Building a Shaving Horse for Free (WIP, Pic Heavy)

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Aug 31, 2012
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I have been wanting to build me a shaving horse for a couple months now for shaping hafts among other things. Since I was out of work (I have since found employment) and had no money I was thinking of potential sources of material for the bench in particular. I also had acquired these 2 broad hatchets recently and figured I could hew legs and stuff for the horse. Then one day back in December my sister had an alder come down on her property. I thought about it and finally decided to try and get the bench out of part of that tree.

The alder tree.

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I limbed it and bucked it up and 3 other trees my brother in law wanted taken out too. From the tree above though I cut out a couple 7' or so sections of the trunk and split them.

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The trunk had some twist to it but I figured I could hew a piece somewhat flat before hewing the other side to make a plank.

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I brought them home to figure out what I wanted to do with them.

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I picked out the one that looked best for the bench and hewed the center flat or mostly flat.

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Then it was time to cut the juggles and knock em out. I cleaned it up with the broad hatchet. Yes, all the rough hewing was done with that little Craftsman broad hatchet. I know I need to get a proper broad axe. I do have access to one but wanted to give the little hatchet a workout. I had also just cleaned up and sharpened the drawknife that was my grandfather's and came to me via my parents. I used it to strip the bark and it worked beautifully.

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That little hatchet did pretty good considering what I was asking of it. The rough hewing was complete.

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Wet alder is fairly white when it is first cut but turns this crazy orange color within a day or two of exposure to the air. I find this very interesting and am wondering what color it will be when fully dried. Here it has turned orange and is getting ready to be smooth hewn with my great grandfather's piiluja.

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Mind you I have no idea how this piiluja is supposed to be wielded so I developed my own technique of making potato chips with it.

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I certainly didn't make it completely smooth and I am sure my great grandfather was laughing at me. I did manage to get it a lot smoother and flatter with the piiluja than it was.

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It was then time to break out the big boy block plane.

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And work up a real sweat making it smoother and flatter. I was pleasantly surprised at how well it cut the soaking wet alder and made ribbons.

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It did rip a little and required constant cleaning of the knife but after a couple hours I had one pretty nice side

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I started to plane the other side. I got tired of it and gave in to the dark side and broke out the thickness planer. I ran it through the power planer and got it down to about 2 inches thick. I think that will make a mighty fine bench for the shaving horse provided it doesn't crack.
 
When I was over at my sister's gathering the alder the neighbor lady came over and asked if I wanted a madrona. She pointed out the small tree overhanging the driveway that she wanted gone so I gathered that too. I picked out a few pieces that I thought I might be able to carve something out of and cut up the rest for fire wood. Seeing as how I need legs for my shaving horse I figured madrona might work. Hopefully it will shrink less than the alder and everything will stay tight once its all assembled.

Anyway, here are the pieces I started with. Oh, and the front leg I already shaped out of a piece of madrona that I had previously carved into a kind of axe haft shape.

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I wanted to do a sort of side by side comparison of the Craftsman and Plumb broad hatchets so I carved one leg using only the Craftsman and one using only the Plumb.

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I found the Plumb to be more aggressive and able to take larger bites out of the wood more easily. It made quick work of taking off lots of material. The Craftsman excelled at the finer work of shaping and smoothing the leg more round. Both did the job and worked quite well. The next carving jobs I will use the Plumb to rough out the shape and the Craftsman to fine tune the shapes.

I then used the cheese grater to further smooth out the legs. I am not looking to have identical legs here so I didn't spend time making them perfectly round and uniform. I want them to have character and be similar not perfect.

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The legs have since been scraped with the cabinet scraper and the ends got paint to hopefully prevent cracking between now and when they get cut to length and fitted to the bench.

Here I am tuning up the tenon on the front leg.

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Now its time to start thinking about what the treadle frame will be made out of. Hmm....
 
Great project and thread. Thanks for posting this. I'd like to find out more about this tool.

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Never seen one before. What is the country of origin?
 
I wish people around me had trees they wanted me to take home. This is a fantastic project you have going on. I really like how thorough all of your progress reports are. They're almost like tutorials. I just built one of these last week that I sort of modeled after the one in the link provided by pialia above. Now I get home from work at 6 and stay in the garage until midnight!
 
Good job! What flavor is that draw knife? Looks very similiar to my favorite Greenlee.

Hope you keep use posted on your progress. I want to see how the shave horse goes. I enjoy seeing a craftsmans work.
 
Great thread, CedarEater! I love this kind of stuff. Can't wait for the next installment of this WIP.

I think that will make a mighty fine bench for the shaving horse provided it doesn't crack.

Coat the ends. Water wicks out the end faster than it leaves the edges of wood. This is what causes checking/cracking. You might still get some checking even coated but it will be much less.

Red Alder was used extensively as a dye/stain by the First People of the NW coast. It's the inner bark and cambium layer that turn red when exposed to the air. The wood is good in the smoker, especially for salmon.
 
tradewater: I too would like to know more about how that tool is used too. As Memphis stated it is from Finland. It is a piiluja (Finnish broad axe) and as far as I can gather this particular size and/or shape is used for smooth hewing. How to properly use it is still a bit of a mystery to me.

garry3: There are no markings on the drawknife. It has an 8" edge and was never abused or even used much for that matter. It takes a very sharp edge and is a real pleasure to work with. I can't wait to get this horse done so I can use the drawknife more easily.

Pegs: I did coat the ends with paint so hopefully that will work. Thats interesting about the dye/stain being used from the bark. It explains why some of the shavings are not turning orange.
 
With regards to garry3's inquiry; I only have one draw knife, but it seems identical to yours, handles and all. It is, in fact, stamped Rockford Greenlee.
 
Well, its been awhile since I have worked on this thing. I started framing houses full time again back in January and frankly I haven't felt much like working on this shaving horse very much at all. For some reason I got inspired today to finish fitting the last leg. The other two legs have been fitted for at least a month.

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After fitting and glueing the third leg I used my little block plane to smooth out the top of the bench and gave the whole thing a light sanding.

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The bench still needs to be cut to length

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but at this point it is puppy approved.

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I guess I need to start thinking about what to do for a treadle frame and the rest of the business.
 
Puppy knows best.
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It looks great. Must be pretty dry by now. Has it been stored indoors?
 
Puppy knows best.
ja.gif


It looks great. Must be pretty dry by now. Has it been stored indoors?

Thanks. Yes, it has been stored indoors in what we are calling "the sun room" (basically an enclosed porch thats not heated). Its dry enough so that the block plane was cutting clean and not leaving fuzzies behind. I am still a little hesitant to cut off the painted ends though. I will do that after the treadle frame is installed and I will get a coat of something on it right away. It hasn't cracked and I would like to keep it that way.
 
Your Finish axe is really in good condition, almost like new. These can better be called in English carving axes. You cannot make a flat surface with them and they are not supposed to make a flat surface. In fact one of the uses is to create a sort of decorative effect on the internal walls of log constructions. In use it is important to make a definite slicing motion as you are cutting down across the grain in a straight line.

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Ideally you achieve a layered effect on the surface with the waves of a series of cuts and the underlying scales of each individual cut. Always two things to keep in mind on every stroke. Not difficult with the right wood but it takes concentration. Also, the surfacing is done after the walls are erected. I have heard that this was done periodically in the dark winters to remove soot on the walls for a brighter interior. I have also tried it to clean off a road-side shelter vandalized by grafitiests.

E. DB.
 
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