Great Work from a Small Shop

A Place for Every Tool
How does Millard produce such high-quality, detail-oriented work from his small shop?

The majority of his furniture making is handwork, but of course, power tools play an important, although somewhat lesser, role for him. Millard’s most important power tool is the 14″ band saw that stands prominently centered in the shop as he works his magic. On casters so it can be maneuvered at day’s end, the band saw is responsible for most of the ripping and cutting action. And it becomes even more of a workhorse when slicing and fitting small pieces to create strips of inlay and shop-cut veneer.

He does own a table saw, a 10″ benchtop model. The day we stopped by, the table saw, shown hanging in the photo at below right (look closely, it’s hard to see), had a generous coating of shop dust – evidence that the tool had not been used in a while.

Other power tools in the shop include his favorite, a benchtop planer (which was serving as a television stand on the day of our visit), a benchtop drill press and a small lathe that are stored behind cupboard doors, as is a scroll saw. A small aged shaper that Millard says is rarely used (but handy to have around) sits as a “catch-all” table in one corner of the shop.

These normally stationary tools are pulled from the deep recesses of storage when called into action and plunked onto benches to do their jobs. Afterward, they return to the wings to await another work order. By putting all his tools back in their spaces when not in use, Millard makes the best use of his space.

In addition, he has all the customary hand-held power tools that you would expect in a woodshop. A jigsaw, miter saw and random-orbit sander are close at hand, but neatly stored in out-of-the-way closets. He has a couple hand-held drills and a selection of routers that, while not his favorite tools in the shop, he finds extremely useful when it comes to his style of woodworking.

It’s All About Hand Tools
The crux of Millard’s woodworking is hand tools. He creates his furniture with the same tools and techniques as the original period furniture makers. Accurate reproductions are what he strives to create.
 
His assortment of planes is impressive, if not overwhelming. He names most numbers associated with planes when asked to create a list. There are examples from Lie-Nielsen (a No. 4, a large shoulder plane and a miter plane), a Veritas scraper plane as well as a jointer plane by Clark & Williams. But the majority of his planes have the name Stanley embossed on the tools – evidence that you don’t have to break the bank in order to produce great work. Millard also has a couple wooden planes that he built himself.

When persuaded to pick his favorite plane or planes he answered, “I have two favorites, the Stanley/Bailey No.7, I purchased new in 1979, and the Lie-Nielsen No. 4.” He also favors his other Lie-Nielsen planes as well as a homemade scrub plane that sees a lot of use.

Other hand tools found stored conveniently in the shop are a couple dozen Pfeil carving tools, a small selection of Japanese chisels (preferred because of the hollow-ground backs which Millard feels makes them easy to keep sharp and they’re well balanced in his hand), a couple marking gauges and a few Starrett layout tools along with a number of handsaws. His favorite handsaw is his 1925 Disston crosscut saw that was part of his grandfather’s collection back in the day.

Millard says, “I don’t have a lot of tools because it doesn’t take many to make furniture.”

You might be surprised by what he says is his overall favorite woodworking tool: “My homemade, and somewhat crude veneer hammer, because it is central to the signature part of Federal furniture. Of all the aspects of furniture making, I enjoy veneering the most.” pw