How to shape wood with hand tools and other machinery
Design & Technology students must understand how to mark out, cut, drill, and shape timber. This article summarises basic woodworking tools, methods, and practical techniques. It concludes with sample examination questions from the Cambridge AS/A Level syllabus.
How to mark out wood
Marking out means to carefully measuring and drawing the required shapes on materials ready for cutting. This usually requires taking dimensions from a ‘working drawing’ (an orthographic drawing showing multiple views, drawn accurately to scale).
WOODWORKING TOOLS FOR MARKING OUT
Carpenter pencil
Description
Uses
Chunky pencil (doesn’t get easily damaged in a workshop) sharpened to a fine tip
Line stays on surface (doesn’t penetrate into wood) and can get sanded off
Can go blunt / snap
Accurately drawing lines
Marking knife
Description
Uses
A scribing tool with a wide, robust blade for marking saw lines
Damages surface of wood (but not a problem if marking saw lines)
Can cause injury
Marks lines onto wood
Marking awl
Description
Uses
A scribing tool that can be used for scratching thin lines / indentations into timber and other materials
Damages surface of wood
Can cause injury
Marking lines onto wood
Marking nail and screw holes / marking centres for drilling
Tracing contour of one shape onto another
Dot/centre punch
Description
Uses
Hammer is tapped on top to make indentation in the wood or other material, which acts as a guide to stop drill bits from slipping when starting a hole
Similar in appearance to a nail punch which is used to drive a nail head below the surface of the timber
Indentations to guide drill bits
Marking screw holes
Steel ruler
Description
Uses
Resilient in workshop environment
Measuring shorter items
Tape measure
Description
Uses
Retracts / winds up when not in use, saving space
Lip hooks over edge, so can be used by one person
Measuring longer lengths
Try square
Description
Uses
Hooks over edge of timber and holds steel ruler perpendicular to edge
An adjustable try square that can be set at any angle
Marking lines at any angle
Mortise gauge
Description
Uses
A type of scribing tool also known as marking gauge
Slides along edge of timber – scratches a line parallel to edge (adjustable)
Faster than measuring
Scratches into surface
Marking parallel lines to edge of timber
Carpenter’s dividers
Description
Uses
Like a compass but has two points
Scratches circles and arcs
Can be used to mark equal lengths or transferring measurements
Also useful for plastic / shiny surfaces that a pencil compass wouldn’t work on
Calipers
Description
Uses
Various types, i.e. inside calipers, outside calipers, and odd-leg calipers
Used for measuring unusual or complicated parts of an object
Digital calipers have an electronic display so are easier to use
Measuring external dimensions (i.e. diameter of a dowel) or internal dimensions (i.e. width of a groove)
Measuring the distance between two surfaces at different levels
Stencils and templates can also be used to improve quality control when more than one product (such as small batch production) or multiple identical parts are needed.
CAD software can also be used to mark out shapes, when using CAM methods.
Cutting, drilling, and shaping timber
WOODWORKING TOOLS FOR CUTTING
Cross-cut saw
Description
Uses
Hand saw for cutting across the grain
Straight cuts across the grain
Tenon saw
Description
Uses
Has rigid supporting piece running down top of blade
Can’t cut very deep
Fine, neat straight cuts
Coping saw
Description
Uses
Inexpensive saw for cutting curves
Easy to snap/twist blade
Can’t cut deeper than top bar
Fine, curving cuts
Fret saw
Description
Uses
Like a coping saw
Deeper arm and finer blade
Easy to snap/twist blade
Intricate, curving cuts in thin materials
Scroll saw
Description
Uses
Thin, straight blade that moves up and down rapidly
Extremely precise detail work, very tight curves
Only cuts thin material
Puzzle pieces
Decorative, curving cutouts
Bandsaw
Description
Uses
Blade is a large band that rotates on two wheels
Cannot do tight curves
Cuts thicker material than scroll saw
Reversing is prone to snap blade
Dangerous – hair and fingers must be kept away from blade
Straight and curving cuts
Circular saw
Description
Uses
Portable electric saw, also known as a skill saw
Fast and loud
Slight curves or straight cuts
Very dangerous – rarely used by students (exposed rotating blade)
Cutting large sheets of plywood, MDF etc, or trimming ends of planks / boards
Drop saw
Description
Uses
Saw mounted to bench
Arm pulled down to lower rotating saw blade
Cuts exactly at right angles (or other set angles)
Very dangerous (exposed rotating blade)
Trimming ends of planks / boards at exact angles
Panel saw
Description
Uses
Large electric saw used for cutting big sheets of plywood and MDF
Straight cuts in large sheets
Laser cutter
Description
Uses
Suitable for thinner sheets (MDF, plywood etc)
More intricate shapes than are possible by hand
Perfect, exact shapes, repeating many times as needed
Can burn edges
Precise, complex shapes
CNC router
Description
Uses
CNC = computer numerical control
Has a rotating cutting bit that can cut, drill, and engrave
Cuts thick wood at varying depths and often big sheets
Perfect, exact shapes
Not as detailed as laser cutter
Raised reliefs, carved textures, chamfered edges, or complex 3D contours
Flat pack MDF furniture
WOODWORKING TOOLS FOR SHAPING
Sandpaper
Description
Uses
Also known as abrasive paper
Made from abrasive particles (sand, glass, synthetic particles) bonded to a backing material of paper or fabric
Start with rougher grit and move to fine
Low grit numbers are coarser (P60 grit is rougher than P240 grit)
Rub in direction of the wood grain so fine scratches align with grain and are less visible
Sanding timber surfaces
Orbital disc sander
Description
Uses
Handheld electric sander
Has velcro-backed sandpaper discs
Can leave circular scratches
Sanding timber surfaces
Belt sander
Description
Uses
Rotating belt of sandpaper
Can be hand-held or fixed
Easy to sand knuckles
Can sand off too much
Sanding timber surfaces
Rasp
Description
Uses
Handheld tool with raised teeth to rapidly remove material (like a cheese grater)
Many different shapes / profiles
Leaves rough surface
For initial shaping
File
Description
Uses
Like a rasp but with fine teeth
Removes material more slowly but creates a smoother finish
Can be better for precise control of edges and details (such as inside holes) than sandpaper
For smoother finishing
Chisel
Description
Uses
Sharp flat bladed tools
Can be used by hand or tapping on end with a hammer or mallet
Can be curved or hollowed for carving
Cutting out internal slots for joints or door locks
Paring wood to exact fit
Carving and shaping
Hand Plane
Description
Uses
Sharp blade held in an adjustable body
Shaves off thin curls of wood
Works best in same direction as the grain
Taking off sharp edges
Smoothing surfaces of wood
Reducing thickness of a piece of timber
Wood lathe
Description
Uses
Wood held tightly between two points and spins rapidly while a turning chisel held against it
Produces perfectly round, symmetrical items
Dangerous – needs right technique or chisels go flying
Turning table legs, bowls, vases, platters, or any other cylindrical wooden objects
A woodworking lathe in action:
DRILLING TOOLS
Drill bits
Description
Uses
Assorted types shapes, and sizes for various purposes
Twist drill bit – normal holes
Flat drill bit – large holes in soft timber
Counter-sink bit – making indentation for countersunk screw heads
Hand drill
Description
Uses
Portable tool for boring holes by hand
A drill bit is inserted in chuck and tightened (sometimes with a chuck key).
Can control speed of drill precisely
Pilot holes for screws or nails
Holes for dowels or hardware
Electric drill
Description
Uses
May be battery powered / cordless
Variable speed trigger
Forward / reverse switch
Often has a keyless chuck so drill bits can be swapped quickly
Drilling holes
Driving / removing screws
Drill press
Description
Uses
Stationary drill, often mounted to a bench (also known as a pillar drilling machine)
Precisely controls depth and position of holes – perfectly straight holes at consistent depth
Lever operated – lowers drill
Essential for precision work and batch / mass production
Note: a CNC router can also be used for drilling.
Timber forming methods
When bending timber you often need to create a former and jig to help hold and shape the item while it dries.
Jig: a custom-made tool or device to guide the motion of another tool or holds a workpiece in a specific position while making it. Jigs help to ensure consistency when repeating a processes multiple times. For example, a drill jig might be used for precise placement, or to help hold timber while bending around a mould.
Former: an object that provides a solid form that other materials are shaped around or over (like a mould, except that a mould has an internal cavity). For example, a former is used to vacuum form PVC sheets, or to bend and laminate timber around to create consistent curves or shapes.
TIMBER FORMING
Steam bending
Description
Uses
Wood placed inside a watertight steam box, which heats it and makes it soft and pliable (soaking timber in water for 24hrs first can help)
Heated wood is quickly bent around a former
Clamped in place on a jig until it dries
Compression straps help prevent splitting on outer curve
Boats
Instruments
Furniture
Cold bent lamination
Description
Uses
Thin strips are bent very easily and glued / laminated together
Clamped around a former / jig to dry
Some wood is pliable when green (freshly harvested) so cold bending can also be used for larger pieces
Boats
Instruments
Furniture
Kerfing
Description
Uses
Closely-spaced slots (kerfs) cut partway through the wood, allowing it to bend
Remaining “bridges” of wood act as hinges
Often kerfs are filled with glue or veneered afterwards
Weakens wood
Ornamental parts of curved stairways
Situations where the inside of curve will be hidden
Used when steam bending isn’t practical (wood too thick, inflexible timber, or extreme curves needed)
Segmented construction
Description
Uses
Individual pieces of wood are cut into precise geometric segments and then glued together
Fit together like puzzle pieces
Often arranged in rings or layers to create patterns
Can also be turned on a lathe
Chopping boards
Bowls / vases
Decorative elements
Wastage vs Additive processing techniques
Wastage processing techniques (as opposed to additive methods) involve starting with a larger piece of material and removing (cutting away) portions to create the final shape. The removed material becomes “waste” or “wastage.” Cutting, sanding, and drilling are all wastage methods.
Additive manufacturing methods build up the final product by adding material and joining pieces together (most products involve wastage and additive methods). Laminating and steam bending are additive methods.
Amiria has a Bachelor of Architectural Studies, Bachelor of Architecture (First Class Honours) and a Graduate Diploma of Teaching. She is a CIE Accredited Art & Design and Design & Technology Coursework Assessor. Amiria now teaches Art, Design & Technology at ACG Parnell College.
