(me announcer) WHETHER YOU'RE HELPING THEM I'M SO THERE.TO WALK... (announcer) OR TEACHING THEM TO DRIVE... [tires screeching] (girl) SORRY.
OH, YEAH, I'M THERE.
(announcer) WHEREVER YOU ARE IN LIFE, STATE FARM IS THERE, PROUD SPONSOR OF  THE WOODWRIGHT'S SHOP.
[horns beeping] [banjo strumming] [upbeat fiddle music] [metal rasping] HEY, HELLO AGAIN.
WELCOME BACK TO  THE WOODWRIGHT'S SHOP.
I'M ROY UNDERHILL, AND I'M SO GLAD YOU CAN BE WITH US AGAIN TODAY, BECAUSE WE HAVE OUR VERY GOOD FRIEND MASTER BLACKSMITH PETER ROSS WITH US TODAY.
PETER, GOOD TO SEE YOU.
HEY, RON.
HEY, GOOD TO SEE YOU.
NOW, PETER, YOU DON'T HAVE YOUR FIRE WITH YOU.
HOW ARE WE GONNA DO BLACKSMITHING IN HERE?
AHH, I'M HERE TO SHOW YOU THE BRIGHT SIDE.
OH, THE BRIGHT SIDE,OKAY.
IT'S COLD, BUT IT'S THE BRIGHT SIDE OF IRONWORK.
THIS IS THE OTHER HALF, THOUGH, YOU SAY, 'CAUSE EVERYBODY THINKS THE BLACKSMITH HAS TO, YOU KNOW, HIT THE IRON, AND IT COMES RIGHT FROM THE FIRE, AND THAT'S IT.
BUT THAT'S NOT TRUE?
NO, A LOT OF PEOPLE THINK ONCE YOU'RE DONE HAMMERING, THE PIECE IS DONE.
BUT THIS IS LIKE STARTING WITH ROUGH-HEWN TIMBER.
THAT'S NOT ALWAYS THE END OF THE PROCESS; IT'S THE BEGINNING.
YEAH, ALL RIGHT, YOU GOT TO PLANE IT AND SCRAP IT.
WE'RE STARTING WITH A ROUGH FORGED PIECE, BUT NOW WE'RE GONNA FILE THE SURFACE TO SMOOTH IT.
SO HERE WE ARE-- THIS IS THE SURFACE-- WHAT WE'RE SEEING ON THTHIS IS A DOOR PULL.
IT'S A ROUGH FORGED DOOR LATCH, AND SO FAR, I'VE FILED THIS PART, THE HANDLE.
YEAH.
AND SO AGAIN, YOU'RE JUST WORKING, AND WEARING THAT DOWN WITH THE-- RIGHT, THE FILE JUST SCRAPS OFF-- HUH.
AND IF YOU GUIDE THE FILE PROPERLY, IT MAKES THE SURFACE CONFORM TO IT, LIKE PLANING.
YEAH, OKAY, WELL, THAT'S GREAT.
NOW, THIS IS BASED ON A HISTORICAL-- I MEAN, YOU WORK REPLICATING HISTORICAL WORK, SO YOU HAVE PRECEDENCE FOR ALL THIS STUFF?
RIGHT, I'M NOT JUST MAKING THIS UP.
THAT'S ALWAYS GOOD.
I BROUGHT A COUPLE OF ANTIQUES WITH ME.
OH, ALL RIGHT.
COME LOOK OVER HERE.
THAT'S KIND OF LIKE WHAT YOU WERE WORKING ON, RIGHT HERE.
RIGHT, THAT'S EXACTLY WHAT I BROUGHT: SOME LATCHES.
NOW, IF YOU LOOK AT THAT LATCH, WHICH IS THE WAY MOST ANTIQUES LOOK, YOU SEE IT'S BROWN AND DARK, AND YOU THINK, "OH, WELL, THAT'S JUST THE WAY IT WAS FORGED" THAT'S THE WAY IT ALWAYS WAS.
RIGHT; BUT LOOK CLOSELY AT THIS SURFACE HERE, AND SEE HOW IT'S MUCH SMOOTHER THAN THE REST OF THE LATCH.
THAN RIGHT DOWN HERE?
RIGHT.
SO THIS IS THE FORGED-- THIS WAS LEFT FORGED AS YOU'RE DOING, AND SO THAT'S JUST WHAT YOU'RE REPLICATING.
BUT WHAT'S IN THE MIDDLE WAS BRIGHT ORIGINALLY INSTEAD OF-- AND FILED.
RIGHT.
ALL RIGHT, AND YOU CAN ALMOST SEE THE HAMMER MARKS AND CERTAINLY THE FLARE OF THE PUNCH MARKS ON THE BACK SIDE.
SO IN AN ANTIQUE, YOU OFTEN HAVE TO LOOK FOR THE TEXTURE, NOT A COLOR DIFFERENCE.
I SEE.
OKAY 'CAUSE-- NOW, HERE'S A NEW ONE.
ALL RIGHT, AND THIS IS ONE YOU HAVE DONE...
RIGHT.
AGAIN, TO REPLICATE THAT COMBINATION OF SURFACES.
IT'S A LOT CLEARER IN A NEW PIECE, BUT AFTER 200 YEARS OF WEATHER, IT'S A LITTLE HARDER TO SEE.
ALL RIGHT, SO HERE WE'VE GOT, AGAIN, THIS FILED BRIGHT, AND UP HERE ON THE LEAF, I GUESS YOU CALL THIS-- IT'S BEVELED A LITTLE BIT RIGHT THERE AROUND THE EDGES, BUT OTHERWISE, THAT'S STILL FROM THE HAMMER.
EXACTLY.
THERE'S ANOTHER ONE-- ACTUALLY, THERE'S ANOTHER ONE HERE THAT HAS THE REMNANT OF SOME DECORATION ACROSS THE MIDDLE OF THE HANDLE.
AHH, OKAY.
ALL RIGHT, SO THIS-- HERE IT IS NEW.
YOU CAN SEE IT BUT VERY FAINTLY RIGHT THERE.
RIGHT.
AGAIN, DON'T JUDGE THE PIECE JUST BY ITS COLOR.
DON'T JUDGE A LATCH BY ITS COLOR.
[laughs] WELL, THERE'S A LOT OF HAND MARKS ON THERE TOO AND HAND OIL AND SUCH LIKE THAT AND JUST WEAR ON THIS PIECE.
SO TIME REALLY DOES TAKE A TOLL ERASING IT.
WELL, LET'S LOOK AT-- YOU'VE GOT THIS DECORATIVE WORK, LIKE ON THIS HINGES HERE.
OH, THOSE ARE SOME OTHER GOOD EXAMPLES.
ALL RIGHT.
WHAT YOU GOT?
IF YOU TURN ONE OF THESE OVER, YOU'LL SEE THE BACK SIDE, WHICH WAS LEFT UNFILED.
OKAY, ALL RIGHT, SO THAT'S-- AND SEE THE CONTRAST BETWEEN THE BACK SIDE AND THE FRONT.
OH, RIGHT, THESE WOULD BE-- NOW, HOW OLD ARE THESE, DO YOU THINK?
THOSE ARE LATE 18TH-CENTURY HINGES, I BELIEVE.
BUT SEE, THE WHOLE SURFACE WAS FILED BRIGHT, NOT JUST THE EDGES.
THE WHOLE FACE.OKAY.
WOW.
ALL RIGHT.
VERY CLEAN WORK, AND WOULD HAVE HAD A VERY STRONG IMPACT WHEN IT WAS NEW AND BRIGHT.
BUT IT STILL DOES.
I MEAN, THE BRIGHT DOESN'T CORRODE AS BADLY AS A ROUGH SURFACE.
IS THAT RIGHT?
A BRIGHT POLISHED SURFACE WILL RESIST RUST MUCH BETTER THAN THE FORGED SURFACE.
SO THAT'S ANOTHER REASON FOR DOING IT.
WELL, THAT'S DECORATIVE STUFF.
NOW, I WANT TO ASK YOU ABOUT MECHANICAL, LIKE ON A LOCK.
OH, YEAH, THERE'S A GOOD EXAMPLE.
ACTUALLY, I BROUGHT ANOTHER ONE WITH ME.
LET'S LOOK AT BOTH OF THESE.
ALL RIGHT.
THIS IS A MORTISE LOCK FROM ABOUT 200 YEARS AGO.
SO THOMAS JEFFERSON WAS PRESIDENT WHEN THIS WAS TURNING A KEY TO-- OH, LOOK AT IT.
YOU'LL SEE THE OFFSET CUT ON THAT SCREW THERE.
YEAH, BECAUSE THESE HAVE COVERS, OFTEN THE INSIDES STAY PROTECTED.
MM-HMM, AND IT'S ALSO THE WOOD-- OH, MY GOSH.
[laughs] I'M SORRY.
SEE, LOOK AT HOW BRIGHT THAT IS AND CLEAN INSIDE.
WOW, THAT'S INCREDIBLE.
SO THAT'S A 200-YEAR-OLD SURFACE.
THAT'S ASTOUNDING, AND AGAIN-- AM I SEEING THE STROKES OF THE FILE GOING DOWN THE LENGTH OF IT?
EXACTLY.
I'M GONNA SHOW YOU HOW TO DO THAT IN JUST A MINUTE.
JEEZ, THAT'S AMAZING.
AGAIN, THOMAS JEFFERSON WAS PRESIDENT WHEN THIS WAS DONE.
THIS WENT INTO THE DOOR, SO IT'S NOT ONLY IN THIS CASE BUT IN THE WOOD AND JUST THAT PROTECTED.
RIGHT, VERY WELL PROTECTED.
SO THIS ONE MUST HAVE BEEN-- THIS IS A SURFACE LOCK THERE, I GUESS.
THAT'S A RIM LOCK.
THAT WOULD BE ON THE SURFACE OF THE DOOR.
[laughs] NOT QUITE AS PROTECTED THERE.
EXACTLY, BUT YOU KNOW, SOMETIMES THEY'RE CLEAN.
YOU CAN SEE UNDER THIS BOLT UNDER THE STAPLE, IF YOU PUSH THAT BOLT IN...
RIGHT HERE?
YOU'LL SEE THE BRIGHT SURFACE HIDDEN UNDER THE STAPLE.
ALL RIGHT, AND SO THIS WHOLE THING WAS BRIGHT LIKE THAT WHEN IT WAS MADE?
EXACTLY.
EXACTLY.
WOW.
AGAIN, DON'T JUDGE A LOCK BY ITS COLOR.
[laughs] BY IT'S COLOR-- ORIGINALLY IN TIME-- BUT BOY, I GUESS IF I WAS 200 YEARS OLD, I WOULDN'T LOOK-- THAT'S LOOKING PRETTY GOOD.
YEAH, RIGHT.
WELL, HAVE YOU GOT A BOLT WE COULD WORK ON?
SOMETHING LIKE THE PIECE FROM THE LOCK?
HERE'S THE SAME BOLT.
ALL RIGHT.
THIS IS THE FORGING.
I MADE THIS FORGING FOR ANOTHER LOCK.
MM-HMM, AND THIS IS JUST-- THIS IS HAMMER WORK HERE AGAIN.
RIGHT.
SO YOU'VE STRETCHED IT OUT OR THICKENED IT-- YOU WANT TO START WITH A GOOD FORGING.
AND ONE OF THE OLD SAYINGS IS, "TEN MINUTES AT THE FORGE WILL SAVE YOU AN HOUR AT THE VISE."
AH, ALL RIGHT.
SO THE CLOSER YOU ARE AT THE ANVIL, THE LESS FILING YOU'LL HAVE TO DO.
ALL RIGHT, SO THAT'S-- BUT THAT'S GOT TO BE, NOW, MADE MECHANICALLY SMOOTH AND BRIGHT.
LET ME SHOW YOU HOW TO DO THAT.
WE'RE GONNA START BY FILING THE EDGE OF THIS BOLT.
ALL RIGHT.
WHY ARE WE GONNA START WITH THE EDGE?
WELL, IT'S JUST BETTER TO CLEAN UP THE PROFILE BEFORE YOU DO THE SURFACE, THEN YOU KNOW WHAT YOU'RE WORKING WITH.
WELL, YOU THINK OF WOODWORKING, THIS IS LIKE DOING EDGE JOINTING OR SOMETHING.
RIGHT.
IN THIS CASE, IT'S NOT-- IT'S NOT A REFERENCE SURFACE, BUT IT'S A LITTLE BIT MORE EFFICIENT.
AH.
SO YOU'RE FILING KIND OF DIAGONALLY.
I'M TRYING TO FILE SO THAT I MAKE A LONG STRAIGHT STROKE WITHOUT DIPPING THE FILE EITHER WAY.
THAT'S WHAT YOUR BODY WOULD LIKE TO DO.
SO IT TAKES SOME PRACTICE.
WELL, IT'S FUNNY.
IT'S BOTH ENGINEERING-- [loud, sharp rasping] [laughs] IT'S NOT TOO LOUD EXCEPT WHEN IT'S-- BUT, YOU KNOW, ENGINEERING STUDENTS-- APPRENTICES WOULD REALLY SPEND A LOT OF TIME BEING TAUGHT TO FILE VERY STRICTLY.
RIGHT, EVEN BLACKSMITHS IN THEIR INITIAL TRAINING ARE OFTEN TAUGHT TO DO THIS PART OF THE WORK FIRST.
SO THEY LEARN WHAT A STRAIGHT, FLAT SURFACE LOOKS LIKE.
WELL, HOW DO YOU TELL IF IT'S STRAIGHT?
'CAUSE I KNOW WITH A PLANE, WE CAN TELL 'CAUSE IT RUNS THE FULL LENGTH.
WELL, LET ME DO E FACE OF THIS 'CAUSE IT WILL BE EASIER TO ANSWER THAT QUESTION IN A SECOND.
THAT'S AMAZING HOW QUICK IT WORKS.
SO I'M GONNA DO THE FACE.
I'M JUST TIPPING THE FILE UP ON THE CORNER A LITTLE TO CUT THROUGH THE SCALE.
AND THAT'S THE SCALE LEFT FROM FORGING.
RIGHT.
OOH.
WE'RE ALMOST--ALMOST GOT TO THE BOTTOMS OF THE PITS.
YEAH.
[facetiously] NOW, WHO DID THIS FORGING?
[laughs] WELL, THAT'S WHAT YOU WERE SAYING, THOUGH-- 'CAUSE YOU GOT A LITTLE BIT OF AN ANOMALY RIGHT THERE, AND BECAUSE OF THAT, YOU'RE HAVING TO FILE A LITTLE BIT LONGER.
YEAH.
SEE THAT RIGHT THERE.
YEP, SO WE HAVE TO FILE TO THE BOTTOMS OF WHATEVER-- OH, ALL RIGHT.
WHATEVER'S THERE.
ALL RIGHT, SO YOU-- NOW, TO TELL IF YOU'RE FILING FLAT, YOU WATCH THE REFLECTION OF THE LIGHT OFF THE SURFACE.
OHH, OKAY.
SO YOU CAN SEE WHETHER THAT-- WHAT ARE WE LOOKING FOR?
'CAUSE IT'S BRIGHT.
IF IT'S FLAT, THE WHOLE SURFACE WILL REFLECT AT ONCE.
AH, OKAY, JUST KIND OF FLASH AT YOU, A PART OF IT WILL.
IF IT'S CROWNED, YOU'LL GET A STREAK.
I GOT YA.
ALL RIGHT.
SO ALMOST ALL OF THIS CAN BE JUDGED BY EYE.
[laughs] THAT'S GREAT.
ALL RIGHT, SO THEN THIS-- AH, LET'S SEE.
NOW, LET ME SHOW YOU THE NEXT...
SO THAT WAS CROSS-FILING.
THAT WAS CROSS-FILING.
THAT'S THE BEST WAY TO REMOVE THE BULK OF THE MATERIAL.
BUT IF YOU WANT A FLATTER, SMOOTHER SURFACE, WE CAN DRAWFILE.
ALL RIGHT, NOW I'VE HEARD THAT GUNSMITHS DO THAT WITH THE BARRELS AND STUFF LIKE THAT.
THEY ALWAYS TALK ABOUT HOW LABORIOUS IT IS TO DRAWFILE SOMETHING.
WELL, ANYTHING THAT'S FLAT LIKE THIS IS A GOOD CANDIDATE FOR DRAWFILING.
AND INSTEAD OF HOLDING THE FILE THIS WAY, YOU HOLD THE FILE ACROSS-- ATHWART THE WORK.
ATHWART THE WORK.
AND YOU WORK BACK AND FORTH LIKE THIS.
AH.
AND IT DOESN'T DULL THE FILE GOING BACKWARDS?
I MEAN, IT CUTS ONLY ON THE FORWARD STROKE.
WELL, I'M ACTUALLY CUTTING JUST ON THE PULL STROKE.
OH, SO YOU'RE LIFTING JUST A LITTLE BIT... YEAH.
THAT I CAN'T-- ALL RIGHT.
AND I SEE-- YEAH, ALL RIGHT.
NOW THE LINES ARE GOING LONG-GRAIN EVEN THOUGH THERE'S-- WELL, IS THIS WROUGHT IRON OR STEEL?
THIS IS WROUGHT IRON.
SO IT DOES HAVE A GRAIN TO IT TO SOME DEGREE, BUT THAT'S NOT WHAT WE'RE SEEING.
IT DOESN'T AFFECT THE FILING MUCH.
SO I'M GONNA GO DOWN TO A SMALLER FILE-- IT'S STILL A FAIRLY COARSE FILE-- AND CONTINUE.
MM.
AND THIS IS THE WAY I SHARPEN MY AX BITS.
AGAIN, THE SAME THING: THIS DRAWFILING DOWN THE EDGE TO GET A SHARP SHOULDER.
AND YOU'VE GOT SHARP CORNER ON THE SIDE TOWARDS ME AND A VERY SMOOTH SURFACE.
AH, THAT'S WONDERFUL.
NO, DON'T TOUCH THAT.
ALL RIGHT, NOW, YOU ALWAYS TELL ME, "DON'T TOUCH."
I WANT TO TOUCH IT, BUT YOU TELL ME NOT TO.
I KNOW.
YOU WOODWORKERS WANT TO TOUCH THINGS, BUT THE OIL FROM YOUR FINGERS KEEPS THE FILE FROM CUTTING.
AH, SO THAT WOULD KEEP THE FILE SKATING OFF IT?
IT WOULD SLIDE OVER THAT WAY.
ALL RIGHT, SO DON'T TOUCH-- ALL RIGHT, YEAH, BUT THAT'S THE WAY WE WANT IT THERE.
BOY, THAT IS BEAUTIFULLYMOOTH AND BRIGHTWORK.
YEAH, AND THAT'S ALSO MUCH MORE OF A WORKOUT THAN THE FORGING.
I'M ALWAYS MORE OUT OF BREATH AFTER THIS.
[laughs] WELL, YOU WERE GOING RIGHT AT IT.
ALL RIGHT, SO THAT'S JUST ONE-- OH, DON'T TOUCH IT.
I'M SORRY.
[dryly] YEAH, I GUESS WE'RE DONE.
[laughs]OKAY.
WELL, LET'S SEE WITH SOME OF THE OTHER PARTS NOW, 'CAUSE YOU GOT TO FIT THIS INTO THE CASE, DON'T YOU?
RIGHT.
LET'S LOOK AT THIS LOCK AGAIN, BECAUSE IN ADDITION TO-- THIS ONE HERE?
YEAH.
IN ADDITION TO FILING THE PARTS, THERE'S A LOT OF INTERESTING ASSEMBLY METHODS THAT YOU DON'T THINK OF, I GUESS, SO MUCH IF YOU'RE THINKING ONLY OF THE HOT WORK.
RIGHT.
RIGHT.
AND WHAT I WANT TO TALK ABOUT IS HOW THE CASE ITSELF IS CONSTRUCTED.
ALL RIGHT, THIS IS ONE IN PROGRESS RIGHT HERE?
YEAH, THIS IS ESSENTIALLY THE SAME SIZE LOCK.
OOH, YEAH.
OH, LOOK.
OKAY.
YEAH, TAKE THE RAIL OFF.
ALL RIGHT, AND THESE-- HOW ARE THESE LITTLE PIECES PUT ON THERE?
THERE'S, LIKE, A THIRD-- I DON'T KNOW WHAT YOU CALL 'EM.
HERE'S ONE OF THOSE NONCONFORMIST... [laughs] TRIPLE-ENDED, TENONATED PINS.
I DON'T KNOW WHAT YOU CALL 'EM.
THERE'S NO NAME FOR 'EM 'CAUSE THEY'RE DOWN INSIDE THE LOCK, BUT THEY ARE WHAT JOIN THE TWO PIECES TOGETHER, THESE ENDS.
RIGHT.
SO HERE'S ANOTHER RAIL...
OKAY.
READY FOR THE TENON-- WHATEVER THAT IS-- TO BE RIVETED IN.
OKAY.
AND IT GOES INTO A SQUARE SLOT THERE, ALL RIGHT.
ALL RIGHT?
ALL RIGHT.
LET'S RIVET THIS ONE ON.
ALL RIGHT, LET ME GET THIS-- ALL RIGHT.
AND YOU'RE GONNA WORK ON YOUR LITTLE ANVIL HERE.
WHAT'S THIS CALLED?
WELL, PETER NICHOLSON IN HIS  MECHANIC'S COMPANION CALLS THIS A BENCH ANVIL, SO EVIDENTLY, THAT'S WHAT YOU'D CALL IT.
[laughs] SO I NEVER WOULD HAVE-- I NEVER IN A MILLION YEARS WOULD HAVE THOUGHT OF TO CALL IT THAT, BUT-- THE ANVIL THAT SITS ON THE BENCH-- ALL RIGHT, SO HERE WE'LL GET PEENING THAT IN.
WHAT KIND--THAT HAMMER IS DIFFERENT, NOW.
THAT'S NOT A REGULAR HAMMER THAT WE'D THINK ABOUT.
IT'S A CROSS PEEN.
AND A PEEN, A STRAIGHT PEEN OR A CROSS PEEN LIKE THAT, ALLOWS YOU TO DIRECT THE SPREADING, AS OPPOSED TO A BALL PEEN WHICH MAKES IT SPREAD IN ALL DIRECTIONS.
SO YOU WERE SPREADING IN THIS DIRECTION THERE, AND I SEE THOSE LITTLE RIDGES THERE WHERE YOU WERE HITTING IT THERE.
SO THEN, IS THIS FINISHED NOW?
THAT'S JUST ABOUT FINISHED.
I'M GONNA WHACK IT ONCE OR TWICE MORE.
[laughs] OKAY, OH, ALL RIGHT, WITH THE FLAT OF THE HAMMER THERE OR THE ROUNDED AREA.
YEAH, NOW IT'S WAY SMOOTH.
ALL RIGHT, SO THAT LEAVES YOU WITH KIND OF A ROUGHITUDE THERE RIGHT THERE.
YEAH.
LET ME GO BACK TO THE BENCH VICE FOR A MINUTE.
ALL RIGHT.
I'M GONNA STRAIGHTEN IT OUT.
AND THEN I'LL FILE THE TOP OF THIS TENON.
OH, OKAY, SO YOU JUST-- BOY, THAT'S SOMETHING.YEAH.
SO I'M JUST FILING IT TO MATCH THE SURFACE OF THE RAIL.
YEAH.
SO BEAR UP TO THE SHOULDER BUT ALSO AROUND TO FIT THROUGH THE HOLE THAT YOU'RE GOING TO DRILL, I GUESS, OR PUT THROUGH THE SHEET.
RIGHT, SO THAT WAY, I DON'T HAVE TO PREDETERMINE THE LENGTH OF THE TENON.
IT'S JUST MADE TO MATCH.
WHEREVER IT ENDS UP ON THE RAIL, I FILE IT TO MATCH.
NOW, LET'S PRESUME WE'RE GONNA FASTEN THAT TO THIS SHEET AS IF IT WERE A PART OF A LOCK.
ALL RIGHT.
ALL RIGHT.
SO I'M JUST USE THE EXISTING TENONS AS THE GAUGE... ALL RIGHT.
IF THIS WERE TO GO ON THIS WAY.
RIGHT.
RIGHT.
WE'LL JUST MARK THE DISTANCE BETWEEN THE HOLES.
SO YOU DON'T KNOW-- I MEAN, NOT MEASURING ANYTHING HERE.
WELL, I AM.
I'M MEASURING BY USING THE EXISTING PIECE.
AH, SO THE EXIST-- AH, BUT IT'S NOT LIKE-- YOU DON'T KNOW HOW MANY INCHES IS THAT OR-- I REALLY DON'T CARE.
SO YOU DO ONE PIECE AND THEN BUILD UPON THAT INFORMATION.
EXACTLY.
EXACTLY.
THAT SEEMS TO BE A KEY TO THIS HANDWORK.
OH, IT'S SO MUCH FASTER WHEN YOU'RE WORKING BY HAND.
YOU HAVE TO-- YOU DON'T HAVE TO MAKE EITHER ONE TO A PREDETERMINED SIZE.
ALL RIGHT, BUT WE'VE GOT OUR PRECISION MARKERS THERE.
SO YOU REDUCE THE NUMBER OF PRECISION STEPS AND-- TO FINAL MOVEMENT OF ATTACHING IT.
RIGHT.
I'M SAYING THAT VERY CLUMSILY, BUT I GOT THE IDEA.
NOW I'M GONNA MAKE THE HOLES FOR THOSE TENONS TO GO THROUGH.
I'VE GOT THE MARK.
AND I'M JUST GONNA USE A FLAT BOTTOM PUNCH AND A BOLSTER WITH A HOLE IN IT.
ALL RIGHT.
NOW I'LL JUST SET THE PUNCH ON THE MARK... ALL RIGHT.
AND OVER THE HOLE.
[hammering sharply] WOW.
YEAH, LOOK AT THAT.
ALL RIGHT, AND THAT WENT AND KNOCKED THE SLUG CLEAN OUT THERE.
IT DID.
LET'S LOOK UNDERNEATH.
(both) THERE'S THE SLUG.
OKAY, YEAH.
SO THAT'S-- I'D HAVE SAID DRILL IT, BUT YOU DIDN'T.
YOU DID IT WITH THE PUNCH.
YEAH, WHEN YOU WEREN'T LOOKING.
OH, I GUESS YOU WERE LOOKING.
[laughs]I WAS.
I THOUGHT YOU WEREN'T LOOKG.
CERTAINLY, THEY  HAD  DRILLS?
WELL, THEY DID, BUT AS YOU CAN SEE, THIS IS PRETTY QUICK.
YEAH, BOY, AND CLEAN.
IT STUCK TO THE PUNCH THERE.
THAT IS STRONG.
WELL, IT'S CLEAN.
THERE IS A LITTLE SHRAPNEL ON THE BACK SIDE THERE, THOUGH.
OKAY, YEAH, I'M GONNA GET RID OF THAT JUST BY FLATTENING THE BURR.
UH-HUH.
NOW... YOU'VE GOT TO FIGURE OUT WHICH OF THE...
WHICH IS THE ONE WE WERE LOOKING AT.
I THINK THIS IS THE ONE THAT YOU HAD TO FIT IN THERE.
I OPEN THESE HOLES JUST A LITTLE.
ALL RIGHT.
NOW, LET'S SEE IF WE'RE ANYWHERE CLOSE.
CLOSE ENOUGH.
CLOSE ENOUGH, I THINK.
THE HAMMER'S GONNA GET YOU.
ALL RIGHT.
LET'S SEE IF WE CAN'T HELP THIS ONE.
ALL RIGHT.
THE TENSION MOUNTS.
[laughs] YEAH.
ALL RIGHT.
SO NOW THAT'S GOT THE TENONS THROUGH THERE, AND I SEE THE HOLES ARE KIND OF COUNTERSUNK, AND SO THAT ELIMINATEDA STEP.
DOING THE PUNCHING FROM THIS SIDE, MADE IT V-SHAPED.
WELL, LET'S LOOK AT THE PIECE WE'RE COPYING.
THE NOSE-- THAT NOSE PIECE RIGHT THERE.
THE NOSE PIECE RIGHT THERE.
IF YOU SEE, IN THE FINISHED PIECE, WE DON'T WANT THE HEAD OF THE RIVET TO SHOW.
THERE'S NO-- AH, OKAY.
SO WE WANT THAT TO BE A FLUSH RIVET.
SO PUNCHING ACTUALLY MAKES A TAPERED OR COUNTERSUNK HOLE.
AND SO WE HAVE A COUNTERSUNK HOLE HERE ALREADY TO PEEN THAT INTO.
I GOT IT.
ALL RIGHT.
SO NOW WE'LL USE THE SAME LITTLE CROSS PEEN, AND WE'LL PEEN THE TENON.
AND IF WE HAD DRILLED IT, WE WOULDN'T HAVE THAT KIND OF COUNTERSINKING AT ALL.
RIGHT, WE'D HAVE TO DO THE COUNTERSINKING AS A SEPARATE STEP.
YEAH.
AH, THIS IS GREAT.
SO THAT-- THAT'S JUST AMAZING.
NOW, THE--THE-- [laughs] AND SO A LITTLE BIT OF FILE WORK, AGAIN, ON THAT, AND THIS WOULD BE THE BRIGHT KEEPER.
LET'S TAKE THIS BACK TO THE VISE.
YEAH, ALL RIGHT.
AND SO YOU'RE GONNA FILE THAT WHOLE SURFACE OF THAT PLATE.
WELL, WE'LL JUST TAKE OFF ENOUGH TO SMOOTH OUT THE TENDONS.
MM-HMM.
AND THERE IS THE EQUIVALENT OF WHAT WE HAD IN OUR SAMPLE.
THIS ONE RIGHT-- [metal clinking] OOP, OOP, OOP, OOP, OOP.
GONNA DROP YOUR HAMMER ON MY FEET THERE.
WHY DON'T YOU HOLD THEM BOTH?
ALL RIGHT.
NOW, IF YOU'VE GOT A PIECE LIKE THIS, HOW DO YOU CUT THESE-- THIS STUFF TO LENGTH?
I MEAN, YOU'VE GOT THIS LONG, AND THIS PIECE WRAPPED AROUND THERE.
RIGHT.
I MEAN, THERE'S GOT TO BE SOME WAY TO SLICE THIS STUFF UP.
IS THAT COLD CHISEL WORK?
SURE, THAT'S ONE OF THE COMMON WAYS, AND LET ME SHOW YOU HOW TO DO THAT.
I HAVE A COUPLE OF SCRAPS OF STEEL.
'CAUSE, AGAIN, THAT'S WHAT WE'RE DOING, IS THE COLD-- THE COLDSMITHING.
RIGHT.
ALL RIGHT.
SO ONE OF THE EASY WAYS TO TRIM-- LET'S SAY YOU HAVE A PIECE THAT'S TOO BIG.
ONE OF THE EASY WAYS TO TRIM IS TO USE A SHARP CHISEL, A COLD CHISEL, AND EVERYONE PROBABLY HAS SEEN PEOPLE THAT CUT THROUGH THIS WAY AND CUT MOST OF THE WAY THROUGH.
AND THEN YOU CAN JUST BENT IT AND FATIGUE IT TO-- AND YOU COULD SNAP OFF WHAT'S LEFT.
THAT--THAT ALMOST GOES WITHOUT WORDS.
YEAH, THAT'S WHAT I WAS THINKING.
BUT THERE'S ANOTHER COMMON WAY OF TRIMMING SHEET USING THE VISE AND THE CHISEL.
SO WE JUST SET THE PIECE IN THE VISE... UH-HUH.
AT THE POINT WHERE YOU WANT TO MAKE THE CUT.
YEAH.
AND THEN WE'LL CHISEL ACROSS THIS WAY.
I'M RESTING THE CHISEL ON THE VICE.
SO IT'S ALMOST LIKE A PAIR OF SCISSORS THERE, A PAIR OF SHEARS.
RIGHT, WE'RE MAKING THE CHISEL AND THE VISE... [sharp tapping] YEAH.
ALL RIGHT.
YOU CAN SEE IT DOESN'T TAKE MUCH EFFORT.
AND VERY QUICKLY, JUST SHEAR IT-- [laughs] ALL RIGHT.
AND THEN A LITTLE BIT OF FILING, AND THAT'S IN GOOD SHAPE.
A LITTLE BIT OF FILING, AND IT'S READY IN A BIT, READY TO GO.
WELL, I'M GONNA GET YOUR RIVETING HAMMER.
OH, YEAH, WE MAY NEED THAT.
YOU KNOW, ONE OF THE GREAT MYSTERIES IN WOODWORKING IS DOING A SQUARE HOLE.
BUT I SAW IN THIS, YOU HAVE GOT SQUARE HOLES ALL THROUGH THIS, SO WHAT DO YOU DO?
OH, YEAH, I'M GLAD YOU ASKED.
YOU MAKE A SLOT OF-- AND THEN OPEN IT UP?
YOU COULD EITHER PUNCH SEVERAL HOLES IN A ROW AND FILE 'EM OUT, BUT THAT'S REALLY TORTURE.
SO INSTEAD, WE'RE GONNA USE A RECTANGULAR PUNCH.
IS THAT WHAT YOU USED RIGHT HERE?
YEAH, YEAH, I THINK THAT'S THE SAME PUNCH.
ALL RIGHT, VERY GOOD.
COME BACK FOR THE VISE.
THE VISE IS DOING LOTS OF WORK FOR YOU.
I KNOW.
IT'S GETTING TRIPLE DUTY HERE TODAY.
BUT YOU SAID THIS IS A LITTLE LOWER THAN WHAT YOU'D LIKE THE VISE TO BE.
A VISE FOR FILING AND GENERAL BENCH WORK OUGHT TO BE AT YOUR ELBOW HEIGHT.
AH, MAN.
OKAY.
WELL, WE JUST PUT THIS ON MY WOODWORKING BENCH HERE.
YEAH, THIS IS A GOOD SAW-SHARPENING HEIGHT PERHAPS.
[laughs] WELL, THAT'S GOOD FOR ME.
SO WE'RE GONNA USE THIS FLAT BOTTOM PUNCH.
AND OPEN THE JAWS UNTIL THE PUNCH JUST CLEARS.
PHOO.
ALL RIGHT.
AND THEN WE'LL JUST DRIVE THE PUNCH THROUGH INTO THE GAP.
AND THAT'S IT.
WOW.
GEE, DID THAT POP THE SLUG?
NO, THE SLUG IS STILL IN IT.
NO, IT'S STILL THERE, BUT IT WILL TAKE JUST A SECOND.
ALL RIGHT.
YOU CAN PULL THAT IN THE VISE.
'CAUSE I'M FASCINATED BY THIS, 'CAUSE THIS IS THE SAME WAY YOU KNOW, TOYS WHEN I WAS A KID WERE MADE, TIN TOYS WITH TABS PUT THROUGH AND BENT OVER.
OH, I BROUGHT MY FAVORITE MATCH HOLDER WITH ME.
THIS THING RIGHT HERE?
YEAH.
AGAIN, THAT'S THAT SAME THING WHEN I WAS A KID-- THE TINS TOYS WITH THE-- YOU'VE GOT TO SHOW THE FRONT OF IT THOUGH.
OH, WELL, IT'S BEAUTIFUL; IT'S RUSTIC.
[dryly] YEAH, IT'S A BEAUTY.
[laughs] RUSTIC-- WELL, YOU KNOW, FOR ME, THIS WAS THE BIG THING, 'CAUSE YOU COULD BEND THESE TABS AND TAKE STUFF APART AND PUT IT TOGETHER.
BUT THAT'S TAB "A," SLOT "B" KIND OF CONSTRUCTION THERE.
EXACTLY.
SO IT'S A VERY OLD, OLD THING.
SO LET'S SEE.
WE'VE GOT OUR LOCK ABOUT DONE, I GUESS, THERE.
SO IT'S MECHANICAL WORK, AND THEN DECORATIVE, I GUESS, CAN GO WAY BEYOND THIS KIND OF STUFF.
WITH THE HOLLOWS AND STUFF.
SO FAR WE'VE BEEN TALKING ABOUT JUST HOW TO MAKE THINGS FIT.
NOW, LET ME PICK SOMETHING DECORATIVE FROM RIGHT HERE LIKE THIS-- THESE THINGS.
THESE ARE A MYSTERYTO ME.
OH, YEAH, THERE'S A GOOD EXAMPLE.
WHAT IS WITH THESE THINGS HERE?
SO THESE ARE TOBACCO TONGS.
THEY'RE THE TOOL YOU USE TO LIGHT YOUR PIPE FROM AN EMBER IN THE FIRE.
SO YOU GET AN EMBER FROM THE FIRE AND THEN TAKE IT OVER TO YOUR PIPE AND LIGHT YOUR PIPE.
AND THEN YOU'VE ACTUALLY GOT A TAMPER AND A PICK AND-- THE TAMPER AND A BOWL PICK AND A STRAINER TO LIGHT THE THING AND HOOK TO HANG IT UP.
THEY WERE REALLY A MULTIPURPOSE TOOL.
NOW, THIS ONE IS, OF COURSE, JUST VERY SIMPLE DECORATION, AND IT HAS THAT CORROSION, BUT MY GOSH, THIS IS THE ONE YOU HAVE MADE, AND LOOK AT THE BEAUTIFUL-- RIGHT, WHEN THEY'RE NEW AND BRIGHT... AND THIS IS COPIED FROM A PAIR THAT SETH POMEROY MADE IN THE 1750s.
SO I WOULD LOOK AT THAT AND THINK-- I THINK WITH MOST PEOPLE-- WOULD SAY, "WOW, THAT HAD TO BE CAST TO GET THOSE SHAPES, 'CAUSE HOW COULD DO YOU THAT IN METAL," BUT NO.
IF YOU'RE NOT A GOOD SMITH, THEN YOU'D CAST IT.
[laughs] YOU'D HAVE TO CAST IT.
BUT THAT IS JUST FORGED DECORATION.
WELL, COULD TAKE A LOOK AT-- WELL, LET'S SEE.
HERE'S PROBABLY A SIMPLER ONE.
THERE'S A MUCH SIMPLER MOLDING.
LET'S LOOK AT HOW TO DO THAT, 'CAUSE THAT'S A REALLY FUN KIND OF THING.
ALL RIGHT, THIS IS A BEAD, I GUESS.
YEAH.
COME BACK TO THE VISE.
ALL RIGHT, AND DONE ON A FORK-- HERE WE HAVE JUST A PIECE OF ROUND BAR.
THIS IS IF YOU HAD FORGED THIS OUT ROUND.
ALL RIGHT.
SO LET'S PUT THIS IN THE VISE, AND WE'LL-- AND CLAMP IT UP GOOD.
ALL RIGHT.
LET'S FIND THE RIGHT FILE.
SO I'M GONNA USE A HALF-ROUND FILE.
AND THESE ARE ALL FAIRLY COARSE CUT.
AND YOU'RE CUTTING A LITTLE SHOULDER WITH THE CORNER OF THE FILE.
RIGHT; SEE, I'VE JUST MAKE A NOTCH.
THEN I CAN ROLL THE FILE AND DO ANOTHER ONE.
MM-HMM.
YEAH.
HOPEFULLY, THEY'RE PARALLEL OR CLOSE.
THIS IS LIKE LATHE TURNING.
WE WOULD DO IT IN LATHE IF WE'RE WOODWORKING.
THEN I CAN JUST ROLL THE FILE IN BETWEEN.
OH, YOU MEAN ACTUALLY IN THE MIDDLE OF THE STROKE YOU'RE ROLLING IT.
SO I'M TWISTING AS I MOVE.
I GOT YA.
OKAY.
IN BOTH DIRECTIONS.
YEAH.
AH.
IT'S ACTUALLY PRETTY QUICK.
YOU KNOW, YOU'D THINK OF IT-- AND "BOY, THIS WOULD TAKE A LONG TIME TO FILE DECORATIONS," BUT IF THEY'RE NOT VERY DEEP, THEY DON'T TAKE A LONG TIME.
YEAH.
ALL RIGHT.
NOW I'M GONNA FILE THOSE LITTLE ACCENT LINES.
YEAH.
AND SO YOU'VE-- [laughs] A BEAD AND FILLET IT THERE, ALL RIGHT?
YEAH, YEAH, OH, YEAH.
NOW, THIS IS JUST ON ONE FACE HERE THOUGH.
I MEAN, YOU'VE GOT TO CONTINUE THIS ALL AROUND AND MAKE IT EVEN.
RIGHT, I COULD TURN IT A QUARTER TURN AND CONTINUE.
SO USUALLY, YOU CAN DO A QUARTER OF IT AT A TIME.
UH-HUH.
AND THEN, ONCE YOU'RE DONE, YOU CAN TAKE THE SAME FILE AND SPIN THE WORK A LITTLE.
OH, I LOVE IT.
ALL RIGHT.
SO IT IS ALMOST GETTING LIKE A LATHE, AND I SEE IT GETTING EVEN SMOOTHER AS YOU'RE WORKING IT ALONG.
RIGHT.
EVEN OUT THE BUMPS A LITTLE BIT.
AND THERE IT IS.
WE START TO SEE THAT BEAD FORMING THAT YOU HAVE IN THIS WONDERFUL FORK THERE.
YEAH.
YEAH.
VERY SIMPLE DECORATION... OH, THIS IS GREAT.
BUT YOU MAKE A REALLY STRONG CLASSICAL FORM THIS WAY.
AH, SO WHETHER IT'S SOMETHING LIKE A FORK OR WONDERFUL TOOLS LIKE THIS WITH THE WONDERFUL CHAMFERS-- THAT BRIGHTWORK-- THAT'S THE STUFF THAT THE BLACKSMITH DOES... [laughs] AFTER THE FIRE.
YOU DON'T NEED A FIRE FOR THIS SIDE OF THINGS.
WELL, AND YOU-- ACTUALLY, IF YOU WANT, YOU REALLY WANT TO START WITH A FORGING THAT'S CLOSE TO THE END RESULT.
YOU DON'T WANT TO FILE THIS OUT OF A BIG BLOCK.
THIS IS WONDERFUL.
PETER ROSS, THANK YOU SO MUCH FOR JOINING ME HERE IN THE WOODWRIGHT'S SHOP.
I APPRECIATE IT.
NICE TO BE HERE.
AND THANKS FOR JOINING US.
WE'LL SEE YOU NEXT TIME.
SO LONG.
(announcer) LEARN MORE ABOUT THE WOODWRIGHT'S SHOP AND TRADITIONAL WOODWORKING ON OUR WEBSITE.
YOU CAN FIND US ONLINE AT: Captioning byCaptionMax www.captionmax.com [upbeat fiddle music] (male announcer) MAJOR FUNDING FOR THE WOODWRIGHT'S SHOP IS PROVIDED BY: (male announcer) WHETHER YOU'RE HELPING THEM LEARN HOW TO WALK...
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(announcer) WHEREVER YOU ARE IN LIFE, STATE FARM IS THERE, PROUD SPONSOR OF  THE WOODWRIGHT'S SHOP.
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(male announcer) ROY UNDERHILL IS THE AUTHOR OF  THE WOODWRIGHT'S GUIDE: WORKING WOOD WITH WEDGE AND EDGE, AS WELL AS OTHER BOOKS ON TRADITIONAL WOODWORKING, ALL PUBLISHED BY THENIVERSITY OF NORTH CAROLINA PRESS AND AVAILABLE IN BOOKSTORES AND LIBRARIES.