Gottshall Block 2: Electric Boogaloo

If you follow the Popular Woodworking Editors’ Blog, you might remember Bob Lang writing a series of posts about a hand tool exercise called the Gottshall Block. The block is an exercise in layout and handwork, the idea being to take a rough sawn board and create this object, that has specific dimensions and contains most types of joinery, by hand.

When first reading the series of posts, I thought that this was an interesting project for refining a woodworker’s skills. I consider myself a hybrid woodworker, but right now I definitely lean to the power tool side of center. I’m also a bit of a smartass, so I thought to myself “Why not try to make one of these with just power tools?” Here is the result:

I was true to the “power tool only” constraints I placed on myself for this exercise. Here’s how I cut each part:

  • Front Edge & Bottom Face – Jointer
  • Top Face/Thickness – Planer
  • Back Edge, Rabbet - Table Saw
  • Mortise, Dados, Gain – Hollow Chisel Mortiser
  • Concave Curve – Forstner Bit
  • Convex Curve – Spindle Sander
  • Miter – Miter Saw

I have to thank Matt Gradwohl of UpperCut Woodworks. I don’t own a hollow chisel mortiser and he was kind enough to let me use his when I was visiting Seattle back in late July. We also  jointed and planed the board in his shop.

I have a couple of thoughts on my choices of tools. I cut the rabbet with my normal blade on the table saw, a la Norm Abram, chipping away at the wood. If my shop wasn’t in complete disarray (and I wasn’t butted up against my self imposed deadline of finishing this before Woodworking In America) I would have used my stacked dado set to cut the rabbet.  That would have likely left a smoother cut. The convex curve would have been cut on the bandsaw if it were larger, but the amount of wood that needed to be removed was so small that the sander was enough for the whole cut, not just the finishing.

The one place that I wasn’t able to get great results with just power tools was the inside corners of the gain:

The way I approached this cut was to plunge with the mortiser down into the face of the board at the inner most shoulder of the gain. Then I flipped the board on edge and plunged down the “length” of the gain. This gave me crisp lines on the face of the board, but the inner corners are a mess. I tried to clean some of it up with the smallest router bit I had, but that didn’t go very well. Perhaps if I had the world’s smallest router bit with a bearing, it could have worked. As it is, this is easily the most sloppy part of the block.

I’ll be bringing this with me to Woodworking in America this weekend – hoping to get Bob to sign it for me!  If you want to check it out, find me milling about during the conference and come say hi!

Category(s): Projects, Techniques
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