Making The Cut

By Joshua Brown

Since before the beginning of recorded history, people have made useful and beautiful articles out of wood using simple tools. Woodworking is enjoyable, creative and (sometimes) profitable.

I’ve taught woodworking for over 30 years. I’m always sad when a fellow woodworker gives up after an accident or illness, and I’m even sadder when I meet people who won’t try woodworking because they think their physical disabilities make it impossible.

I tell them that I’ve found ways to make it happen. I injured my back 10 years ago, and this has affected my mobility. Arthritis makes my hands hurt much of the time. Rather than give up woodworking, I’ve adapted my tools and techniques to suit my needs, and I’ve helped many of my friends with physical disabilities start or keep on woodworking.

SAFETY FIRST
Before you get started, talk with your doctor or physical or occupational therapist about your abilities. Ask about lifting limits, strength exercises, and any special equipment you may need, and whether it’s safe for you to handle power tools.

Always wear eye protection. I prefer a full-face shield instead of goggles, which fog up easily. Magnifying spectacles or lighted magnifiers, which clamp to a tabletop or bench, can help people with low vision. I wear earmuff-type hearing protection or soft foam ear plugs when using noisy machinery.

Wear a mask in dusty conditions, and sweep or vacuum up shavings and scraps so you won’t slip. If you use supplemental oxygen for emphysema or another health condition, be sure to stay away from sparks (created by many power tools), pilot lights or open flames. Choose sensible footwear.

Never remove safety guards, and always think ahead — preventing accidents is better than relying on first aid! SET UP YOUR WORKSPACE
Having a bench that really fits is critical, whether you work standing or sitting. If you don’t have the right bench or work area, experiment and improvise until you have a set-up that is comfortable and safe. Here are some general guidelines:

General work surface
2”-3” (5-8 cm) below bent elbow height when standing or sitting; this allows you to push down on work easily.

Working on medium details
This should be at bent elbow height when you’re sitting or standing; best height for all-round work.

Working on fine details
4”-6” (10-15 cm) below chin height; good for working on miniatures, fine carving, etc.

Power tool work surface
Navel to mid-chest height — you must be able to look down at your work from above. Benches and tool stands must be sturdy and must not move around. I anchor benches to the wall, or make them heavy and massive. If you use a wheelchair, allow adequate clearance below. A cutout centre section lets you reach all parts of the bench easily.

I work standing, but I keep a lightweight 8-inch (20 cm) footstool handy — working with one foot up really helps my back. I also have resilient rubber mats by my bench and lathe to ease the strain of working on a concrete floor. Add wellanchored hand grips and grab rails wherever needed.

Holding work steady can be a challenge. I use a standard woodworking vise and all-purpose work holders like the Black & Decker Workmate, which holds odd or angled pieces.

Your workspace should be well-lit with natural or fluorescent light, easy to clean, and organized so that tools and materials are within easy reach.

Woodworkers who use a wheelchair or walker may want to attach a tray or caddy of frequently used tools to their equipment.

A friend or family member can help you move large projects safely. Don’t be too proud to ask for help! I use a two-wheel hand truck or a four-wheel dolly to move heavy items, or I slide them across the floor on a scrap of carpet or old blanket. Be sure that stored wood, panels or other materials won’t fall over and hurt you.

TOOL TIME
Selecting the right tools can make a big difference, and each person has different needs. For example, twisting and repetitive motions aggravate the pain in my hands, so one of my favourite tools is my cordless drill/power screwdriver.

Gripping larger tool handles is easier — most handles from stores are too small. I’ve made larger handles for many of my lathe tools, and specially sculpted handles for my chisels. If you can’t make these yourself, ask a carpenter.

I really like Japanese hand saws and hand planes, which cut on the pull stroke. They cut much more easily, and are easier to control.

Carving with mallet and gouges may be challenging. I use a Dremel Moto-tool for fine details. Serious carvers may want to invest in air-powered gouges or a Foredom rotary carver. Many power tools are designed for people who can work standing and use two hands, and who have good physical strength and mobility. Table saws, routers, jointers and planers are particularly troublesome. Consider using scaled-down “bench top” power tools, or get a friend or family member to help. Use add-on fences, bigger tables, rollers, clamps, work jigs or other aids to steady and hold your work.

Be sure that you can start, stop and control a power tool before you turn it on! You may need to relocate a switch or add a foot-control switch to use a tool safely. Also, a new device, SawStop, applies a power brake to table saw blades within five milliseconds if you accidentally touch a moving blade. This safety feature is well worth the extra cost (see sidebar, left, for where to buy).

I use one-inch and three-inch (25 mm and 75 mm) drum sanders mounted on a drill press instead of a power jointer/ planer. For smaller projects, you can use a scroll saw instead of a table saw or band saw.

I often use mail order and the Internet to shop for wood and other materials. The quality is usually excellent, I can see exactly what I’m getting, and the products are delivered to my home. Many lumber yards or home improvement centres will cut larger boards or panels to a custom size and deliver for a nominal charge.

Planning ahead, choosing the right tools and making simple modifications can make woodworking a pleasurable hobby. Don’t let physical disability or illness stop you! You’ll be repaid many times over in pride and confidence, and in showing off work you’ve done yourself.

Joshua Brown lives in Richmond, Indiana.