Woodworking Adventures: From Glue-Ups to Oak Harvests in My Shop

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Hey everyone, welcome back to my little corner of the internet where I share my woodworking escapades. If you’re new here, I’m just a hobbyist tinkerer who loves turning bits of wood into something special – or at least trying to! Today, I wanted to walk you through a project that’s been keeping me busy in the shop: creating 1.5-inch blocks from random hardwood strips for birdhouse ornaments and other compound-cut scroll-saw pieces. It’s all about resourcefulness, a bit of elbow grease, and learning from those “never again” moments. I’ve put together a collage of photos from the process, so let’s dive in and break it down step by step.

Starting with the glue-up phase – that’s where the magic (and the mess) begins. In the top-left photo, you’ll see me gluing up those strips of random hardwoods into sturdy 1.5-inch blocks. I had to whip up some custom cauls for this one: the flat pieces clamped on top and bottom to keep everything even while the glue sets. I coated them heavily with wax to prevent any glue from sticking.

The top-right shot shows some of the square stock fresh out of the clamps after the glue has fully cured.  There’s something therapeutic about peeling off the clamps and seeing your creation hold together without a hitch. I ended up with a mix of woods here – walnut, maple, cherry – whatever scraps I had lying around. Recycling at its finest!

Now, onto the cutting tools that make it all possible. The bottom-left image features my trusty Shopsmith table saw. Note the 7.25-inch saw blade I’m using – these smaller blades are a game-changer for me. They’re super affordable, cut like butter through hardwoods, and leave a smoother edge than you’d expect. I hardly ever reach for the bigger 10-inch blades anymore unless I’m ripping something massive. The Shopsmith is a versatile beast; it’s got that dust collection hose snaking around, keeping the shop somewhat clean (emphasis on “somewhat” – woodworking is dusty business).

Shifting gears a bit, let’s talk about sourcing materials. The center-right photo highlights some oak boards I milled from a fallen tree that came down during a hurricane a few years back. I salvaged some heartwood and let it air-dry in the garage for a few years. It was a reality check: it was way too much work. Planing, jointing, dealing with checks and twists – I’ll stick to buying kiln-dried lumber from now on. But hey, these boards turned out pretty decent.

And speaking of waste, the bottom-right pic shows more of those oak boards stacked up after cutting from the logs. Brutal honesty time: 60-70% of the material ended up as sawdust or scraps. Between knots, checks, and other unusable sections. Still, the usable pieces are gorgeous – straight-grained, ready  for whatever project comes next. Lesson learned: appreciate the pros who mill lumber for a living!

All in all, these projects have been a fun mix of creativity and problem-solving. Those birdhouse ornaments are shaping up nicely on the scroll saw.

 

Cutting a Peterdactyl using my EX-21 Scroll Saw

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In this behind-the-scenes photo from my workshop, I'm using a scroll saw to meticulously cut out the individual pieces for a handmade Pterodactyl figurine from oak hardwood. The main body showcases the sleek, curved silhouette of the prehistoric creature with cutouts for wings and details. Scattered around it are the detached components—wings, legs, and other elements—each carefully labeled with thickness measurements like 1/2", 3/4", 5/8", and 1 1/2" to ensure precise assembly later. The wood dust and the scroll saw highlight the hands-on craftsmanship that goes into every creation. If you're enchanted by this dino design but prefer to skip the DIY, fully assembled Pterodactyl figurines are available for purchase in my Etsy shop—perfect for collectors, kids' rooms, or anyone who loves a touch of whimsical paleo-art!

 

Cutting A Peterdactyl Using the EX-21 Scroll Saw

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Making a Peterdactyl figurine is a fun and rewarding project.

Tools and materials I used.

• EX-21 scroll saw
• Printed Pterodactyl pattern
• 3/4-inch-thick wood for the body.
• Spray adhesive

I used spray adhesive to attach the pterodactyl pattern directly to the wood.

I use a Pegas #3MGT blade to cut the pterodactyl. This is by far my most-used scroll saw blade.

As a rule, I drill any entry hole for interior cuts before cutting out the body.

 

 

Crafting Elegant Fretwork Shelves in Oak

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For woodworkers and DIY enthusiasts! If you're like me, there's nothing quite as satisfying as turning a simple piece of wood into something functional and beautiful. Today, I'm sharing how I make a pair of intricate fretwork shelves made from 1/4-inch-thick oak, all cut using my scroll saw. These little gems are perfect for displaying small items. The process was a mix of precision cutting, careful assembly, and a bit of patience while waiting for the finish to dry. I'll walk you through the steps, complete with photos from my workshop. Let's dive in!

Materials and Tools

Here's a quick rundown of what I used:

• Wood: 1/4-inch-thick oak plywood
• Pattern: I prepared a flowing, ornamental fretwork pattern inspired by Victorian scrollwork – think swirls and flourishes for that elegant touch.
• Tools: Scroll saw with fine blades (I used #3MGT for the intricate cuts), clamps, wood glue, sandpaper (220-grit), and shellac.

Preparing and Cutting the Pieces
I started by printing out my fretwork pattern and adhering it to the oak using spray adhesive. The design features symmetrical curves and cutouts that give the shelves their airy, decorative look. With the pattern in place, it was time to fire up the scroll saw.

The key here is slow and steady – scroll sawing intricate designs like this requires a light touch to avoid blade breakage or splintering the wood. I cut out the main shelf brackets first, following the lines meticulously. Drill small pilot holes for interior cutouts for threading the blade.

Once the brackets were free, I moved on to the smaller decorative elements and the shelf platforms themselves. The collage shows the pieces laid out after they were cut.
 

Assembly and Gluing
With all the parts cut, it was time for assembly. I dry-fitted everything first to ensure a snug fit, making minor adjustments with sandpaper where needed. Then, I applied wood glue to the joints – nothing fancy, just good old Titebond.

Clamping is crucial for strong bonds, especially with thin material like this. The images capture the gluing process: orange clamps holding the brackets together while the glue sets. Let it cure for at least an hour, or overnight if you can wait (patience is a woodworker's best friend).

Finishing Touches
After unclamping, I gave everything a thorough sanding to smooth out any rough edges from the saw. Then, it was time to finish. I opted for a couple of coats of shellac.

The final photos in the collage show the completed shelves hanging up, drying in the workshop. They're lightweight yet sturdy, with a small ledge at the bottom for stability. No hangers are required. A tiny nail or pin will do. 

The Finished Product
And there you have it – a pair of fretwork shelves ready to grace any wall! Total time? About 4-5 hours spread over a couple of days, including drying time. 

 

What Should I Look For In A Scroll Saw

 

Excalibur EX-21 Scroll Saw

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Avoid purchasing a saw that uses pinned blades. You will regret it.

For me, the ease of use and speed of blade changes are paramount.

 

My saws:

• Excalibur EX-21 was purchased used a lot. I have completely rebuilt it. 
• Pegas 21-inch I bought used in like-new condition.

 

What I appreciate about these saws is that when they are properly aligned, no tension adjustment is necessary. You flip a lever to change the blade, then flip it back into place. This design tilts the blade instead of the table, which makes angled cuts easier to achieve. I have access to parts for both of these saws and have completely rebuilt the Excalibur EX-21.

 

The Harbor Freight Bauer scroll saw operates similarly to the EX-21/Pegas saws. The lift mechanism is different. It is the lowest-cost saw of all the saws mentioned here. Harbor Freight's in-store warranty is as good as it gets. If it breaks during the warranty period, you can return it to the store and they will provide you with a replacement. If I were in need of a new saw, I would give this one serious consideration.

 

The Seyco saws are quite similar, but they feature a larger table and a

different tilt mechanism. However, I'm not fond of the table on the Seyco saws. Seyco saws have awesome support. They also support Excalibur and  Pegas saws with parts available for both.

 

Other Scroll Saws

• The Dewalt DW788 is well-regarded and widely available in the US. I have never used a DeWalt saw, but I understand they cut very aggressively. DeWalt saws can be rebuilt.
• Hegner scroll saws are known for their exceptional durability, but I find the blade mounting and tensioning system to be cumbersome. Additionally, they are quite expensive.
• Hawk scroll saws are known for their durability and are made in the USA. I used an older one for several years, but I eventually became frustrated with the blade mounting system. When a blade broke, the clamps would sometimes go flying, and I often found myself crawling on the floor with a flashlight trying to locate them. The newer models may have an improved clamping system.

Why I Think A Scroll Saw Is A Better Tool For Toymakers Than A Bandsaw

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I own two bandsaws and two scroll saws. For making toys, a scroll saw is much more useful than a band saw. In making toys, the only thing I have used my bandsaw for is resawing and rocking horses. Scroll saws cut smooth and require very little sanding. Scroll saws easily make inside cuts, something you can't do with a bandsaw. You can make bowls, baskets, puzzles, bandsaw boxes, and much more with a scroll saw.

Woodworking Projects

• Fretwork: Intricate designs cut into thin wood, often used for decorative panels or overlays.
• Intarsia: Mosaic-like wood art where different wood pieces are cut and fitted together to create images or patterns.
• Marquetry: Similar to intarsia, but typically involves veneers to create detailed inlays for furniture or wall art.
• Puzzles: Wooden jigsaw puzzles with interlocking pieces, customizable in shape and complexity.
• Toys: Small wooden toys like cars, animals, or figures with smooth, detailed cuts.
• Ornaments: Holiday or decorative ornaments, such as Christmas tree decorations or seasonal cutouts.
• Clocks: Decorative clock faces or components with intricate patterns or numbers.
• Boxes: Small jewelry or keepsake boxes with detailed lids or inlaid designs.
• Signs: Custom wooden signs with letters, numbers, or logos cut out for home decor or businesses.
• Furniture Accents: Decorative trim or inlays for furniture, like table edges or cabinet panels.
• Picture Frames: Custom frames with unique cutout patterns or designs.
• Shelves: Small decorative shelves with scrollwork edges or supports.

Craft and Decor

• Wall Art: Stand-alone cutouts or layered designs for wall hangings, often with nature or abstract themes.
• Silhouettes: Profile portraits or thematic silhouettes (e.g., animals, people, or landscapes).
• Plaques: Personalized name plaques or inspirational quote signs.
• Coasters: Thin wooden coasters with engraved or cutout patterns.
• Bookmarks: Thin, decorative wooden bookmarks with intricate designs.
• Lampshades or Lanterns: Delicate wooden panels for light diffusion with patterned cutouts.

Functional Items

• Keychains: Small, detailed wooden keychains with custom shapes or names.
• Utensil Handles: Custom handles for kitchen tools or knives.
• Plant Stands or Holders: Small decorative stands for potted plants or vases.
• Pen Holders: Desktop organizers with scroll-cut designs.

Specialty Materials (Beyond Wood)

• Plastic Projects: Cutting thin acrylic or plastic sheets for signs, stencils, or decorative pieces.
• Metal Crafts: With the right blade, cutting thin non-ferrous metals (e.g., brass, copper) for jewelry or small art pieces.
• Foam Crafts: Cutting foam for model-making, cosplay props, or packaging inserts.
• Leather Accents: Cutting thin leather for detailed patterns in accessories or decor.

Miscellaneous

• Model Components: Parts for scale models (e.g., architectural models, trains, or ships).
• Musical Instruments: Decorative parts for instruments, like guitar inlays or ukulele soundhole designs.
• Stencils: Reusable stencils for painting or etching on various surfaces.
• Custom Gears: Small wooden or plastic gears for mechanical or decorative purposes.

Personalized Handmade Christmas Ornaments: Choose from a Santa, Sleigh, Teddy Bear, Peace Dove, or Nativity scene.

 

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The holiday season is just around the corner, and what better way to celebrate than with personalized ornaments that add a unique touch to your festive décor? This year, I'm announcing the return of my personalized, handmade Christmas ornaments, featuring a selection that is sure to bring smiles to family and friends.

Choose Your Favorite Style
You can choose from a variety of enchanting designs, including:

• Santa in His Sleigh: Capture the magic of Santa’s journey with this whimsical ornament.
• Teddy Bear: Adorned with a classic Santa-style hat, this sweet bear is perfect for kids and the young at heart.
• Peace Dove: Symbolizing hope and goodwill, this dove carries a beautiful olive branch for a message of peace.
• Nativity Scene: This timeless depiction of the Christmas story serves as a lovely reminder of the season’s true meaning.

Craftsmanship You Can Trust
Each ornament is meticulously handcrafted from 1/4-inch thick maple hardwood plywood, ensuring not only beauty but also durability for years to come. Whether you're hanging them on your tree, using them as gift tags, or displaying them in your home, these ornaments are a charming addition to your holiday traditions.

Custom Orders and Patterns Available
In addition to the current set of designs available for order, I’m also working on two other sets to expand your options this holiday season. As soon as the final design is complete, I’ll make those available as well!

If you’re crafty and would like to make your own ornaments, I can create a pattern for you! Feel free to contact me to purchase a custom pattern—either through my Etsy shop or via email. 

Get ready to spread some holiday cheer with these personalized handmade ornaments. Whether you’re keeping them for yourself or giving them as gifts, they’re sure to bring joy and warmth to your celebrations. 

Discovering a New Resawing Technique

The wings, arms, and horns on this baby dragon were resawn from thicker wood on my Shopsmith table saw.

 

Buy This Dragon In My Etsy Shop
Buy This Dragon At Odin's Toy Factory
 

A little while ago, I stumbled upon a fantastic way to save wood while working on my projects. Rather than resawing and planing thick piece, I began cutting out parts from thicker stock and then resawing the parts to the desired thickness. This technique started on my scroll saw with a zero clearance insert but soon transitioned to my band saw.

My latest project was a dragon figurine, which presented a bit of a challenge. The parts were quite small, and the wood I had on hand was too short for my planer. To add to the dilemma, my bandsaw was acting up, so I decided to experiment with the table saw instead.

Using a simple method, I attached the small part to a larger piece of wood with two-sided tape. Running it through the table saw slowly, I was pleasantly surprised by the outcome. The cut was incredibly smooth, leaving only a tiny nub where the blade exited. This method allowed me to resaw not just the main body of the dragon but also the wings, horns, and arms—all essential components that required precision.

Unfortunately, I got so caught up in the process that I forgot to take photos of the the other parts along the way. But the result was well worth it, and I’m excited to share this breakthrough with others. If you’re working on small, intricate pieces, I highly recommend giving this technique a shot. It’s a great way to maximize your resources and achieve clean, precise cuts.

This is the baby dragons are attached to a larger piece of oak using double sided tape.

This is the setup I used to resaw all the thinner dragon figurine pieces using my Shopsmith table saw and a 5 1/4 inch thin saw blade.

My Handmade Wooden Heart Shelf

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There's something special about creating handmade items that hold a personal touch. Recently, I had the opportunity to create a unique piece that I'm sharing with you: my handmade wooden heart shelf, crafted from beautiful walnut wood. 

Typically, I create these charming shelves from oak, known for its durability and beautiful grain. However, one of my customers had a specific vision in mind; she requested a shelf stained a particular color. As much as I appreciate a good stain, I prefer to work with the natural beauty of the wood. So, I presented an alternative: a heart shelf made from walnut.

The result? A piece that showcases the rich, warm tones of the walnut, combined with the sweet charm of a heart-shaped design. The customer was thrilled, which truly made my day.

I'm pleased to announce that you can now order these heart shelves in both walnut and oak. Whether you're looking for a unique way to display your trinkets, photos, or other small treasures, these handcrafted shelves add a touch of warmth and love to any space.

If you're interested in adding one of these beautiful pieces to your home or as a gift, visit my shop on Etsy or at Odin's Toy Factory. 

Thank you for supporting handmade craftsmanship! 

Crafting a Pair of Oak Fretwork Shelves

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Welcome to my latest blog post! Today, I'm sharing the process of crafting a pair of oak fretwork shelves, which are now available in my Etsy shop. These shelves are more than just functional pieces; they are a testament to the beauty of skilled woodworking and the rich grain of oak.

 

Step 1: Preparation and Design

The journey begins with a solid plan. I create a detailed template for the fretwork design, ensuring precision in every cut. This stage sets the foundation for the entire project.

 

Step 2: Cutting the Fretwork

Next, I carefully cut out the design using my scroll saw. This process requires patience and attention to detail. You can see the intricate patterns coming to life as the saw navigates through the oak, leaving behind a stunning silhouette that will soon become a beautiful shelf.

 

Step 3: Assembly of Pieces

Once all the pieces are cut, I arrange them on my workbench and dry-fit all of the pieces to see how they will come together. This stage is not just about assembling but also about appreciating the natural beauty of the oak. The distinctive grains and textures truly enhance the aesthetic of the shelves.

 

Step 4: Gluing the Parts Together

I use clamps to secure the shelves during the assembly. Clamping is necessary to achieve the optimal glue bond, which provides strength and stability. Clamping the irregularly shaped pieces can be challenging.

 

Step 5: Finishing Touches

After assembling the shelves, I apply a finish, then hang them up to allow this protective layer to cure properly, ensuring a durable and beautiful surface. This process is repeated with sanding in between coats until I am happy with the look and feel.

 

If you're interested in bringing a piece of this craftsmanship into your home, feel free to check them out in my Etsy shop.