kitchens…12 bathrooms…7 fireplaces…miles of molding and trim…and more!

The McCullough home seems to be straight out of the English countryside. It’s amazing what a serious D-I-Y guy can accomplish!

Charles ran full size doors — 76 of them! — through his 50″ wide Woodmaster Drum Sander.

For Charles McCullough, home is 13,000 square feet big in the style of an English country home. Throw in a 1,000 square foot guest house and a 3,200 square foot workshop and you’re pushing 18,000 square feet of living space. But besides the sheer size and scale, the remarkable fact is Charles built all this himself. With help, of course, from the best contractors in his area, and his Woodmaster Drum Sander and Molder/Planer. Here’s what Charles emailed us recently when he entered our Drum Sander Photo Contest…

Dear Woodmaster,

Can an entire house be considered a ‘woodworking project?’ It was, for me, the biggest woodworking project I have ever undertaken.

We broke ground for our ‘dream home’ in 2004 and I convinced my wife that she should let me build my dream workshop first so I could make all the interior woodwork for the home right here on site. She bought into that idea so we built a 3,200 square foot workshop, sawmill shed, and dry kiln before starting the 13,000 square foot home.

I bought a new sawmill from TimberKing, a Nyle L200 dry kiln unit, a Woodmaster 725 Molder/Planer with all the options and a boatload of knives, a Woodmaster 5075 Drum Sander, and your Big Max DB500 dust collector.

I hired the best craftsmen this area had to offer. We bought truckloads of logs from the local area and began sawing, drying, and milling lumber. The house has 76 interior doors, four kitchens, around a dozen bathrooms, and miles of crown molding, trim, cabinets, bookshelves, 7 fireplaces (with mantles, of course) and we made it all right here on site.

The project was completed in June, 2007. The home has been featured in “Avenues” magazine, and has been the site for several charitable fundraisers, a couple of weddings, and lots of entertainment.

The Timberking mill and the Woodmaster machines performed very well throughout the construction period. Support from your staff was excellent and prompt throughout and I highly recommend your products to my woodworking friends.

Regards, Charles McCullough

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Charles tells the rest of his story…

“I’ve always been a ‘wannabe woodworker’ but never had the opportunity to spend the time or money on woodworking. My wife and I had built half a dozen homes in our 43 year marriage. This is the biggest but we were comfortable doing it.

Charles says this outstanding bar was inspired by a bar in Boston. Cheers!

We have three grown children who come up for weekends. We wanted a home big enough to have everybody at once including our grandchildren. My wife and I decided now was a good time to do it.

Biggest & best equipment for this BIG D-I-Y project

I got a TimberKing sawmill to saw trees into lumber. I got the 25” Woodmaster 725 Molder/Planer to dress and size the lumber. I got the 50” 5075 Woodmaster Drum Sander primarily for sending doors – all 76 of them and all the cabinet doors throughout the house. I wanted the biggest and best machines you sell.

Here’s Charles’ walnut paneled library. He made the paneling himself with his Woodmasters and saved a bundle.

Our home is 13,000 square feet. The guest house is 1,000 square feet. There are 76 interior doors, four kitchens, and about a dozen bathrooms. There are miles of crown molding, trim, cabinets, and bookshelves. There are seven fireplaces (each with a mantle, of course!).

We’ve been planning and saving blueprints and articles for years. I realized that the millwork I’d need for this home would bust the budget so I build a workshop and stocked it with really good tools including a Woodmaster Drum Sander and a Woodmaster Molder/Planer. I figured making the millwork myself could save enough to pay for the workshop.

The first year, we ran our TimberKing Sawmill and sawed out 200,000 board feet of lumber. We dried 6,000 board feet at a time in our dry kiln and kept it running around the clock for 18 months. We broke ground in 2005, hired the best contractors in our area as I built, and we moved in two and a half years later.

Extraordinary details everywhere you look

The building with the green roof is my workshop. The house itself is styled as an English country home. Outside, its exterior is Arkansas limestone. The beams and curved arches are cypress – there are 36 of them! Inside there’s a study with walnut paneling. The main kitchen has an island made of black cypress from the Black River Swamp in Black River, Arkansas.

The bar is modeled after a bar in Boston. It’s solid walnut, cabinets and all. The guest house kitchen is made of 100-year-old barn wood from the corn crib from a dairy farm. It’s probably red oak. It’s not stained, I just used tung oil to bring out the natural color.

Foreign machines can’t compare with Woodmaster

Besides his Woodmaster Drum Sander, Charles owns a Woodmaster Molder/Planer, shown here. Between these two tools, he has everything he needs to turn roughcut lumber into finished trim and molding. And that’s exactly what he did.

I looked at foreign-made equipment but there was nothing to compare with Woodmaster machines. Plus, foreign machines use metric measurements – 9mm, 11mm, and so on. Woodmaster is American made and I’d rather deal with American dimensions like ½”, 3/8”, etc.

Both my Woodmaster Drum Sander and my Molder/Planer have fully variable feed rates. Other machines have just two speeds. This is a very good feature because you can slow it down to a crawl to get an excellent surface.

Commercial duty

I wholeheartedly recommend Woodmaster Drum Sander and Molder/Planer. I have nothing but good things to say about them. I use them as hard as if they’re in a commercial manufacturing environment.”

— Charles McCullough, Woodmaster Drum Sander & Molder/Planer Owner, Missouri

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