Old Woodworking Machines

MAJOR FUNDING FOR "THE WOODWRIGHT'S SHOP" IS PROVIDED BY... MORE THAN 40 MILLION PEOPLE WHO CARE FOR THEIR CARS AND HOMES CHOOSE STATE FARM FOR THEIR INSURANCE.

STATE FARM--A PROUD SUPPORTER OF "THE WOODWRIGHT'S SHOP."

CAPTIONING MADE POSSIBLE BY U.S. DEPARTMENT OF EDUCATION HI.

I'M ROY UNDERHILL.

WELCOME BACK TO "THE WOODWRIGHT'S SHOP."

NOW, IF YOU EVER FIND YOURSELF IN THE OLD NEW YORK RESORT TOWN OF SHARON SPRINGS, JUST SOUTH OF THE ADIRONDACKS, WHAT YOU WANT TO DO IS HEAD ON UP THE HILL FROM THE OLD HOTELS AROUND THE OLD HEALING SPRINGS.

HEAD ON UP TO WHERE THE RAILROAD TRACK USED TO RUN.

FIND THE OLD RED TRAIN STATION.

WHEN YOU FIND IT, WHAT YOU WANT TO DO IS LISTEN OUTSIDE.

LISTEN FOR A RUMBLE FOR A LITTLE BIT.

IF YOU HEAR THAT RUMBLE COMING FROM INSIDE, YOU WANT TO STEP UP ON THE PORCH AND KNOCK ON THE DOOR... [KNOCKING SOFTLY] BECAUSE IF YOU GET INVITED INSIDE, YOU WILL ENTER... [MACHINERY RUMBLING] A WONDERLAND OF DRIVESHAFTS TURNING HUGE PULLEYS THAT PULL LONG LEATHER BELTS THAT ALL TOGETHER RUN A SASH AND MILL WORKSHOP THAT LOOKS LIKE-- IN FACT, IT DID COME RIGHT OUT OF THE 1880's, AND IT'S ALL RUN BY THESE GENTLEMEN RIGHT HERE-- MR. ALDEN WITHAM.

ALDEN, GREAT TO SEE YOU.

AND HIS SON STEVE.

HEY, STEVE.

HELLO, ROY.

HOW ARE YOU?

ALL RIGHT.

NOW, WHAT HAVE YOU GOT RIGHT HERE, ALDEN?

THIS IS A SASH SANDER, AN EARLY SASH SANDER, ABOUT AN 1860's.

WOW.

THIS IS THE FINAL STAGE, I GUESS, IN MAKING THE WINDOWS-- SANDING IT DOWN.

YES, IT IS.

THE FINAL SANDING.

AND STEVE, ALL THIS RUNS OFF OF BELTS, THESE BELTS?

THAT'S RIGHT.

ALL THESE MACHINES RUN OFF ONE BELT.

IT RUNS ALONG UP TO A MAIN POWER SHAFT, LINE SHAFT OVERHEAD.

RUN BY ONE POWER SOURCE.

SO THAT SHAFT IS ALWAYS TURNING UP THERE.

WELL, HOW DO YOU CUT THE THING ON AND OFF?

TO TURN IT ON AND OFF, WE HAVE A TIGHT AND LOOSE PULLEY.

HA HA.

AND THIS IS AN IDLER PULLEY THAT'S LOOSE.

AND I SEE THE MACHINE GRINDS TO A HALT.

WONDERFUL.

NOW, WHEN I SAY A SASH AND MILL WORKSHOP, ALDEN, THAT MEANS WINDOWS AND MOLDINGS, IS THAT RIGHT?

YEAH.

WE MAKE WINDOW SASHES, REPRODUCTION WINDOW SASH FOR EARLY HOMES.

WOW.

SO THEY CAN GET A WINDOW THAT'S MADE ON THE SAME MACHINE THAT IT WAS DONE A HUNDRED YEARS AGO.

OH, IT'S THE MOST AUTHENTIC THAT WAY.

ABSOLUTELY.

SANDING IS THE FINAL STAGE.

A LOT GOES INTO MAKING A WINDOW LIKE THIS, SAY, LIKE THE RAIL HERE.

WHAT GOES INTO THIS SINGLE PIECE?

WELL, WE HAVE TENONS.

THESE ARE PRECISE JOINTS THAT ARE NECESSARY IN WINDOW SASH.

AND I SEE IT'S COPED AWAY RIGHT THERE, TOO.

IT IS.

IT'S MADE ON A VINTAGE TENONER.

THAT'S GREAT.

AND THEN AFTER THAT, IT GOES THROUGH AN OLD STICKER THAT MAKES THIS-- IT'S CALLED A STICKER MACHINE THAT MAKES THIS PROFILE.

AND THAT'S THE MOLDING THERE FOR THE GLASS AND THE INSIDE MOLDING.

AND THEN...WHAT?

AND THEN LATER IT GOES INTO RELISH, WITH AN OLD RELISHING MACHINE.

IT RELISHES THE GOODS OUT OF THE CORNER.

THAT'S A WORD I'VE NEVER HEARD.

BUT A RELISHER CUTS THAT PART AWAY, AND THEN FINALLY?

FINALLY, THIS SERIES OF HOLES HERE IS CUT OUT BY A HOLLOW-CHISEL MORTISER.

I SEE.

ALL RIGHT.

SO IT'S ALL MORTISE AND TENON.

STEVE, IS IT ALWAYS MORTISE AND TENON JOINTS THAT HOLD THESE TOGETHER?

WELL, YOU'RE HALF RIGHT, ROY.

YOUR LOCK RAIL ON YOUR WINDOW SASH IS ACTUALLY A DOVETAIL JOINT.

THEY'RE BUILT ON A SPECIALTY MACHINE.

HAVE YOU GOT THAT MACHINE HERE, TOO?

YES, WE DO.

NEEDS A LITTLE WORK, BUT... OH, ALL RIGHT.

I'LL SHOW IT TO YOU.

MAYBE YOU COULD GET IT WORKING BEFORE WE HAVE TO LEAVE.

IN THE MEANTIME, ALDEN, CAN WE TAKE A LOOK AND SEE HOW--LET'S JUST SEE HOW YOU MAKE THIS PIECE RIGHT HERE.

OH, OF COURSE.

I'D LOVE TO SHOW YOU.

ALL RIGHT.

FOLLOW ME.

ROY, I AM SO PROUD TO SHOW THIS MACHINE TO YOU.

OH, THIS IS BEAUTIFUL.

THIS IS ONE OF MY FIRST MACHINES.

IT'S A RALEIGH HERMANTZ TENONING MACHINE, BUILT IN PENNSYLVANIA IN 1871.

IT'S BEAUTIFUL.

AND YOU'VE BEEN USING THIS SINCE YOU BEGAN YOUR BUSINESS?

OH, I'VE BEEN USING THIS MACHINE-- THIS WAS THE FIRST ONE I GOT.

THAT'S GREAT.

OF COURSE, IT CUTS THE TENON AS WE SEE HERE.

IT ALSO DOES THAT COPING, THE CUTAWAY RIGHT THERE?

YES.

IT DOES BOTH.

WITH THESE HEADS?

NOW, CAN YOU OPERATE THAT A LITTLE BIT THERE?

I SEE THE NICKER THAT GOES ACROSS THE GRAIN.

AND WHY ARE THE IRONS, THE CUTTING BLADES, DIAGONAL?

OH, BECAUSE THEY'RE ON AN ANGLE LIKE THAT, IT MAKES SUCH A WICKED GOOD CUT.

IT SHAVES.

IT SHAVES.

ACROSS THE GRAIN.

ALL RIGHT.

SO THAT'S THE SAME THING YOU SEE IN A HAND PLANE-- YOU HAVE A DIAGONAL SHEARING CUT.

AND I SEE ALSO DOWN BELOW, THE COPING HEAD.

NOW, THAT'S SQUARE ACROSS BECAUSE IT'S GOING THROUGH END GRAIN.

ALL RIGHT.

WELL, THE WAY TO UNDERSTAND IT IS FOR ME TO GET MY FINGERS OUT OF THE WAY AND LET YOU CRANK HER UP HERE.

OK. ALL RIGHT.

SO YOU GOT A PIECE... THAT'S THE STOCK.

AND WHAT ARE YOU CUTTING HERE?

IS IT PINE?

WE'RE CUTTING PINE, NATIVE WHITE PINE.

ALL RIGHT.

AND YOU GET ONTO THE DRIVE.

OH, LOOK AT THAT GO.

ALL RIGHT.

UP TO SPEED.

ALL RIGHT, AND YOU JUST FEED HER THROUGH.

AND THERE'S THE TENON.

AND THERE'S THE COPE.

WONDERFUL.

ALL RIGHT.

I CAN SEE HOW SMOOTH THAT IS ACROSS THE GRAIN.

THAT REALLY WORKS.

AH, IT'S SO SMOOTH.

AND I AM SURPRISED, WHEN I LOOK AT THE SPEED THAT THE HEAD IS GOING, IT CUTS SO SMOOTHLY.

OH, THAT'S BECAUSE, ALTHOUGH IT SEEMS TO BE RUNNING SO GRACEFULLY, THE HEAD IS LARGE, SO WE GET RIM SPEED THAT'S VERY FAST.

SO IT'S THE SURFACE SPEED THAT MAKES THAT WORK THERE.

IT DOES.

ALL RIGHT.

SO, NOW THERE'S THE TENON AND THE COPE, BUT WE'VE STILL GOT TO GET TO THIS STAGE RIGHT HERE.

SO WHAT DO WE NEED TO DO NEXT ON THIS PIECE?

WELL, NEXT, IN ORDER TO DO THIS, WE NEED TO GO TO THE STICKER MACHINE THAT PUTS THE PROFILE ON.

OK. FROM THIS TO THIS WITH THE STICKER MACHINE, SO LET'S GO TO THE STICKER MACHINE.

OK. LET'S FIND IT.

I THINK YOU'RE GOING TO LIKE THIS VINTAGE MACHINE, TOO.

IT DATES 1875.

OH, IT'S BEAUTIFUL.

SO THAT'S, LIKE, A YEAR BEFORE CUSTER MADE HIS LAST STAND.

THEY WERE MAKING MACHINES LIKE THIS THAT DID THIS WONDERFUL MOLDING, STUFF I WOULD DO WITH A HAND PLANE.

AND IT MAKES THE GLASS REBATE, TOO, AT THE SAME TIME.

AH, THAT'S WHERE THE GLAZING GOES IN.

DONE WITH KNIVES.

I SEE THE 2 KNIVES ON THE CUTTER HEAD.

THEY ARE SQUARE ACROSS.

SO THAT'S OK?

IT WORKS JUST LIKE A HAND PLANE-- WITH THE GRAIN.

OK.

SO THE DIAGONAL YOU NEED ONLY FOR CROSSGRAIN WORK.

ALL RIGHT.

NOW, MY REAL QUESTION IS, ALDEN, CAN I GO AHEAD AND CUT IT ON?

UH...YES.

I WOULD LIKE YOU TO.

ALL RIGHT.

NOW, I JUST PULL THE BELT OVER HERE?

OVER ONTO THE TIGHT PULLEY.

AND THEN PUT DOWN THE FEED ROLLER HERE.

[MACHINE WHIRRING] AND PUT IT IN.

THAT'S GOING TO SHOOT THAT OTHER ONE OUT THE OTHER END.

HA HA HA!

IT'S LIKE A BLIZZARD.

LET ME CUT IT OFF NOW.

AH.

OK, SO NOW IT'S ONTO THE IDLER.

WELL, IT'S BEAUTIFUL, BUT-- NOW, ALDEN, I GOT TO SAY, I DO SEE KIND OF A SCALLOPING.

IS THAT SOMETHING YOU WANT TO SAND OUT FOR YOUR CUSTOMERS?

OH, I WOULDN'T WORRY ABOUT THAT AT ALL.

THAT'S AUTHENTIC, AND THAT'S WHAT THEY REALLY WANT IN THAT VICTORIAN HOME.

SO THIS IS THE WAY-- YOU MAKE IT LOOK EXACTLY LIKE IT DID ORIGINALLY.

NOW, SO WE'RE MOVING ALONG NOW.

OUR NEXT STEP, YOU SAY, IS CUTTING THIS PART OUT, AND THAT IS A PROCESS I'VE NEVER EVEN HEARD OF, MUCH LESS SEEN.

WHAT'S THAT CALLED AGAIN?

THAT'S BEING RELISHED OUT.

THAT'S BEING RELISHED OUT ON A RELISHING MACHINE.

ALL RIGHT.

WELL, HOT DOG.

I'D LIKE TO SEE YOUR RELISHER, IF I MAY.

WELL, IT'S OVER HERE.

THIS IS A RELISHER MACHINE.

AND THEY'RE QUITE RARE.

AND WHO WOULD WANT ONE OF THESE THINGS?

MAYBE A SASH SHOP, BUT WHAT ELSE?

A SASH SHOP.

WELL, I TELL YOU, I WOULD NOT RECOGNIZE ONE OF THESE THINGS IF IT REACHED OUT AND BIT ME, AND I GUESS IT COULD.

I CAN SEE THAT VERY SHARP IRON THERE.

IT'S SET DIAGONALLY, SO WE KNOW THAT CUTS ACROSS THE GRAIN.

BUT THIS I DON'T FOLLOW.

THERE'S A LITTLE AUGER BIT RIGHT THERE.

OH, THAT LITTLE AUGER BIT IS WHAT DRILLS THE WEEP HOLE IN THE LOWER SASH.

SO THIS DOESN'T HAVE IT, BUT YOU'LL PUT-- ALL RIGHT, LET ME JUST TURN IT ON.

SHALL I GO AHEAD AND SLIP THE BELT?

YES.

I PUT THE BELT ON THE FIXED PULLEY.

WHOA.

IT SPINS UP.

HAVE AT IT.

RELISH AWAY.

[MACHINE WHIRRING] AND THAT'S ALL IT DOES?

AND THAT'S GOING TO BE THE WEEP HOLE THERE AFTER YOU MORTISE IT.

SO THAT LETS THE WATER OUT.

NOW, LET ME CUT THIS THING OFF.

I CAN SEE WHY, IF THAT'S ALL IT DOES, ONLY A SASH SHOP WOULD NEED IT, BUT IN A SASH SHOP, YOU'VE GOT TO DO ZILLIONS OF THESE THINGS, SO THIS IS VERY HANDY.

AND IT'S BROUGHT TO YOU, OF COURSE, BY, I SEE, THE GREENLEE BROTHERS AND COMPANY, CHICAGO, ILLINOIS, 1874.

SO THIS THING'S A YEAR EARLIER THAN THAT LAST ONE.

IT IS.

IT IS.

BUT THAT'S GOT SOMETHING-- LOOK AT THIS RIGHT THERE.

I ALSO SEE PINSTRIPING AND ALMOST GOLD LEAF ON THERE.

OH, I DIDN'T TELL YOU ABOUT THAT.

IT'S TYPICAL OF THE EARLY MACHINES TO HAVE THIS PINSTRIPING, AND THEY'RE JUST SO DECORATED.

THEY PUT EVERYTHING THEY COULD INTO THESE MACHINES.

SO UNDER THE GRIME, YOU'LL FIND, IS THIS TREASURE OF DECORATIVE WORK.

OH, INDEED.

YEAH.

NOW, ALL RIGHT, SO OUR FINAL STOP NOW, WE'VE GOT TO DO THE MORTISES IN HERE.

DO WE HAVE ANOTHER MACHINE?

OH, THIS MACHINE REALLY IS DESIGNED TO MAKE THESE MORTISES.

SO THIS WAS WHAT?

OH, ALL RIGHT.

I GOT IT RIGHT HERE.

OH, BUT WE CAN'T DO IT.

WE CAN'T?

WHY NOT?

THIS END OF THE MACHINE IS NOT RESTORED YET.

WE NEED A BUSHING FOR IN HERE.

BUT THIS IS REALLY A HOLLOW-CHISEL MORTISER, AND YOU PUT THE WOOD RIGHT HERE, AND HOW DO YOU FEED IT IN?

WELL, IT WOULD BE PLACED THERE, AND THEN THERE'S A FOOT PEDAL TO BRING THE CARRIAGE IN AND MAKE THE SQUARE HOLES.

HA HA HA!

ALL RIGHT.

THAT'S WONDERFUL.

WELL, I SEE WE NEED TO, THEN, DO THAT FINAL STEP ON A DEDICATED MORTISING MACHINE, AND I'M NOT GOING TO BE SILLY ENOUGH TO ASK IF YOU HAVE ONE HERE.

I JUST HAVE TO ASK YOU WHERE IT IS.

OK.

THIS WAY.

ALL RIGHT.

ROY, I HOPE I DON'T REALLY DISAPPOINT YOU WITH THIS MACHINE.

IT'S A LOT LATER DATE.

IT'S WONDERFUL.

IT DATES UP INTO MAYBE THE 1920's.

THAT'S SOMETHING.

NOW, NO PINSTRIPING ON THIS ONE.

THIS ONE IS PURE BUSINESS HERE.

IT IS.

BUT I STILL SEE THE SAME PRINCIPLE DOWN HERE.

THERE'S THE HOLLOW CHISEL WITH THE BIT FLYING INSIDE OF THERE.

YES.

ALL RIGHT.

NOW, HOW DO YOU GET THIS GUY GOING?

WELL, THERE'S A FOOT PEDAL DOWN HERE, AND WHEN WE PRESS THIS FOOT PEDAL, IT WILL RECIPROCATE.

YOU MEAN IT GOES ON ITS OWN ACCORD?

YES.

SHALL I TRY IT?

YEAH.

PLEASE.

SO...SO WAIT A MINUTE NOW.

YOU'RE NOT HAVING TO FORCE THE CHISEL DOWN HERE.

THIS IS GOING AUTOMATICALLY.

IT'S AUTOMATIC, BUT I HAVE TO PAY ATTENTION IT BE RIGHT ON THE LINE EACH TIME.

SO DOES THAT MEAN EVERY 10 SECONDS, THIS HOLLOW AUGER IS COMING DOWN AND HITTING THE WOOD, READY OR NOT?

IT ISN'T GOING TO WAIT FOR ME.

OH, MY GOSH.

WELL, I DON'T LIKE THIS, NOW.

FIRST OF ALL, IT'S LOST ITS PINSTRIPING.

IT'S NOT DECORATIVE ANYMORE.

AND NOW YOU ARE HAVING TO BE THE SERVANT TO THE MACHINE.

IT'S TELLING YOU WHAT TO DO!

IT'S RUNNING MY LIFE AT THE MOMENT.

I DON'T LIKE THIS, BUT ANYWAY, THIS IS, AS YOU SAY, ABOUT 1920, AND IT BECOMES AUTOMATED AT THE PACE OF WORK.

OH, MY GOSH.

ALL RIGHT.

SOME PEOPLE SAY, "HEY, IT'S WHOEVER "IS HOLDING THE FOOT PEDAL DOWN.

"THAT'S WHO IS DETERMINING THE PACE, AND IF IT'S NOT YOU, IT'S SOMEBODY ELSE."

BUT NEVERTHELESS, LET ME GO AHEAD AND CUT THIS GUY OFF BECAUSE I THINK THIS IS ALSO THE INTRIGUING THING OF RUNNING THIS KIND OF BUSINESS-- NOT JUST THE MACHINES, BUT THE THINGS THAT RUN THE MACHINES, THESE INCREDIBLE PULLEYS AND BELTS AND THE SHAFTS AND THE BEARINGS.

THIS IS A WHOLE NEW THING.

THIS IS--THERE'S BELTS AND PULLEYS AND MAINTENANCE, AND EVERYTHING HAS TO BE RUNNING LIKE A CLOCK.

BY GOSH, THAT'S A SPECIALTY IN ITSELF.

COULD WE SEE A LITTLE BIT ABOUT THAT?

YES.

OVER HERE, STEVE IS LACING A BELT.

ALL RIGHT.

WELL... LACING A BELT.

NOW, STEVE, THEY CALLED IT LACING, BUT I GUESS YOU DON'T DO IT WITH A THREAD AND NEEDLE.

NO, WE DON'T.

WE USE A CLIP ON EACH END OF OUR BELT.

THAT'S PUT TOGETHER WITH A METAL PIN.

THAT PIN GOES THROUGH THERE, AND SO IT'S LIKE A HINGE.

IT RUNS AROUND THE BELT, AROUND THE PULLEY.

THAT'S RIGHT.

AND THAT'S ABLE TO TRANSMIT ALL THAT HORSEPOWER YOU NEED THERE?

GIVES ALL OF OUR BELTS THAT CLACKING NOISE ON THE PULLEY.

I LOVE THAT CLACKING NOISE.

NOW, HOW DO YOU DO IT?

I SEE YOU'VE GOT A MACHINE HERE, I SEE YOU'VE GOT A MACHINE HERE, BUT YOU'VE GOT TO START WITH A BUNCH OF STUFF THERE.

WE TAKE OUR CLIPS.

THEY COME IN LENGTHS, OUR LACINGS.

AND YOU CUT THAT TO THE WIDTH OF YOUR BELT.

AND THEN THAT GOES INTO THIS BIZARRE MACHINE.

I SEE ALL THE TEETH DOWN THERE.

ALL RIGHT, I'LL LET YOU OPERATE THAT, BECAUSE I DON'T WANT TO GET MY FINGER CAUGHT IN THERE.

SLIDE THE BELT RIGHT DOWN IN TILL IT HITS THE BOTTOM OF THE MACHINE.

OK.

SO YOU MAKE SURE THOSE ARE SQUARE ACROSS.

THAT'S RIGHT.

THEN YOU CRANK THE HANDLE.

AND EVERY ROTATION OF THE HANDLE WILL TIGHTEN IT UP A BIT MORE.

OH, I SEE.

OK.

SO YOU SET IT A LITTLE DEEPER.

RIGHT.

THERE'S A RATCHET TO TIGHTEN UP ON IT.

WOW.

AND THIS THING WOULD DO BIG, WIDE BELTS, LIKE 6 INCHES WIDE.

WELL, YOU COULD DO WIDER.

YOU COULD DO A CLIPPING THE WIDTH OF THE MACHINE AND THEN GO OVER ITS WIDTH AND DO ANOTHER LACE.

SO YOU COULD DO A 2-FOOT BELT.

AND THAT'S IT.

SO THESE ARE PUSHED THROUGH AND KIND OF CLENCHED NOW.

THAT'S RIGHT.

AND THEN YOU PUT A METAL THROUGH THAT TO HINGE IT?

RIGHT.

THAT CLIP WILL GO RIGHT THROUGH AND HOLD IT.

AND DO THAT.

GREAT.

ALL RIGHT.

NOW, LET'S GET THE BELT OUT OF HERE BECAUSE I WANT TO SEE NOW WHAT THAT BELT RUNS ON.

YOU'VE GOT A WHOLE ASSEMBLY HERE.

IT'S UPSIDE-DOWN, BUT, ALDEN, CAN YOU TELL ME, WHAT HAVE YOU GOT HERE NOW?

WELL, THIS CONSISTS OF A BEARING HANGER, AND THE BEARING IS IN THE MIDDLE OF IT.

AND THEN THERE'S AN IRON SHAFT AND IRON PULLEYS.

ALL RIGHT, NOW, IS ONE OF THESE-- I SEE IT RIGHT THERE.

ALL RIGHT.

SO THAT ONE'S LOOSE.

THAT'S A LOOSE PULLEY AND A FIXED PULLEY, AND THAT'S THE TYPICAL WAY OF SHIFTING FROM IN GEAR TO OUT OF GEAR.

ONE SHIFTS IT ON.

ALL RIGHT.

AND THIS IS JUST THE SAME AS THE OTHER PULLEY, BUT THIS ONE DOESN'T HAVE THE SET SCREW TIGHTENED?

NOW, THESE ARE IRON.

THEY ALSO... YOU LIKE THE WOODEN ONES AS WELL?

OH, THIS IS THE TYPE I LIKE VERY WELL.

I'M PARTIAL TO THESE BECAUSE THEY'RE EARLIER.

AND IT HAS THIS KIND OF INSERT.

IS THAT FOR DIFFERENT SIZED SHAFTS?

THAT'S FOR DIFFERENT SIZED SHAFTING, IT IS.

I LOVE THE WAY-- I LOOK ON THE END HERE.

YOU SEE THE WAY IT'S KEYED THERE, KIND OF IN THE CONSTRUCTION, TO KEEP IT LOCKED UP.

LITTLE DETAILS YOU WOULDN'T THINK OF.

A LOT OF WORKMANSHIP IN A WOODEN PULLEY.

NOW, STEVE, YOU'VE ALSO GOT THE BEARING HERE.

CAN I TAKE THIS APART?

SURE.

NOW, THIS IS UPSIDE-DOWN.

SO THIS WOULD BE THE HANGER.

AND I GUESS THAT WOULD TENSION IT.

AND, ALL RIGHT, SO IT'S A SPLIT BEARING.

WHAT IS THIS?

THERE'S IRON ON THE OUTSIDE, BUT WHAT'S THIS GOING ON INSIDE HERE?

THAT MATERIAL ON THE INSIDE IS BABBITT.

BABBITT?

BABBITT IS MADE OF TIN AND LEAD, AND IT'S HEATED AND POURED INTO THE BEARING.

AND THAT MAKES THAT CASE TIGHT THERE.

SO NOW THIS IS ONE THAT'S KIND OF FRESHER NOW.

SO WHEN YOU POUR IT IN, I MEAN, IT'S JUST TIGHT.

IT'S A DEAD GRIP.

THERE'S NO PLAY.

THAT'S RIGHT.

HOW DO YOU GET A LITTLE CLEARANCE FOR OIL IN THERE?

WE TAKE WHAT ARE CALLED BABBITT SCRAPERS.

THEY HAVE AN EDGE ON THEM, AND WE TAKE THAT RIGHT DOWN IN AND SCRAPE OUT ANY BURRS OR ANY EXCESS BABBITT THAT'S LEFT IN THE BEARING.

SO THIS BEING LEAD AND TIN, YOU DON'T WANT TO EAT THAT.

YOU DON'T WANT TO EVEN PUT YOUR HANDS ON IT, YEAH.

LEAD THERE.

SO THIS IS A BEARING SCRAPER.

YOU HAVE OTHER STYLES OF THIS HERE?

WE DO.

SOME BEARINGS ARE LARGER.

WE HAVE LARGER SCRAPERS.

WHOA.

THIS IS THE KIND YOU'D USE IF YOU WERE DOING A RAILROAD ENGINE OR SOMETHING LIKE THAT.

SO A BIG BABBITT BEARING.

ALL RIGHT.

AND THAT GOES ON THERE.

AND YOU, OF COURSE, HAVE TO KEEP IT OILED AND SUCH.

THAT EXPLAINS MOST OF THE MYSTERY OF THIS EXCEPT FOR... ALDEN, WHAT ON EARTH?

I SEE THESE RINGS ON THIS SHAFT, AND I SEE THEM ON THE SHAFT UP THERE-- RINGS RUNNING BACK AND FORTH ON THE SHAFT.

WHAT IS THAT ALL ABOUT?

OH, THOSE WE CALL MICE.

THOSE LITTLE RINGS KEEP THE SHAFTING CLEAN.

BUT ARE THEY GOING THROUGH EACH OTHER?

THEY LOOK LIKE THEY'RE PASSING THROUGH EACH OTHER.

THAT'S GOING TO HAVE TO REMAIN A MYSTERY.

OK. WELL, I'LL KEEP MY EYE ON THEM.

I'LL TELL YOU WHAT.

NOW, THIS IS... STEVE, YOU'VE GOT TO DO THESE KIND OF BEARINGS ON ALL SORTS OF MACHINES AS WELL.

THEY'RE NOT JUST ON THE SHAFT.

THAT'S RIGHT.

ALL OF OUR MACHINERY HAVE A BABBITT BEARING.

IS THAT SOMETHING YOU HAD TO DO ON THE DOVETAIL MACHINE?

WE DID.

IS IT READY TO GO?

IT IS.

WOULD YOU LIKE TO SEE IT RUN?

YEAH, I'D LIKE TO SEE IT.

LET'S GO.

HOLY COW!

STEVEN WITHAM, THIS IS ONE SCARY-LOOKING MACHINE.

THIS IS A VERY DANGEROUS MACHINE, ROY.

IT DESERVES A LOT OF RESPECT.

I'D HATE TO BE SITTING ON THIS THING EATING MY LUNCH WHEN SOMEBODY CUT IT ON.

TOSSED SALAD.

AND THIS IS A DOVETAILING MACHINE, AND THAT'S A DOVETAIL JOINT.

THAT'S THE DOVETAIL ON THE LOCK RAILS.

AND THAT STILE KIND OF HANGS IN THERE AND SLIPS IN AND HANGS SO THAT IT LOCKS IT ALL TOGETHER.

THAT'S RIGHT.

THEY LOCK RIGHT TOGETHER.

ALL RIGHT, BUT I CANNOT SEE HOW THESE KIND OF BLADES COULD CUT THIS UNLESS YOU WERE TO CHANGE THE POSITION OF THE WOOD.

IT DOES.

IT DOES TRAVEL ON THE TABLE.

IT TILTS BACK AND FORTH.

WHAT CHANGES THE POSITION OF THE TABLE?

WHAT KEEPS IT PRECISE?

THE POSITION IS CHANGED BY A TRAILING PIN ON THE BACK OF THE TABLE THAT TRAVELS ALONG EACH OF THE TRACKS OF THE SIDE, AS A GUIDE.

OH, ALL RIGHT.

WELL, TO UNDERSTAND IT, WE'RE GOING TO HAVE TO RUN IT.

CAN I GO AHEAD AND CUT IT ON?

GO AHEAD.

START IT UP.

ALL RIGHT, ALL RIGHT.

NOW I'M GOING TO CHANGE FROM THE IDLER PULLEY OVER TO THE DRIVE PULLEY.

ARE YOU CLEAR?

I'M CLEAR.

ALL RIGHT.

I WANT TO BE SURE.

AND THERE SHE GOES.

OK. WE START OUT BY TRAVELING IN THE TOP TRACK.

ALL RIGHT.

FIRST WE'LL GO THROUGH TO OUR TRIM SAW TO CUT OUR STOCK TO LENGTH AND THEN ENTER THE FIRST PART OF THE DOVETAIL SAW.

[SAW WHIRRING] THE TABLE WILL THEN DROP DOWN ONE GROOVE... OH, NOW IT'S HORIZONTAL.

I SEE.

THAT'S RIGHT.

SO CUT ON A CENTERED HEAD.

AT THAT POINT, YOU BACK UP AND DROP DOWN TO THE THIRD TRACK, TO THE BOTTOM TRACK, AND CUT THE REMAINDER OF THE DOVETAIL.

I'LL BE DARNED.

AND THERE IT IS.

THAT'S THE DOVETAIL JOINT.

THAT'S IT.

HA HA HA!

ALL RIGHT.

STILL A SCARY, SCARY MACHINE.

IT DOES A GREAT JOB.

WE NEED TO CUT THIS THING OFF NOW, I GUESS.

NO, ACTUALLY, I'D LIKE TO LEAVE IT RUNNING.

WE JUST POURED THE BEARINGS.

I'D LIKE TO WEAR THEM IN.

I NOTICE THAT'S ONE THING YOU'VE BEEN DOING, IS SNIFFING THE AIR TO MAKE SURE THERE'S NOTHING RUBBING FRICTION AND GETTING HOT.

RIGHT.

NO BURNING.

WE USE PLENTY OF OIL.

WELL, THIS CAN'T BE-- THIS ISN'T THE END OF ALL YOUR CHAMBER OF SCARY WOODWORKING MACHINES.

WE HAVE A TON MORE MACHINES.

WOULD YOU LIKE TO SEE THEM?

I'M READY.

THEY'RE RIGHT OVER THIS WAY.

OK. ON OCCASION, ROY, WE ACQUIRE A MACHINE WE HAVE NO IDEA ITS USE.

WE KNOW IT'S WOODWORKING, BUT THAT'S AS FAR AS IT GOES.

BUT YOU GO AHEAD AND GET IT.

THAT DOESN'T STOP YOU.

MAYBE YOU CAN GUESS WHAT IT IS.

OH, I'VE GOT TO GUESS ON THIS ONE?

CAN YOU TURN IT A LITTLE BIT?

JUST KIND OF TURN THE CRANK SO I CAN SEE?

ALL RIGHT.

I'VE GOT A CRANK TURNING KIND OF A SAWING... A DOUBLE-LEVEL SAWING DEAL AND 5 CENTER BITS.

I HAVE NO IDEA WHAT IT DOES.

NO IDEA?

OK. WE'LL HELP YOU OUT.

ALL RIGHT.

IT'S A PULLEY BORING MACHINE.

OH.

ALL RIGHT.

SO THIS DOES THE SOCKET RIGHT THERE FOR THE PULLEY TO GO INTO.

YEAH.

AND IT COUNTERSINKS IT, TOO.

THAT'S WONDERFUL.

ALL RIGHT.

AND THAT'S, OF COURSE, FOR THE COUNTERWEIGHT AND ROPE SYSTEM THAT HELPS YOU MOVE THE WINDOW UP AND DOWN.

ALL RIGHT.

WELL, WE'VE GOT TO RUN THIS ONE.

I'VE GOT TO SEE HOW THIS GOES NOW.

WHERE DO YOU SET THE BOARD?

RIGHT IN THROUGH HERE.

HERE'S A BOARD.

PICK THAT ONE UP.

SLIDE THAT RIGHT THROUGH HERE.

OH, I LOVE THAT SYSTEM YOU'VE GOT RIGHT THERE.

IT'S KIND OF A SLIDING WEDGE TO LOCK IT IN.

RIGHT, AND JUST UP TO...

RIGHT ABOUT TO HERE.

OK. AND THEN LOCK IT IN.

ALL RIGHT.

AND NOW YOU'RE GOING TO ENGAGE IT.

ALL RIGHT.

PULL OVER ONTO THE DRIVE.

PUT STEADY PRESSURE IN.

UH-HUH.

GOSH.

IT TAKES A LOT OF PRESSURE.

YOU'VE GOT TO REALLY LEAN INTO IT.

BUT YOU'VE GOT 3 CENTER BITS BORING AT THE SAME TIME.

RIGHT.

YOU'RE BORING A CLEARANCE RIGHT NOW FOR THE PULLEY.

ALL RIGHT, AND NOW IT'S DOING THE COUNTERSINK AND SAWING IT OUT AT THE SAME TIME.

OH, THAT'S GREAT.

ALL RIGHT.

SO NOW I TAKE IT OUT.

LET ME GO AHEAD AND DISENGAGE THE DRIVE THERE.

THAT'S WONDERFUL.

IT'S A WHOLE SYSTEM OF STUFF-- NOT JUST SASH, BUT YOU HAVE TO HAVE THE PULLEY SYSTEMS THERE, TOO.

THAT'S RIGHT.

NOW, HOW DO YOU GET INTO THE WEIGHTS THAT ARE INSIDE THE BOARD HERE?

THAT'S THE NEXT MACHINE.

WE HAVE A DOOR CUTTER.

ALL RIGHT.

WELL, IT'S GOT TO BE OVER HERE.

IT'S RIGHT OVER THERE.

ALL RIGHT.

THANK YOU.

WHOA.

OK, STEVE, NOW THIS, YOU TELL ME-- THIS IS THE MACHINE THAT CUTS THE POCKET TO GIVE YOU ACCESS TO THE SASH WEIGHT.

YES, IT DOES.

ALL RIGHT.

I GOT THAT MUCH.

THIS MACHINE RUNS ON A PITMAN ARM IN THE BACK UP TO THIS ROCKER SHAFT.

GOES UP TO THE ROCKER.

THAT RUNS THE 2 CROSSCUT SAWS ON EITHER SIDE.

AND I LOVE IT.

WHAT IT ENDS UP DOING IS JUST IMITATING 2 GUYS WITH HANDSAWS CUTTING AWAY.

ALL RIGHT.

WELL, IF WE'RE GOING TO REALLY UNDERSTAND IT, YOU'RE JUST GOING TO HAVE TO RUN IT FOR US HERE.

OK.

I CAN DO THAT.

ALL RIGHT.

WE HAVE A CAM LEVER TO HOLD OUR STOCK IN PLACE.

UH-HUH.

ALL RIGHT.

AND I SEE YOU'RE HITTING A FOOT TREADLE THERE, AND THE LITTLE SAWS START TO WORKING.

NOW, DO THEY STOP AUTOMATICALLY?

THEY STOP.

THEY REACH A CERTAIN DEPTH, THEN THEY STOP.

ONE FROM BELOW AND ONE FROM ABOVE.

THEN WE SLIDE OUR MATERIAL DOWN TO OUR GUIDE LINE.

AND NOW THE 2 RIP BLADES WILL COME UP THROUGH... [SAW BLADES WHIRRING] OH.

HA HA HA.

JUST LIKE THAT.

I LOVE IT.

ALL RIGHT.

AND NOW WHAT DO YOU DO?

THEN WE CAN TURN IT OVER, TAKE A HAMMER...

RIGHT HERE?

THAT'S RIGHT.

AND JUST WHACK IT?

KNOCK IT RIGHT OUT.

THERE WE GO.

JUST LIKE THAT.

AND THAT GIVES YOU A POCKET THAT HAS ACCESS... FOR YOUR WINDOW WEIGHTS.

TO THE SASH WEIGHTS THAT COUNTERBALANCE THOSE HEAVY VICTORIAN SASH.

WELL, I TELL YOU, STEVE, THIS LOOKS GREAT, BUT IT SCARES ME.

I KNOW YOU GREW UP IN A SHOP LIKE THIS, BUT THIS LOOKS VERY DANGEROUS.

I MEAN, YOU COULD GET REALLY HURT IN HERE IF YOU DIDN'T KNOW WHAT YOU WERE DOING.

THAT'S RIGHT.

YOU COULD GET VERY HURT.

YOU HAVE TO KEEP YOUR MIND AND YOUR EYES ON YOUR WORK.

BUT DID YOU KNOW THAT WE HAVE A MACHINE THAT WAS RUN BY A BLIND MAN?

A BLIND MAN?

NO.

THAT'S RIGHT.

WOULD YOU LIKE TO SEE IT?

I GOT TO SEE IT.

ALL RIGHT.

FOLLOW ME.

OH, MY GOSH.

I CAN'T BELIEVE IT.

THIS IS SCARY.

THERE'S, LIKE, 4 BLADES SPINNING AROUND.

ALDEN, YOUR SON HAS TOLD ME THAT A BLIND MAN USED TO RUN THIS MACHINE.

THAT CAN'T BE TRUE.

THAT IS TRUE.

HE WAS A BLIND MAKER.

HA HA HA!

I "SHUTTER" TO THINK...

SORRY.

IT'S THE OLDEST JOKE IN THE BUSINESS HERE.

HE MADE SHUTTER SLATS ON THIS MACHINE.

ALL RIGHT.

STEVE, COULD WE SEE HOW IT WORKS THERE?

YES, WE CAN.

ALL RIGHT.

AND WHAT DOES THIS DO?

ALL RIGHT.

IT... TRIMS IT TO LENGTH.

THAT'S RIGHT.

AND PUTS A TENON ON THE END.

AND CUTS THE ROUND TENON THAT IT PIVOTS ON.

THAT'S RIGHT.

ALL RIGHT.

OH, THAT'S GREAT.

AND THAT WOULD FIT RIGHT IN THIS OLD SHUTTER RIGHT HERE.

OH, THIS IS BRILLIANT.

SO YOU'VE GOT WINDOWS COVERED FROM THE SASH TO SHUTTERS.

INSIDE AND OUT.

EVERYTHING YOU NEED.

IT LOOKS LIKE YOU'VE GOT A WINDOW OVER HERE READY TO GO TOGETHER IN THIS KIND OF PRESS ARRANGEMENT.

WHAT IS THIS, NOW?

WELL, THIS ASSEMBLES A WINDOW.

IT PUSHES IT ALL TOGETHER.

PRESSES IT ALL TOGETHER.

HERE WE'VE GOT THE PIECE WE WERE MAKING EARLIER.

AND I SEE THE JOINT IS STILL LOOSE.

SO, NOW HOW DO YOU OPERATE THIS?

WELL, THERE'S A PEDAL HERE, AND I PRESS THE PEDAL, AND IT PUSHES IN ON ALL SIDES OF THE WINDOW AT ONCE.

AH.

SQUARES IT UP.

THAT'S WONDERFUL.

AND THEN WHEN IT'S HELD AND ALL TOGETHER, YOU CAN, I GUESS, DO THE PEGGING AND SUCH AND WEDGING?

AND SO HERE'S ANOTHER WINDOW THAT JOINS THE MANY THOUSANDS THAT HAVE COME OUT OF YOUR SHOP.

NOW, ALDEN, WHY ON EARTH DID YOU GO INTO MAKING WINDOW SASH?

THIS IS A VERY DIFFICULT BUSINESS, I THINK.

THROUGHOUT THE YEARS OF MILLWORK, I THOUGHT ABOUT WHAT I DISLIKED DOING THE MOST, AND PROBABLY EVERYONE ELSE WOULD, TOO.

AND IT WAS WINDOW WORK?

IT WAS BUILDING WINDOW SASH.

SO YOU WENT INTO THIS BECAUSE YOU HATED IT?

OH, BECAUSE I DISLIKE IT, I KNEW IT WOULD BE A NICHE.

OH, BECAUSE EVERYBODY ELSE WOULD HATE IT, TOO.

YOU'D HAVE IT ALL TO YOURSELF.

AND I GUESS, WHAT, USING THE OLD MACHINES IS PART OF WHAT MADE IT ENJOYABLE AND PLEASURABLE FOR YOU.

IT MAKES IT-- IT'S A HOBBY.

HA HA HA!

A GREAT BUSINESS.

WELL, WONDERFUL.

SO YOU'VE GOT ALL THESE WONDERFUL MACHINES HERE, A WONDERFUL BUSINESS.

THANK YOU, STEVE WITHAM.

THANK YOU, ROY.

COME BACK AGAIN.

I APPRECIATE IT SO MUCH.

ALDEN WITHAM, HERE AT YOUR WONDERFUL SHOP IN SHARON SPRINGS, I APPRECIATE IT.

HEY, AND THANK YOU FOR JOINING US HERE IN "THE WOODWRIGHT'S SHOP."

WE'LL SEE YOU NEXT TIME.

SO LONG.

TO LEARN MORE ABOUT "THE WOODWRIGHT'S SHOP" AND TRADITIONAL WOODWORKING, VISIT PBS ONLINE.

YOU CAN FIND US AT PBS.ORG.

CAPTIONING MADE POSSIBLE BY U.S. DEPARTMENT OF EDUCATION CAPTIONED BY NATIONAL CAPTIONING INSTITUTE --www.ncicap.org-- MAJOR FUNDING FOR "THE WOODWRIGHT'S SHOP" IS PROVIDED BY... ROY UNDERHILL IS THE AUTHOR OF "THE WOODWRIGHT'S SHOP" AND OTHER BOOKS ABOUT TRADITIONAL WOODWORKING, PUBLISHED BY THE UNIVERSITY OF NORTH CAROLINA PRESS AND AVAILABLE AT BOOKSTORES AND LIBRARIES.