“One of their VPs was looking for custom communications tool belts for every coach in the League,” Williams says. “Next thing you know, I’m on the sidelines of the Pro Bowl with a handful of prototypes I’d personally designed and sewn … did I mention I taught myself to sew? Ha!”

While Williams considers being approached by the NFL the “opportunity of a lifetime,” it wasn’t just lucky happenstance. A couple of years ago, he founded Calavera Tool Works, which makes a line of integrated gear bags for jobsite users and workshops, as well four styles of handmade leather work aprons. His products are sourced and assembled entirely in the U.S, and they’ve been gaining traction in the marketplace quickly. Williams also knows his way around the world of savvy marketing — he was VP of marketing for Festool USA for several years, prior to starting Calavera.

It also helped that Diamondback Toolbelts are a step ahead of most other tool belt systems, in Williams’s estimation. They were designed by carpenter and windsurfer Jim Skelton in the early 1990’s. Diamondback’s system of interchangeable pouches and holsters are based on nylon and webbing that’s lightweight and durable, modeled after windsurfing gear.

“Those pouches are the closest thing you’ll find to indestructible. Every day we find more nuances that demonstrate the level of care and thought that went into the design,” Williams adds.

That jobsite ruggedness has earned Diamondback a cult following of sorts over a quarter century, Williams has learned, and the two new owners intend to take that legacy a step further. “With my marketing and product background and Connor’s understanding of processes, we’re going to build something really special through better organization and improved marketing strategy.”

And when a potential client as big as the National Football League knocks at your door with a problem to solve, luck favors the prepared. Diamondback’s integrated tool belt system, in some derivation, seemed a plausible solution to the League.

Here was the conundrum: every coach wearing a Bose® headset requires both an intercom and a radio, worn at the waist. “The belts they were using before were difficult to get in and out of and worse, provided virtually no security or protection for those extremely high-dollar support devices,” Williams says.

Some quick thinking, followed by plenty of prototypes, conference calls and even late-night texts with League officials led to the Diamondback belt system that Williams presented to NFL brass.

“Our finished commbelt is built on the idea of personalization and customization, with device-specific holsters that can be secured around the body according to each coach’s needs and comfort,” Williams explains. “The holsters provide another measure of protection for the devices, too. On top of that, we incorporated these incredible Cobra quick-release buckles, making them super easy to put on and take off … We’re using only the highest grades of materials and components, with all our manufacturing done here in the USA.”

The NFL was impressed and awarded Diamondback a contract.

“Let’s just say we now know the waist size for every coach in the League,” Williams jokes. To date, Diamondback has supplied the NFL with just over 1,000 commbelt sets, and Williams reports that feedback about their effectiveness this football season has been “nothing short of positive.” He credits this success, in part, to how collaboratively his NFL contacts worked with Diamondback through the development process.

Success with those new communication belts has spring-boarded Diamondback into another new product opportunity with the NFL — this time on the instant-replay side of the game.

“We designed those blue Microsoft® replay cases on the sidelines, too,” Williams says. “Once we had proven ourselves as a strategic partner on the belts, they felt comfortable enough to enlist our help on a new replay system.”

Called a Mobile Replay Unit (MRU), Diamondback’s design secures and supports a Microsoft Surface tablet and related components. Each game operates with two MRUs, one at either end of the field. The innovation allows the replay screen to come to the officials rather than the officials going off the field to a centrally located screen. It speeds up the replay evaluation process considerably.

Every NFL stadium now has a “live” MRU set, plus two more MRUs as backup.

“There were a lot of nerves on the sidelines at the Hall of Fame game when we first went live,” Williams admits. “But there were also a lot of high-fives after the first replay review was under our belts!”

Diamondback is parlaying these opportunities with the NFL into college football as well. Williams says that the University of Virginia, Notre Dame, Clemson and Bowling Green are now sharing their challenges with storing and carrying tools and equipment.

“How to organize, carry and transport your tools and gear are pretty universal issues,” Williams says, “And the guys at the top of their industries are always looking for ways to improve.”

But, despite new product developments for football, Williams maintains that Diamondback’s core tool belt line will always remain firmly rooted in the construction industry — it’s the brand’s “bread and butter.”

In that regard, Diamondback is releasing a new tool belt rig this holiday season. It’s called “The Greenhorn,” with a streamlined design that’s geared toward trim work, installations or for new guys on the jobsite that don’t need to carry as many tools on their waists.

“Though it meets all our insanely high quality standards, the pared-back design allows us to hit a lower price point, which is good for those who want a second setup for quick punch list work or even some shop use,” Williams explains.

The company is also working on new specialized accessories, a steady stream of pouches and holsters to complement Diamondback’s existing belt systems and even some new gear bags that will launch in early 2018.

“These days, it seems we’re adding something new to the line every couple weeks,” Williams adds.

Juggling two wearables businesses, and feeding the sport and construction industries with new products, is more than a full-time job — especially when you may, on occasion, need to take your shift at the sewing machine, too. But Williams wouldn’t have it any other way.

“All my life, I have loved to work with my hands and make ideas a reality,” Williams says. “The opportunity to use that passion in support of men and women who do the hard work of making real and lasting things — whether carpenters, woodworkers, plumbers or whomever else — well, that’s a real honor. There’s great satisfaction and pride that comes from making the best products in the industry, right here in the USA, and without compromise.”

Learn more about Diamondback Toolbelts by clicking here.

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Weighing 726 lbs. (814 lbs. with optional bed extension), the Powermatic 3520C is 96 lbs. heavier than its predecessor, the 3520B. The new lathe’s headstock, tailstock and legs are constructed entirely of heavy-duty cast iron, resulting in a stable, vibration-free work surface. Adjustable riser blocks allow 6 in. of height adjustment to maximize operator comfort while turning.

The lathe is driven by a robust, 2 HP single-phase, 220-volt motor that can manage large, off-balance workpieces. Its electronic variable speed ranges from 15 to 1,200 RPM on low and 40 to 3,200 RPM on high. Maintaining speeds as low as 15 RPM is ideal for creating intricate, ornamental turnings.

A magnetic moveable control box allows convenient operation at a variety of different positions on the lathe. The digital spindle speed and indexing readout, On/Off and forward/reverse switches are conveniently located on the control box. A main power disconnect switch is mounted on the rear of the headstock.

The new lathe provides 36 in. of working distance between centers and a 20 in. swing over the bed. This allows for complex, multi-axis turnings and provides maximum capacity for spindle and bowl turning. A precision-ground bed ensures that the tailstock and tool-rest will slide smoothly. Its upgraded banjo incorporates a non-marring, pinch-style clamp for solid tool-rest placement.

Other features include a self-locating, ergonomic spindle lock for easy one-hand operation and an anti-rotation tailstock key. The lathe also features Acme threads for smooth operation and longevity; a set of dead-centers, which hold a spindle for visual examination; and a sliding hammer knockout rod with brass tip.

An optional 20-in. bed extension is available, increasing the 3520C lathe’s capacity to 56 in. between centers and allowing outboard turning of large, ambitious projects. The lathe incorporates a two-position mount for the optional bed extension.

The Powermatic 3520C Lathe (model 1353001; $4,499) is CSA Certified and is backed by Powermatic’s 5-year warranty, with service centers available throughout the United States. The Bed Extension (item 1353002) sells for $449.99.

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Rockler’s Vacuum Clamp Pod Kit includes two 7/8-in.-high, 3-1/2-in.-square pods that can be screwed to a worktop or secured to jigs or tables that use standard T-tracks, such as those found on many CNC machines, with the included T-bolts and low-profile knobs. When connected to a vacuum pump, like the Rockler Vacuum Pump Kit (item 57519; not included), they produce enough suction to hold a workpiece securely.

Unlike some other vacuum clamps on the market, Rockler’s Vacuum Clamp Pods incorporate a ball valve that allows individual pods to be used without the need to remove others from the series to maintain suction. They also can be connected to additional pods for applications where a wider clamping base is needed. (Depending on how many pods are combined, an additional vacuum pump might be necessary.)

The pods come with four 5/16-in. T-bolts and four fold-down knobs, making them ideal for use with the Rockler T-Track Table Top (item 46654; sold separately) and T-Track System accessories, as well as many CNC machine tables.

Also included in the kit are foam gaskets to ensure a tight seal for strong suction; 8 ft. of plastic tubing; and necessary brass fittings.

The Rockler Vacuum Clamp Pod Kit (item 53418) is priced at $59.99.

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Rod Burrow: Seems like you are maxing out the dado capacity of the saw, which has a short arbor shaft. Most saws today have a maximum dado capacity 13/16 in. If a new saw isn’t on your holiday list this year, then I suggest you use a single blade stabilizer. Blade stabilizers are usually thinner than original equipment arbor washers and should allow the arbor nut to fit securely. Use both if your inner washer is not milled in the arbor. Not having an outer arbor washer could allow the stack to slip and the carbides to collide. Or, here’s another simply solution to the problem: set your dado to 3/8 in. or 1/2 in. instead and make two plow cuts to reach the 3/4-in. width you’re after. This will reduce some of the heat on the carbide teeth as well as stress on your saw’s motor!

Rod Burrow is quality assurance/customer service manager at RIKON Tools.

Chris Marshall: If you take Rod’s advice and purchase a set of blade stabilizers, they’ll serve the added duty of stiffening thin-kerf saw blades. Thin-kerf blades are helpful for lighter-duty saws because the motor doesn’t have to work as hard to drive the blade teeth through what’s being cut. But, they can deflect during cutting — especially on those demanding cuts through thick material or in boards that have internal stresses. Stabilizers will stiffen the blade to make sure your cuts remain flat and square. So, two benefits from one saw accessory. The only downside though, is that stabilizers behave like oversized washers, reducing the cutting capacity of the blade to some extent.

Tim Inman: I’m with Rod on this one. Pulling a dado head involves a lot of resistance beyond the ordinary resistance you might expect from a simple single-saw kerf from a common blade. So having a very secure setup on your saw’s arbor is paramount. I wouldn’t allow for any “half nut” threads or lack of stiffening washers, etc. Set that dado head up exactly as it was intended. I’ll add this to Rod’s answer: When I was a kid (cheap help for my dad and his brother who built custom cabinets and staircases, etc. for a living) we did “double runs” on dadoes many times. We usually set the dado head up for a 1/2-in.-wide cut. Then we made two passes over the dado to get the 3/4-in.-wide dado or plow cut we needed by realigning the rip fence to get the correct dimension in the groove. Why did we set up the 1/2-in. dado? It was just easier to set up the 1/2-in. set on the dado head we had. The little bit of overlap didn’t hurt a thing, and we ended up in the same place in the end: a perfect fit for our boards and a nice clean groove cut to hold them.

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– Dave Croxton
Tucson, Arizona

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Yes, is the answer to that question for some of you. – Editor

“Quartersawn oak, either red or white. You have a good head on your shoulders.” – Ken Koehn

Or, yes with caveats. – Editor

“I like quartersawn oak but, when I have a chance to use it in a project ( such as a small box), I love to use bird’s-eye maple!” – Denny Grant

“I’m with you on quartersawn grain for red and white oak as well as a few special woods like sycamore.  Some other woods, such as hard maple, would bore me to death if it were quartersawn. For other species, though, I love curly grain when it’s available.” – Allen Wagner

“Like you, I am a huge fan of the look of quartersawn oak.  On the other hand, I have had some limited experience with other figures that were equally satisfying.  I was fortunate to find some maple with a tiger stripe figure that went into a case rebuild for a radio. Another time, by sanding down to 600-grit, I was able to uncover a wavy pattern in some ash in a flag case I made for my son.  Now I find myself looking for the hidden figure in all sorts of wood and stone, when I work in that medium for table tops.” – Lee Ohmart

Some were more open-minded. – Editor

“When I do a project, I get a picture in my mind of what it is I want to do. Maybe draw a rough sketch if it’s something bigger so I have an idea of how much wood I’ll need for it. Then my next stop is to paw through my own wood rack and see if I have anything that I think will do the project justice. If not, here in Chicago we are blessed with a place called Owl Hardwoods. They have aisles of many woods in various lengths, widths and thicknesses, mostly semi-rough-cut. Also many available in plain- and quartersawn. Each piece is also individually priced. I find an aisle with a wood that I think will look good (and that I can afford!) for my project and then start selecting pieces and picturing where each  will go on my project. I often buy a few extra as possible alternates for key areas. What doesn’t get used in the current project makes it in some future one. The cool and the bad thing is most of what’s in my rack are interesting pieces. When I need to do a quick and dirty project I’m looking through my supply thinking, ‘I don’t want to use a nice piece of wood like that for THIS project!’” – Bill Koski

Or had a broader philosophy behind their preferences. – Editor

“I was lucky enough to be in the right place at the right time to accumulate wood from hurricane Hugo and a local sawmill. I have created a lot of great projects from the wood (all the Hugo wood is consumed now) and still have defined and undefined projects to create. My wonderful, talented wife is a good source of ideas, and it becomes my challenge to make them realized. One of the time-consuming aspects is finding what I need in what I have. Being from a sawmill, it is always a challenge to find straight and long enough. I have used my finger joint router bit frequently with a lot of grain judgment and, in one case, gluing together to make the final thickness I needed and, in others, being creative in the enhancement of knotholes, etc. All of this is to say, in my case, it has been a case of making the very best of what I have and therefore a bit more pride in the final product.” – Jeff Stikeleather

“I read your column on wood and grain preferences. I am a classically trained (read: apprenticeship in Germany and marquetry program in Italy many, many years ago) designer/maker with 40 years plus years working with clients and participating in shows. The ‘right grain pattern/cut’ is the one that makes the piece so magnificent that your client cannot stop touching and staring at it! Each species has its own variety of grain appearances and all must be selected based upon the appearance one is wanting to create. Thus, quartersawn oak is a fantastic choice if you wish to work in oak and have it appear very polished or noble. Flatsawn oak can make beautiful door panels if one pays attention to the arching grain pattern.  Mahogany or walnut crotch sawn as veneer can give a piece a spectacular look, and burls bring patterns that, when combined with other grain patterns, can result in showstopping pieces. So, if one stretches their imagination to include the many species and lumber cuts, there is no end to what can be created! Throw in sawn veneers, and the options are limitless!” – Clint Struthers

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