Woodcraft Magazine - Issue #073 - Oct, Nov 2016 - Build This Southern Huntboard

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Projects, Techniques, and Products

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Southern Huntboard
MORE
PROJECTS:
■ Serving Tray
■ Toy Trucks
from 2×4s
■ Bookshelf
Speakers
h/>/E'
^</>>^
■ Resawing
■ T&G Joinery
GREAT SHOP
PROJECTS
■ Biscuit Joiner
tŽƌŬƐƚĂƟŽŶ
■ Mini-Workbench
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©2016. Red router bits are a registered trademark of Freud America, Inc. (US) 1-800-334-4107
ŽŶƚĞŶƚƐ͗WƌŽũĞĐƚƐ
KĐƚͬEŽǀϮϬϭϲ
30 Serving Tray
ŌĞƌƚŚŝƐƚƌĂǇŚĂƐĚŽŶĞŝƚƐũŽď͕ǇŽƵ͛ůůǁĂŶƚƚŽŬĞĞƉ
ŝƚŽŶĚŝƐƉůĂǇŝŶƐƚĞĂĚŽĨƉƵƫŶŐŝƚĂǁĂǇ͘ZĞƐĞƌǀĞ
ǇŽƵƌŵŽƐƚďĞĂƵƟĨƵůďŽĂƌĚƐĨŽƌƚŚĞďŽƩŽŵ͘DĂŬŝŶŐ
ƚŚĞƉĂƌƚƐŝƐĂŶŽƉƉŽƌƚƵŶŝƚǇƚŽŚŽŶĞǇŽƵƌƐŬŝůůƐĂƚ
ƉĂƩĞƌŶͲƌŽƵƟŶŐ͕ƌĞƐĂǁŝŶŐ͕ĂŶĚƐƉŝŶĚůĞƚƵƌŶŝŶŐ͘
24 Make a Mini-Workbench
dŚŝƐůŝƩůĞďĞŶĐŚĐĂŶŵĂŬĞĂďŝŐĚŝīĞƌĞŶĐĞŝŶ
ǇŽƵƌƐŚŽƉ͘tŚĞŶƉůĂĐĞĚŽŶƚŽƉŽĨĂĨƵůůͲƐŝǌĞĚ
ǁŽƌŬďĞŶĐŚ͕ƚŚĞŵŝŶŝͲďĞŶĐŚƉƌŽǀŝĚĞƐĂďĂĐŬͲ
ƐĂǀŝŶŐǁŽƌŬƐƵƌĨĂĐĞƚŚĂƚĐĂŶŝŵƉƌŽǀĞďŽƚŚ
ǀŝƐŝďŝůŝƚǇĂŶĚĐŽŶƚƌŽůĨŽƌĂǀĂƌŝĞƚǇŽĨůĂǇŽƵƚ
ĂŶĚũŽŝŶĞƌǇƚĂƐŬƐ͘
45 Toy Trucks from 2×4s

ĂŶǇŽƵƌǁŽƌŬƐŚŽƉďĞĐŽŵĞĂŶ 36 Southern-Style
Huntboard
ĂƵƚŽŵŽƟǀĞĂƐƐĞŵďůǇůŝŶĞ͍zŽƵďĞƚ͘:ƵƐƚ dŚŝƐƚĂďůĞ͛ƐĚĞƐŝŐŶǁĂƐďŽƌƌŽǁĞĚ
ĨŽůůŽǁƚŚŝƐĞǆƉĞƌƚĂĚǀŝĐĞŽŶǁŽƌŬƐƚĂƟŽŶƐ ĨƌŽŵĂŶĂŶƟƋƵĞ͕ďƵƚƚŚĞĐŽŶƐƚƌƵĐƟŽŶ
ƚŽŵĂƐƐͲƉƌŽĚƵĐĞƉĂƌƚƐ͕ĂŶĚũŝŐƐĨŽƌ ĚĞƚĂŝůƐŚĂǀĞďĞĞŶŵŽĚĞƌŶŝǌĞĚƚŽƐƵŝƚ
ƐƉĞĞĚǇĂƐƐĞŵďůǇ͘zŽƵƌƚƌƵĐŬŇĞĞƚǁŝůů ďĞŐŝŶŶŝŶŐͲůĞǀĞůǁŽŽĚǁŽƌŬĞƌƐ͘>ĞĂƌŶ
ďĞĂŚŝƚǁŝƚŚŬŝĚƐ͕ĂƚĐƌĂŌƐŚŽǁƐ͕ŽƌĨŽƌ ŚŽǁǇŽƵĐĂŶďƵŝůĚǇŽƵƌŽǁŶŚĞŝƌůŽŽŵ
ĐŚĂƌŝƚǇŝŶŝƟĂƟǀĞƐ͘ ŽǀĞƌƐĞǀĞƌĂůǁĞĞŬĞŶĚƐ͘
2 woodcraftmagazine.com Oct/Nov 2016 ŽǀĞƌƉŚŽƚŽ͗ZĂůƉŚ>ĞĞŶĚĞƌƐŽŶ

Contents: Projects
50 ŝƐĐƵŝƚ:ŽŝŶĞƌtŽƌŬƐƚĂƟŽŶ
What a smart way to park a portable power
ƚŽŽů͊'ĞƚŵŽƌĞǀĞƌƐĂƟůŝƚǇĨƌŽŵǇŽƵƌďŝƐĐƵŝƚ
ũŽŝŶĞƌďǇŵŽƵŶƟŶŐŝƚŝŶƚŚŝƐǁĞůůͲĚĞƐŝŐŶĞĚ
ǁŽƌŬƐƚĂƟŽŶ͘dŚĞƉƌŽũĞĐƚŝŶĐůƵĚĞƐƐŚŽƉͲŵĂĚĞ
accessories that aid in clamping and aligning
ǁŽƌŬƉŝĞĐĞƐŽĨĚŝīĞƌĞŶƚƐŝǌĞƐĂŶĚƐŚĂƉĞƐ͘
Departments
06 On
Contributors Page/
the Web
53 Awesome Audio
Build a set of bookshelf
08 Christmas
Staying Sharp
in July
ƐƉĞĂŬĞƌƐƚŽƐŚŽǁŽīƚŚĞďĞĂƵƚǇ
of wood and the performance
of premium audio components.
10• News & Views
The cut list challenge
The electronics come in an • California dreamin‘
ĂīŽƌĚĂďůĞŬŝƚ͘zŽƵĐƌĞĂƚĞƚŚĞ and woodworkin‘
ĐƵƐƚŽŵƐƉĞĂŬĞƌƐƵƐŝŶŐƌŽƵƟŶŐ͕ • Workshop keeps working
ǀĞŶĞĞƌŝŶŐ͕ĂŶĚďĂƐŝĐƐŽůĚĞƌŝŶŐ
techniques. It’s a project you can
enjoy every day.
16

Hot New Tools
Zyy͕ƚŚĞŶĞǁƐƵƉĞƌͲƐĂĨĞ
tablesaw from Bosch
18• ATips & Tricks

simple spreader
• ^ƋƵĂƌŝŶŐƐƟĐŬƐƵƉŐƌĂĚĞ
Contents: Tools & Techniques • ^ŶŝƉĞͲĨƌĞĞƉůĂŶŝŶŐ
• ĂŶƟůĞǀĞƌĞĚĐůĂŵƉŝŶŐ
• Drilling sheet metal
ƐĂŶĚǁŝĐŚͲƐƚǇůĞ
27 Resawing on
the Tablesaw
You don’t have to depend on a
60 Joinery Class:
Tongue & Groove
bandsaw to do resawing right.
Take advantage of this expert
advice to get great resawing
64 Buyer’s Guide
results on your tablesaw. Secrets 66 Ad Index
to success cover everything from
ĨĞŶĐĞƐĂŶĚďůĂĚĞƐƚŽƉƵƐŚƐƟĐŬƐ͕
ƚŚƌŽĂƚƉůĂƚĞƐ͕ĂŶĚĨĞĂƚŚĞƌďŽĂƌĚƐ͘
68 WoodSense
White and Red Elm
4 woodcraftmagazine.com Oct/Nov 2016

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Contributors On the Web
Starting out as a seventeen year
old apprentice for a furnituremaker
in Birmingham Alabama David
Traylor has been building custom
furniture like the Southern style
(untboard p for clients across the
Southeast for over years )n
he opened his shop to students and
has been teaching ever since David
is a founding member of the Alabama
Woodworkers Guild and continues
to teach classes and judge the annual Best blades for your tablesaw.
woodworking show David has recently Check out this comprehensive guide
partnered with City (ardwoods a hardwood retail store in to tablesaw blades. It’s got all the
Birmingham to offer classes in a safe and fun environment ŝŶĨŽƌŵĂƟŽŶǇŽƵŶĞĞĚƚŽƐƉĞŶĚǇŽƵƌ
For more information check out cityhardwoods.com ŵŽŶĞǇǁŝƐĞůǇĂŶĚŵĂŬĞƐƵƌĞǇŽƵƌƐĂǁ
ŝƐƐĞƚĨŽƌĂŶǇĐƵƫŶŐĂƐƐŝŐŶŵĞŶƚ͘
Bill Schneider still remembers the giant

speakers that were popular in his college
days But he didn t give audio equipment
much thought until when he
happened to listen to a modern system
at a friend s house The major difference
was obvious much smaller speakers
that can produce excellent sound quality
)nstead of buying an expensive set of
speakers Bill went online to research
D)Y speaker projects with special
emphasis on well matched components
(e s built at least different sets of
speakers in addition to the ones shown
on p Currently teaching photography
at Ohio University in Athens Ohio Bill
considers the problem solving nature of
woodworking to be its biggest appeal
Closely observed and occasionally

counseled by two Maine Coon cats Urban logging! 'ŽƚŽŽƵƌ^ƚĂī
Melanie Powell takes photos writes and blog to learn about (and link to) a
produces technical drawings for various ƐŵĂůůĐŽŵƉĂŶǇƚŚĂƚŽƉĞƌĂƚĞƐĂďŝŐ
publications her workstation illustrations ůŽŐŐŝŶŐĂŶĚƐĂǁŵŝůůŝŶŐŽƉĞƌĂƟŽŶŝŶ
appear on p Beneath Mel s quiet ƚŚĞƵŶůŝŬĞůŝĞƐƚŽĨƉůĂĐĞƐ͗ƌŽŽŬůǇŶ͕
demeanor you ll discover a spirit of Ez͘dŚĞƐĞŐƵǇƐŚĂǀĞĂŶŝŵƉƌĞƐƐŝǀĞ
ϐ ƐĞůĞĐƟŽŶŽĨůŝǀĞͲĞĚŐĞƐůĂďƐŵŝůůĞĚ
physical challenges as evidenced by the from historic trees of New York
well crafted home and studio she built ŝƚǇ͛ƐƐƚƌĞĞƚƐĂŶĚƉĂƌŬƐ͘dŚĞǇĚĞƐŝŐŶ
in the woods of eastern Pennsylvania and build nice slab furniture too.

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Staying Sharp
Christmas in July
Working at process Jim did an excellent Whatever you make it feels
Woodcraft job of preparing for the shoot pretty good to pick a few choice
Magazine can and we made great progress boards from your scrap bin and
seriously disrupt your sense of throughout the morning But create something special that
seasonal priorities As you read by lunchtime the temperature will be valued for many years
these words of welcome to our in his workshop was in the Our goal is to help you make that
Oct Nov issue the chill of winter s We headed to a local diner happen over and over again
is nearly upon us We re enjoying ϐ
the autumn colors and turning sawdust Merry Christmas
our attention to football games Anyway the payoff for
and plans for Thanksgiving working so far ahead is right
and the (olidays But the in your hands As the holiday
production cycle for the last season approaches many folks
two issues of comes in the visit websites and shopping
middle of summer The contents malls to buy gifts for friends
of this cold weather issue and family members But if
were produced while we were you re a woodworker there are
wearing shorts and t shirts and always opportunities to make
complaining about workshops things that can t be found in
without air conditioning Ǥǯϐ
The humor of this seasonal Oct Nov and Dec Jan issues
disconnect came to light a few with projects that make great
weeks ago when ) visited the gifts For example check out
workshop of Probst Furniture the Awesome Audio speakers
Makers probstfurniture.com on p of this issue Jeff
in (amlin WV Jim Probst Noden s Serving Tray p Thinking ahead. :ŝŵWƌŽďƐƚ;ĂƚůĞŌ͕
designed a beautiful Go is also a super gift one that above) came up with an ingenious
gameboard that you ll see in makes the most of a small router jig to create the incised grid of
the Dec Jan issue Our job on ϐǤ ŚŝƐ'ŽŐĂŵĞďŽĂƌĚ͘tĞ͛ƌĞƐƟůůĮŐƵƌŝŶŐ
this mid July photoshoot was to consider getting together with out how to explain his technique in
capture all the important steps some friends to produce a ƚŚĞĂƌƟĐůĞĨŽƌŽƵƌĞĐͬ:ĂŶŝƐƐƵĞ͘
in the project s construction convoy of Toy Trucks p
Contact us: Canada Post: Publications Mail Agreement #40612608

4420 Emerson Avenue, Suite A Canada Returns to be sent to Pitney Bowes,
P.O. Box 7020, Parkersburg, WV 26102-7020 P.O. Box 25542, London, ON N6C 6B2
(800) 542-9125
[email protected] ©2016 by Woodcraft Supply, LLC. All rights reserved.
Oct/Nov 2016 Vol. 12, Issue 73 ^ƵďƐĐƌŝƉƟŽŶƐ͗(U.S. and Canada)
Woodcraft Supply, LLC allows the purchaser of
this magazine to photocopy the included projects
One year: $19.99 and techniques solely for personal use. Any other
Chief Editor: Tim Snyder Single copy: $6.99 reproduction of these projects and techniques is
Senior Editors: Paul Anthony, Joe Hurst-Wajszczuk ĐƵƐƚŽŵĞƌͺƐĞƌǀŝĐĞΛǁŽŽĚĐƌĂŌŵĂŐĂǌŝŶĞ͘ĐŽŵ strictly prohibited.
Art Director: Chad McClung (800) 542-9125
Graphic Designer: Bobby Schehl Safety First! Working wood can be dangerous.
Woodcraft Magazine (ISSN: 1553.2461, USPS ůǁĂǇƐŵĂŬĞƐŚŽƉƐĂĨĞƚǇǇŽƵƌĮƌƐƚƉƌŝŽƌŝƚǇďǇ
Copy Editor: Sharon Hambrick ϬϮϰͲϵϱϯͿŝƐƉƵďůŝƐŚĞĚďŝŵŽŶƚŚůǇ;ĞĐͬ:ĂŶ͕&ĞďͬDĂƌ͕ ƌĞĂĚŝŶŐĂŶĚĨŽůůŽǁŝŶŐƚŚĞƌĞĐŽŵŵĞŶĚĂƟŽŶƐŽĨǇŽƵƌ
Publisher: Gary Lombard ƉƌŝůͬDĂǇ͕:ƵŶĞͬ:ƵůǇ͕ƵŐͬ^ĞƉƚ͕KĐƚͬEŽǀͿĂŶĚƉƌŝŶƚĞĚ machine owner’s manuals, using appropriate guards
Advertising Sales Manager: Vic Lombard in the United States. Postage paid at Parkersburg, WV, and safety devices, and maintaining all your tools
Circulation Support: Kim McLaughlin, and at additional mailing offices. ƉƌŽƉĞƌůǇ͘hƐĞĂĚĞƋƵĂƚĞƐŝŐŚƚĂŶĚŚĞĂƌŝŶŐƉƌŽƚĞĐƟŽŶ͘
WůĞĂƐĞŶŽƚĞƚŚĂƚĨŽƌƉƵƌƉŽƐĞƐŽĨŝůůƵƐƚƌĂƟǀĞĐůĂƌŝƚǇ͕
Stacey Bartenschlag POSTMASTER: Send address changes to guards and other safety devices may be removed
Office Manager: Connie Harmon Woodcraft Magazine, P.O. Box 7020, ĨƌŽŵƚŽŽůƐƐŚŽǁŶŝŶƉŚŽƚŽŐƌĂƉŚƐĂŶĚŝůůƵƐƚƌĂƟŽŶƐŝŶ
Circulation: Circulation Specialists, Inc. Parkersburg, WV 26102-7020. ƚŚŝƐƉƵďůŝĐĂƟŽŶ͘

RETAIL FRANCHISE OPPORTUNITIES
Woodcraft Franchise Opportunity – Why Woodcraft?
• Franchising Since: 1997 • A proven concept – Operated 28 corporately owned stores prior to
entering franchising
• Over 70 Stores Nationwide
• Woodcraft has the largest network of woodworking stores nationwide
• Est. Total Initial Investment: $500,000+ Turnkey • Strength in the brand and name – Associated with quality
• Minimum Market Population Required: • Access to existing customer base
350,000 (20-Mile Radius) • Distribution – Access to over 10,000 products
• Woodcraft store is a “destination” shopping experience – Average travel
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Woodcraft Provides A Complete System To Franchisees Which Covers The Following Areas:
- Assistance with the site selection and development - Marketing support in multiple areas with special focus on the
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- Assistance in securing required equipment, fixtures, supplies and
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our Product Development Team
- Detailed information pertaining to the hiring of a quality staff
- Support for local marketing programs and events
- A POS system and operations guidebook to cover all day-to-day
activity in the store - Clear expectations on sales practices, customer service and
product knowledge
- Training at the corporate office with additional on-site setup
and merchandising - Ongoing support through our Regional Field Consultants, as well
as the entire retail support staff, whose members have many years
- Access to an extensive list of classes, seminars and demos for of experience in retail operations, sales and marketing
store’s educational program
“After 30 years in the travel

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AVAILABLE MARKET OPPORTUNITIES
on and find something else Albuquerque, NM Los Angeles, CA
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Allentown/Harrisburg, PA New Orleans, LA
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Baltimore, MD Oakland, CA
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into a second career.” New Jersey (Multiple Locations) Long Island, NY
Mike Sauder Call for additional store market opportunities.
Multiple Woodcraft
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P.O. Box 245, Parkersburg, WV 26102
F16WD11P
News & Views
The cut list challenge
) m interested in building Ken Burton s My up 1Ψ8" short. There
First Chair the Aug Sept cover wasn’t any particular
project Would Ken mind sharing his cut list error on his part; simply
a combination of little
—Robert Mountrger via the )nternet things that added
up to a big mistake.
Ken Burton replies: Stuff like this is part
Having taught woodworking for nearly 30 years, of woodworking. Had he not been so attached to
I always start my classes by having my students his list, he would have saved himself a little grief.
develop their own materials list—even if there With a chair, a materials list is more of a rough
happens to be an existing list. I believe this exercise guideline than a rule book. For example, because
helps them understand how things go together. the legs are tapered, the stretchers and the crest
I also caution them to be mindful when referencing Ǧϔ
these dimensions and to make adjustments to suit legs to the aprons and can get a measurement.
what they have in hand. Case in point: I recently Also note that you can probably use the offcuts
taught a class using the chair featured in the from the rear legs to make the stretchers.
magazine. One student was adamant about sticking This is probably more than you wanted to know
to the numbers on his list and cut all the pieces to size about materials lists, but it might help you avoid
up front. As it turned out, the side stretchers wound some mistakes. I hope your chair turns out well.

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Oct/Nov 2016 woodcraftmagazine.com 11

News & Views
THE
California dreamin’
and woodworkin’… take 2. INVERTED
ROUTER
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We suffered a bit of a false start when we
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few months back Woodcraft and SawStop s The
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ϐ
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Wood, steel, concrete…what’s next? Enter the California

Dreaming contest, and you might get a chance to work
ĂůŽŶŐƐŝĚĞƚŚŝƐŵŽĚĞƌŶŵƵůƟͲŵĞĚŝĂǁŽŽĚǁŽƌŬĞƌ͘
How to reach us.

Email ĞĚŝƚŽƌΛǁŽŽĚĐƌĂŌŵĂŐĂǌŝŶĞ͘ĐŽŵ,
ŽƌǁƌŝƚĞƚŽtŽŽĚĐƌĂŌDĂŐĂǌŝŶĞ͕
4420 Emerson Ave., Suite A, Box 7020,
Parkersburg, WV, 26102-7020.
Please include your full name, address,

ĂŶĚƉŚŽŶĞŶƵŵďĞƌ͘WƵďůŝƐŚĞĚůĞƩĞƌƐ (704) 508-7000
are edited for length and clarity. www.cronsrud.com

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News & Views
SUPERMAX KNOWS
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K͛EĞŝůů͕:ĞīƌǇ>ŽŚƌ͕>ĂƌŝƐƐĂ,Ƶī͕ĂŶĚZŽďĞƌƚ^ƉŝĞĐĞ͘
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Hot New Tools
REAXX, the new super-safe tablesaw from Bosch
Bosch GTS1041A REAXX™ Jobsite Table Saw
The tablesaw is usually the most important tool in a
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prompting an average of emergency room
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With statistics like these it s easy to recognize the
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Now it s Bosch s turn Their REAXX saw combines
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tablesaw with proven technology from the company s
automotive airbag division What makes the REAXX
unique is that it can save your saw blade or stack dado
ϐǤǡ
REAXX runs a slight electric current through the saw
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the SawStop method the REAXX simply forces the
ϐ
compressed air cartridge Each cartridge is good for
ϐǤ
Workshop worthy. The REAXX has the power ϐǡϐͳͺͲιǡ
and capacity to do the work of a cabinet saw. the wiring and reposition the arbor assembly to make
The included stand is sturdy, stable and mobile. ǤͅͻͻǤ
The REAXX has a simple intuitively designed control
ǯǤǦ
coded icons tell you that the saw is in one of modes
Green ready to use Yellow bypass mode detection
deactivated for cutting wet wood or other conductive
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replacing or other condition Blue service required
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ȋʹͻ Τ ×ʹʹ Τͺ table surface augmented
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Quick recovery. When the arbor assembly is driven below rip fence locks solidly at front and back and the miter
ƚŚĞƚĂďůĞ͕ŝƚĚŽĞƐŶ͛ƚƚĂŬĞůŽŶŐƚŽƌĞƉŽƐŝƟŽŶƚŚĞĂƌďŽƌ͕ gauge is worth holding onto Provisions for tool storage
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miter gauge are well thought without its Gravity Rise stand
out there s even a compartment Fortunately the wheeled stand
to store an extra cartridge and comes with the saw )t folds
the owner s manual But my and unfolds quickly with a
favorite built in feature is the few practice runs and the big
integral sheath for the pushstick wheels make it easy to move
it s perfectly located on the around a garage or jobsite
right corner of the saw s base ͅʹͲͲ
Bosch designed convenient more than the SawStop jobsite
tool less mounting for the blade saw But it s worth considering
guard and anti kickback pawls that when the REAXX safety
Riving knife adjustments are also mechanism activates the saw
tool less Blade height and angle blade isn t destroyed The super
adjustments function well and ) safe technology is impressive
like the fact that blade parallelism but so are the saw s other
and bevel stop adjustments can features )t s expensive but still
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Dust collection was effective when what you might be saving
) hooked up my shop vacuum Space saving. The stand folds to
Weighing in at lbs the boschtools.com ͅͳǡͶͻͻǤͲͲ ƐƚŽƌĞƚŚĞƐĂǁǀĞƌƟĐĂůůǇ͕ǁŚŝůĞƐƟůů
REAXX wouldn t be portable Tester: Tim Snyder allowing you to roll it around.
Photos: Randy O’Rourke Oct/Nov 2016 woodcraftmagazine.com 17

Tips & Tricks
TOP TIP
A simple spreader
Like many furnituremakers ) do my fair
ƌŽƐƐďĂƌ Glue and screw long WŝǀŽƟŶŐďĂƌ Bolt
share of repair work often involving ďĂƌƚŽĐƌŽƐƐďĂƌ͘
disassembly of chairs and other pieces )
have a reversible jaw pipe clamp that can
be used as a spreader clamp but the jaws
aren t very long Plus ) often need more
than one spreader in play so ) devised this
wooden spreader jig based on something
similar ) saw once The jig is simply a long
ϐ
end and a pivoting bar at the other with a
ϐ
bars as shown Tightening the clamp
creates a strong controlled spreading
action on the opposite side of the spreader
Leather facing tŝƌĞĐůĂŵƉƚŽĐƌŽƐƐďĂƌ
ǡ protects project ĂŶĚƉŝǀŽƟŶŐďĂƌ͘
holes in the long bar when necessary ďĞŝŶŐĚŝƐĂƐƐĞŵďůĞĚ͘
—Martin Grasse, Denver, Colorado
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ƵƚŽīƚŽŶŐƵĞ Tongue-and-groove joint dŚƵŵďƐĐƌĞǁ DĂŬĞϭ5Ш8 × 2" locking collar
ĂƚƉŽŝŶƚ͘ ŬĞĞƉƐƐƟĐŬƐƉĂƌĂůůĞů͘ Ш4 -20 × 5Ш8"
1
from 1Ш2ΗͲƚŚŝĐŬŚĂƌĚǁŽŽĚ͘
KƉƟŽŶĂů Ш2"
1
increments
Ш2"
1
DĂŬĞƐƟĐŬƐĨƌŽŵ5Ш8" 15°
ƐƋƵĂƌĞŚĂƌĚǁŽŽĚ͘
^ƋƵĂƌŝŶŐƐƟĐŬƐƵƉŐƌĂĚĞ
) liked Paul Anthony s squaring sticks in issue tapping the face grain edge with a drill and
s Tips Tricks column They work great for Τ tap to accept a thumbscrew ) also decided
comparing diagonal distances to ensure that to downsize the sticks from Τ to Τ square to
cabinets and other cases are truly square (owever make them somewhat easier to handle Finally
) found that using a spring clamp to hold the ) marked increments on one of the sticks which
sticks together in use was a bit clumsy )nstead ) provides easy reference for adjusting them in use
made a hardwood collar to do the job drilling and —Bruce Robertson, Raleigh, North Carolina
/ůůƵƐƚƌĂƟŽŶƐ͗ŚƌŝƐƚŽƉŚĞƌDŝůůƐ Oct/Nov 2016 woodcraftmagazine.com 19

Tips & Tricks
Snipe-free planing
Planer snipe is hard to avoid Sure you can
cut away the sniped ends but that s not
a good approach with expensive woods
ƩĂĐŚƐƚƌŝƉƐǁŝƚŚ
Or you can precede and follow the board double-faced tape.
with scrap of the same thickness but that
can make for clumsy feeding (ere s a
better approach Joint one face and both
edges of the board and make up four
lengths of straight scrap about
long and just a bit taller than
ϐ
ǤǦϐ
surface attach the strips to the edges
of the board at both ends using double
faced tape extending the scraps about DĂŬĞƐƚƌŝƉƐƐůŝŐŚƚůǇ
Clamp them for a few moments to ƚĂůůĞƌƚŚĂŶĚĞƐŝƌĞĚ
ĮŶŝƐŚĞĚƚŚŝĐŬŶĞƐƐ͘
ensure a good bond Now when you feed
the board through the planer the scrap
will take the snipe instead of your stock
—Paul Anthony, senior editor
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ĂŶƟůĞǀĞƌĞĚ ^ƚŽƵƚƐƟĐŬ
serves as beam.
Place clamping pad over
area receiving patch.
ĐůĂŵƉŝŶŐ
The next time you need to
clamp an area that s out
of the reach of your clamp
jaws such as gluing a patch
in a tabletop try this Place
a dowel or triangular strip
of wood near the edge of
the workpiece to serve
as a fulcrum and place a
Dowel serves as fulcrum
protective clamping pad for transferring pressure
over the area to be clamped to end of beam.
Straddle the two with a
stout beam and then put
clamp pressure on the
stick on the inward side of
the fulcrum as shown
—Natalie Simmons,
San Diego, California

Tips & Tricks
Drilling sheet metal

sandwich-style
When making dado head shims ) ve found that
drilling a Τ hole with a twist drill in a piece of
thin sheet metal can be tricky as the stock wants
to spin and distort The solution is to sandwich
the metal between two pieces of hardwood
plywood scrap and then clamp the sandwich to
the drill press table The package secures the
metal and provides back up for a clean cut
—Dan Martin, Galena, Ohio
Share a Slick Tip. Win Cash or a Prize!

Tips & Tricks, tŽŽĚĐƌĂŌDĂŐĂǌŝŶĞ,
P.O. Box 7020, Parkersburg, WV 26102-7020
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ǇŽƵŝĨǇŽƵƌƚƌŝĐŬŝƐĐŽŶƐŝĚĞƌĞĚĨŽƌƉƵďůŝĐĂƟŽŶ͘

Make a Mini Workbench
ůŝƩůĞďĞŶĐŚĐĂŶďĞĂďŝŐŚĞůƉĨŽƌŵĂŶǇǁŽŽĚǁŽƌŬŝŶŐƚĂƐŬƐ
By Chris Hedges
A traditional workbench provides a solid

platform that s convenient for many tasks that
My mini bench
has saved my
require leverage like hand planing for example back while
But a waist high work surface isn t ideal for other enhancing
ϐǡ control and accuracy for all kinds of layout and
the work ) built this benchtop workbench to handle joinery work When clamped to the big bench
woodworking operations that aren t as comfortable the mini bench becomes a sturdy platform
ϐǤ ǯϐǤ
ƵŝůĚĂƐƚƌŽŶŐďĂƐĞƚŽƐƵƉƉŽƌƚĂƐŽůŝĚŵĂƉůĞƚŽƉ
The base and top of my mini bench are made from Ǥϐ
hard maple but other clear dense hardwoods are saw using a stack dado to remove the waste and
also suitable When building your own version my miter gauge to guide each workpiece ) bored
adjust the dimensions to put the benchtop several Τ dia holes in the top for use with bench
around elbow height photo facing page Since hold downs Attach the top by driving screws
sturdiness is a virtue in any workbench ) built through the oversized holes in the top rails
mine with mortise and tenon joinery All the
mortises were cut with a router and shop made
dKW
11Ш2 × 18 × 28"
dKWZ/> ŽŐ,ŽůĞ 3" washer-head screw

7
Ш8 × 2 × 81Ш2" ;ϯƉĞƌƌĂŝůͿ
dĞŶŽŶ
3
Ш8 × 11Ш2 × 1"
WK^d dĞŶŽŶ
11Ш2 × 2 × 111Ш2" 3
Ш8 × 2 × 3Ш4"
1"
1"
^ dĞŶŽŶ ^dZd,Z Construction notes:

21Ш2 × 11Ш2 × 161Ш2" 3
Ш4 × 11Ш2 × 1" Ш8 × 3 × 181Ш2"
7
• ^ƚƌĞƚĐŚĞƌ͕ƉŽƐƚΘƌĂŝů
ůĞŶŐƚŚƐŝŶĐůƵĚĞƚĞŶŽŶƐ͘
• DŽƌƚŝƐĞƐĂƌĞĐĞŶƚĞƌĞĚ
ŽŶƉŽƐƚƐΘďĂƐĞƐ͘
11Ш4"
28" 18"
141Ш2"
2" 1"
161Ш2"
WŚŽƚŽƐ͗>ĂƌƌǇ,ĂŵĞůͲ>ĂŵďĞƌƚ͖/ůůƵƐƚƌĂƟŽŶƐ͗ĂŶdŚŽƌŶƚŽŶ Oct/Nov 2016 ǁŽŽĚĐƌĂĨƚŵĂŐĂǌŝŶĞ͘ĐŽŵ 25

ZĞƐĂǁŝŶŐĂƚƚŚĞdĂďůĞƐĂǁ
/ƚ͛ƐŽŌĞŶƚŚĞƉĞƌĨĞĐƚƚŽŽůĨŽƌƚŚĞũŽď
By Paul Anthony
T he technique of
resawing refers to slicing
wood across its widest
dimension )t s basically
a form of slabbing done
to make thin stock from
thick stock )t s also used
to create book-matched
ϐǡ
pieces are edge joined to
create a mirrored pattern
ǡ
ǡǡ
such as the one on page
Resawing is usually
ǡ
which is good at slicing
ǡ
Ǥǡ
on a bandsaw makes a
ǡ
waste and increasing
Ǥǡ
on a bandsaw can be
ǡ
ǡ
ǡ
fence setup On the
ǡ
on the tablesaw is fairly
straightforward Although
making deep cuts like this
with the stock on edge can
ǡ
it s not dangerous with
the proper saw setup
ǡ /ĨǇŽƵƌƐĂǁŝƐŶ͛ƚĂůƌĞĂĚǇŽƵƞŝƩĞĚ
ǡ DŝƌƌŽƌĮŐƵƌĞ͘KŶĞďŝŐďĞŶĞĮƚŽĨ ǁŝƚŚĂƐƉůŝƩĞƌŽƌƌŝǀŝŶŐŬŶŝĨĞ͕ŐŽ
you can effectively double ƌĞƐĂǁŝŶŐĮŐƵƌĞĚǁŽŽĚŝƐƚŚĂƚŝƚĐƌĞĂƚĞƐ toǁŽŽĚĐƌĂŌŵĂŐĂǌŝŶĞ͘ĐŽŵ for an
the cutting depth of the a nearly symmetrical ďŽŽŬͲŵĂƚĐŚ ĂƌƟĐůĞŽŶƐŚŽƉͲŵĂĚĞƐƉůŝƩĞƌƐ͘
ǡ when the sawn boards are opened
tablesaw to resaw ůŝŬĞƉĂŐĞƐ͘ĚŐĞͲŐůƵĞĚƚŽŐĞƚŚĞƌ͕ƚŚĞƐĞ
stock up to wide boards will become a stunning panel.
Photos: Paul Anthony, courtesy Taunton Press Oct/Nov 2016 woodcraftmagazine.com 27

5 keys to safe, successful resawing
Resawing at the tablesaw 3.ĨĞĂƚŚĞƌďŽĂƌĚ͘For
ϐ safety and accuracy,
ǡǯ set up a featherboard
in front of the blade
5 4
to keep the workpiece
Ǥǯ ĮƌŵůǇĂŐĂŝŶƐƚƚŚĞĨĞŶĐĞ
while allowing forward
ǣ 3 ŵŽƟŽŶĂŶĚŚĞůƉŝŶŐ
ƉƌĞǀĞŶƚŬŝĐŬďĂĐŬ͘
1. The right blade.
For best results in hard 4.ƐƵŝƚĂďůǇƚĂůůĨĞŶĐĞ͘
wood, use a 20-to 30-tooth For proper support, the
rip blade, which will 2 fence should contact
chew through thick stock 1 most, if not all, of the
without bogging down. workpiece. When
A thin-kerf blade will cut ripping work taller than
more easily than a 1Ш8"- the stock fence, set up
kerf blade, especially on an auxiliary tall fence to
underpowered saws. do the job.
2.ƐƉůŝƩĞƌŽƌƌŝǀŝŶŐŬŶŝĨĞ͘A properly aligned 5. A shoe-style pusher. For best control,

ƐƉůŝƩĞƌŽƌƌŝǀŝŶŐŬŶŝĨĞŝƐĐƌƵĐŝĂůďĞĐĂƵƐĞŝƚŬĞĞƉƐ use a pusher with a long sole, which allows
the work against the fence once it passes the holding the work down against the table while
ďůĂĚĞ͕ƉƌĞǀĞŶƟŶŐŬŝĐŬďĂĐŬ͘ůŝŐŶƚŚĞƐƉůŝƩĞƌ the heel of the pusher does the feeding.
with the side of the teeth that face the fence.
Resawing in a single pass

ϐ

ǡ

Ǥ

Ǥ

Τ ̶Ǥ

Τ ̶ǡ
Ǥ
ϐ

ǡ
ǡ
Ǥ
ǡ ^ƚĞĂĚǇĂŶĚĐŽŶĮĚĞŶƚĚŽĞƐŝƚ͘ Begin the cut holding the piece down and against the fence
ǁŝƚŚǇŽƵƌůĞŌŚĂŶĚ͕ǁŚŝůĞƉƵƐŚŝŶŐŝƚĨŽƌǁĂƌĚǁŝƚŚǇŽƵƌƌŝŐŚƚ͘&ĞĞĚĂƐĨĂƐƚĂƐǇŽƵĐŽŵĨŽƌƚĂďůǇ
Ǥ ĐĂŶ͕ĂŶĚĂƚĂƐƚĞĂĚǇƌĂƚĞ͘ƐƐŽŽŶĂƐƚŚĞƚƌĂŝůŝŶŐĞŶĚŽĨƚŚĞďŽĂƌĚŝƐƌĞƐƟŶŐŽŶƚŚĞƚĂďůĞ͕
Ǥ ďƌŝŶŐǇŽƵƌƉƵƐŚĞƌŝŶƚŽƉůĂǇ͘&ŽůůŽǁƚŚƌŽƵŐŚƵƐŝŶŐƚŚĞƉƵƐŚĞƌƵŶƟůƚŚĞĐƵƚŝƐĐŽŵƉůĞƚĞĚ͘

Resawing in Two Passes
Resawing can be done in two passes
instead of one making for a safer operation
because each of the two cuts is shallower
than a full cut Resawing in two passes
also allows you to slice a wider board
Although a typical splitter won t work for
this non through cut you can use a short
splitter mounted in a zero clearance throat
plate See onlineEXTRA When resawing
wide pieces use a tall fence This may be
as simple as an auxiliary fence screwed to
your rip fence or you can make a box style
ϐǤ
ϐ
plus Τ and raise the blade to reach slightly
more than halfway through the stock
Using a featherboard forward of the blade
ϐǡϐ ^ƉůŝƩĞƌ
end for end to make a second pass that will
complete the cut Before resawing the next
slice joint the face that will be contacting
the fence Then repeat the entire process Half-cut for starters. With the blade raised halfway through the
stock, feed the board steadily and as quickly as you comfortably
ĐĂŶ͕ĐŽŶƟŶƵŝŶŐƚŽŚŽůĚƚŚĞƉŝĞĐĞĮƌŵůǇĂŐĂŝŶƐƚƚŚĞƚĂůůĨĞŶĐĞ͘
Flip and repeat. ZŽƚĂƚĞƚŚĞƉŝĞĐĞĞŶĚͲĨŽƌͲĞŶĚ͕ǁŝƚŚƚŚĞƐĂŵĞĨĂĐĞ Smooth follow-through. &ŽƌƐĂĨĞƚǇ͛ƐƐĂŬĞ͕ƵƐĞĂƉƵƐŚĞƌƚŽ

ĂŐĂŝŶƐƚƚŚĞĨĞŶĐĞ͘tŝƚŚĂƐŚŽĞͲƐƚǇůĞƉƵƐŚĞƌĂƚƚŚĞƌĞĂĚǇ;ďĞŚŝŶĚ ĐŽŵƉůĞƚĞƚŚĞĐƵƚ͕ǁŚŝĐŚƉƌĞǀĞŶƚƐƚŚĞƉĂƌƚƐĨƌŽŵƉŽƐƐŝďůǇ
the fence here), begin the second cut in the same manner. ƉŝŶĐŚŝŶŐĂŐĂŝŶƐƚƚŚĞďůĂĚĞĂƚƚŚĞĞŶĚŽĨƚŚĞĐƵƚ͘

Serving END
Create from
3
Ш8 × 2 × 111Ш8" piece.
Tray
An exercise in template-making
ǇŝĞůĚƐĂŐƌĞĂƚŐŝŌƉƌŽũĞĐƚƚŚĂƚ͛Ɛ
ĞĂƐǇƚŽĚƵƉůŝĐĂƚĞ
Ǉ'ĞŽīEŽĚĞŶ
W hen some good friends got married recently

) decided to make them a custom serving tray
require using plywood for stability but ) worried
that it might delaminate due to spilled liquid )
that was certain to stand out among any store realized that ) could use solid wood by letting the
bought gifts ) wanted it to be beautiful unusual bottom run under the tray ends where it could
Ǥϐ move freely in response to seasonal changes ) also
sides but decided against the compound joinery recognized that the bottom would provide a great
involved in angling all four sides so ) stuck with opportunity to resaw some special spalted maple
two This led to the idea of extending two shaped for a one of a kind book match ) ended up with a
sides to accept a pair of spindle turned handles So great gift with a bonus the template that ) created
far so good The next challenge was the bottom to do the shaping makes it easy to duplicate this
Capturing it within grooves in the tray walls would project for future gifts And that s a gift to me

DĂĚĞƚŽƐĞƌǀĞ͖ďƵŝůƚƚŽůĂƐƚ
This solidly built tray will be proudly serving
drinks and snacks for many years to come The ŽŶƐƚƌƵĐƟŽŶƐƚĞƉƐ͗
ends and handles connect to the sides with • Create a half-template of the tray side
mortise and tenon joinery while the solid • hƐĞƚŚĞŚĂůĨͲƚĞŵƉůĂƚĞƚŽŵĂŬĞĂĨƵůůͲƚĞŵƉůĂƚĞ
wood bottom is free to expand and contract • DĂŬĞƚŚĞƚƌĂǇƐŝĚĞƐ
seasonally sliding underneath the tray ends • Turn the handles
• DĂŬĞĂŶĚĮƚƚŚĞďŽƩŽŵĂŶĚĞŶĚƐ
• WƌĞͲĮŶŝƐŚĂŶĚŐůƵĞƵƉ
^ĞĞdƌĂǇ^ŝĚĞ,ĂůĨͲWĂƩĞƌŶďĞůŽǁ͘
See Handle Detail

on page 33.
BOTTOM
Create from
1
Ш4 × 16 × 111Ш8" piece.
67Ш8"
dƌĂǇ^ŝĚĞ,ĂůĨͲWĂƩĞƌŶ;,ĂůĨͲ^ŝǌĞĚͿ
1
Ш2ΗͲĚŝĂ͘ŚŽůĞƐǁŝůůďĞĐŽŶŶĞĐƚĞĚĨŽƌ
ƚĞŵƉůĂƚĞͲƌŽƵƟŶŐƚŚĞĞŶĚŵŽƌƟƐĞƐ͘
Enlarge 200% or go to ǁŽŽĚĐƌĂŌŵĂŐĂǌŝŶĞ͘ĐŽŵĨŽƌĂĨƵůůͲƐŝǌĞĚŚĂůĨͲƉĂƩĞƌŶ͘
KƉĞŶŝŶŐƉŚŽƚŽ͗DŽƌĞŚĞĂĚWŚŽƚŽŐƌĂƉŚǇ͖/ůůƵƐƚƌĂƟŽŶƐ͗&ƌĂŶŬZŽŚƌďĂĐŚ/// Oct/Nov 2016 woodcraftmagazine.com 31

A perfect half makes
for a perfect whole
The most accurate way to make a
symmetrical template is to rout the shape
using a half template that guides the router
Ǥϐ
ǡǦϐ
centerline to complete the other half Because
the shape is dependent on the half template
spend the time necessary to make it well
Begin by sawing two × template
blanks from Τ thick hardwood plywood
Print out the half pattern and glue it to the
face of one of the blanks aligning the bottom
edges Drill the Τ dia holes for the handle
and a hole at each end of what will be the Rout the recess. Using a 1Ш2"-dia. straight bit in a table router,
Ǥϐ ĐƵƚƚŚĞƌĞĐĞƐƐŝŶƚŚĞďŽƩŽŵĞĚŐĞŽĨƚŚĞŚĂůĨͲƚĞŵƉůĂƚĞ͕ŵĂŬŝŶŐ
to perfection and rout the recess as shown sure to extend the recess slightly past the centerline.
Make the full template

using the half-template
Now you re ready to use
your perfect half template to
make a perfect full template
The basic approach is to
use the completed half
template as a drilling and
routing guide to almost
ϐ
half of the full template and
then the second half Begin
by taping the half template
to the full template blank
with their lower edges
aligned drill the handle
and mortise holes and
Ǧϐǡ
staying Τ or so away
from the edges of the half
ǤϐǦ
as shown Flip the template
and repeat the process
to make the other half Flush-trim. Using a bearing-guided ƌĞĂƚĞƚŚĞŵŽƌƟƐĞƐůŽƚƐ͘Carefully draw
After shaping both halves straight bit at the router table, shape half ůŝŶĞƐƚĂŶŐĞŶƚƚŽƚŚĞŵŽƌƟƐĞŚŽůĞƐ͕ĂŶĚ
ϐ ŽĨƚŚĞĨƵůůͲƚĞŵƉůĂƚĞ͕ĐƵƫŶŐũƵƐƚďĞǇŽŶĚ ƚŚĞŶĐƵƚƚŽƚŚĞŵƚŽĐƌĞĂƚĞƚŚĞŵŽƌƟƐĞ
between the mortise holes ƚŚĞƚĞŵƉůĂƚĞĐĞŶƚĞƌůŝŶĞ͘dŚĞŶŇŝƉƚŚĞ ƐůŽƚ͕ĮůŝŶŐŝĨŶĞĐĞƐƐĂƌǇƚŽĐƌĞĂƚĞĂƐŶƵŐ
to create the mortise slots template and repeat for the other half. ĮƚĨŽƌĂ1Ш2"-dia. O.D. template guide.

Make the
tray sides
Making the sides is a simple Acetone dripped
matter because all of the cuts ŝŶƚŽŽƉƟŽŶĂů
are guided by the template holes releases
ĚŽƵďůĞͲĨĂĐĞĚ
(owever before you start tape.
using the template make
sure to mark one face A and
one face B to ensure mirror WĂƩĞƌŶͲƌŽƵƚƚŚĞƉƌŽĮůĞƚŽ
symmetry in use Then use ĮŶĂůƐŚĂƉĞ͘hƐĞĂŇƵƐŚͲƚƌŝŵ
the template to trace the bit in a table router, guiding
shape onto Τ thick stock the bearing against the
aligning the bottom edges ƚĞŵƉůĂƚĞ͘dŽƉƌĞǀĞŶƚƚĞĂƌͲ
of the template and stock ŽƵƚĨƌŽŵƌŽƵƟŶŐĂŐĂŝŶƐƚƚŚĞŐƌĂŝŶ͕ƵƐĞĂ͞ĐŽŵďŽƚƌŝŵ͟ŇƵƐŚͲƚƌŝŵďŝƚ͘ǇŇŝƉƉŝŶŐƚŚĞ
Saw and rout the shape ǁŽƌŬƉŝĞĐĞŽǀĞƌƚŽŝŶǀĞƌƚƚŚĞƚĞŵƉůĂƚĞĂŶĚĂĚũƵƐƟŶŐƚŚĞďĞĂƌŝŶŐŚĞŝŐŚƚ;ŝŶƐĞƚͿ͕ǇŽƵĐĂŶ
and then drill and rout the ĂůǁĂǇƐĐƵƚǁŝƚŚƚŚĞƐůŽƉĞŽĨƚŚĞŐƌĂŝŶ͘^ƚŽƉƐŚŽƌƚŽĨƚŚĞƌĞĐĞƐƐĂƚƚŚĞďŽƩŽŵĞĚŐĞ͘
joints To begin trace the
template shape onto a side
blank and jigsaw to within
Τ of the line )mportant ZŽƵƚƚŚĞŵŽƌƟƐĞƐĂŶĚŐƌŽŽǀĞ͘KƵƞŝƚĂƉůƵŶŐĞ
Do not saw the recess shape router with a 1Ш4ΗͲĚŝĂ͘ƵƉĐƵƚƐƉŝƌĂůďŝƚĂŶĚĂ1Ш2"
at the bottom edge Then O.D. template guide. Then rout the two 1Ш4ΗͲ
attach the template with ĚĞĞƉŵŽƌƟƐĞƐĂŶĚƚŚĞ1Ш4ΗͲĚĞĞƉďŽƩŽŵŐƌŽŽǀĞ͘
double faced tape and use tŚĞŶƌŽƵƟŶŐƚŚĞŐƌŽŽǀĞ͕ƚĂŬĞĐĂƌĞƚŽĨĞĞĚŝŶ
a Τ diameter Forstner Feed ƚŚĞĚŝƌĞĐƟŽŶƐŚŽǁŶƐŽƚŚĂƚƚŚĞďŝƚƐƉŝŶƉƵůůƐ
ĚŝƌĞĐƟŽŶ
bit to drill the Τ deep the template guide against the template edge.
handle holes using the tŚĞŶƌŽƵƟŶŐƚŚĞŽƉƉŽƐŝƚĞƐŝĚĞ͕ŵĂŬĞƐƵƌĞ
template holes as a guide Scrap
to orient the template with the opposite face
ǡϐ plywood upward to ensure perfect symmetry. Finish up
and joints as shown riser ďǇĐŚŝƐĞůŝŶŐƚŚĞĞŶĚƐŽĨƚŚĞŵŽƌƟƐĞƐƐƋƵĂƌĞ͘
Turn the handles

Referring to the drawing for assembly that the distance distance is should you decide
turn the handles Carefully between the tenon shoulders to alter the width of the tray it
ϐ is exactly the same on each will also represent the length
in their holes )t s also crucial handle And whatever that of the tray ends and bottom
Handle Detail
Ш2"
1
Ш16"
11
Ш16"
7 9
Ш16" Ш16"
11 3
Ш4"
1
Ш4" 33Ш8"
Ш8"
1 1
Ш8"
&ƵůůͲƐŝǌĞĚŚĂůĨͲƉĂƩĞƌŶ
Project photos: Paul Anthony Oct/Nov 2016 woodcraftmagazine.com 33

DĂŬĞĂŶĚĮƚƚŚĞ
ďŽƩŽŵĂŶĚĞŶĚƐ
The wide bottom typically needs to be ^ĂǁŝŶŐƉƌĞƩǇ͘&ŽƌďĞƐƚ
glued up from several pieces so ) take ďŽŽŬͲŵĂƚĐŚŝŶŐƌĞƐƵůƚƐ͕ĚŽ
the opportunity to resaw book matched ƚŚŝƐ͗DĂŬĞƚŚĞĮƌƐƚĐƵƚǁŝƚŚ
boards to create a visually harmonious ƚŚĞďůĂĚĞƌĂŝƐĞĚƐůŝŐŚƚůǇŵŽƌĞ
panel See Resawing at the Tablesaw ƚŚĂŶŚĂůĨƚŚĞǁŝĚƚŚŽĨƚŚĞ
page To prepare mill wide stock ƐƚŽĐŬ͘dŚĞŶŇŝƉƚŚĞƉŝĞĐĞ
that s thick enough and long enough to ĞŶĚͲĨŽƌͲĞŶĚĂŶĚƌĞƉĞĂƚ͕ĂƐ
yield pieces at least long The extra ƐŚŽǁŶŚĞƌĞ͘>ŝŐŚƚůǇũŽŝŶƚƚŚĞ
length allows shifting the pieces for a ƐĂǁŶƐƵƌĨĂĐĞŽĨƚŚĞŽīͲĨĂůů
good match during glue up Face joint ƉŝĞĐĞ͕ƚŚĞŶŵĂŬĞƚŚĞŶĞǆƚ
and plane the stock to thickness joint ĐƵƚƐŝŶƚŚĞƐĂŵĞŵĂŶŶĞƌ͕
both edges square and then resaw as ĂůǁĂǇƐǁŝƚŚƚŚĂƚƐŵŽŽƚŚĞĚ
shown Aim to make the resawn pieces ĨĂĐĞĂŐĂŝŶƐƚƚŚĞĨĞŶĐĞ͘
just a hair thicker than Τ That way
after edge gluing the pieces together ĞĂƵƟĨƵůŐůƵĞͲƵƉ͘Go for
minimal sanding will smooth the panel ƐǇŵŵĞƚƌǇ͘,ĞƌĞ͕ƚŚĞƉĂŶĞů
ϐǤǦ ĐŽŶƐŝƐƚƐŽĨƚǁŽŵŝƌƌŽƌͲ
the pieces to create the width ŵĂƚĐŚĞĚďŽĂƌĚƐĂƚƚŚĞ
squarely crosscut the panel to Τ ĐĞŶƚĞƌŇĂŶŬĞĚďǇƚǁŽŽƵƚĞƌ
ǡϐ ŵŝƌƌŽƌͲŵĂƚĐŚĞĚďŽĂƌĚƐ͘ůŝŐŶ
tray grooves Finally cut the tray s end ƚŚĞũŽŝŶƚƐǀĞƌǇĐĂƌĞĨƵůůǇƚŽ
pieces to Τ thick × Τ long × wide ŵŝŶŝŵŝǌĞƐĂŶĚŝŶŐĂŌĞƌǁĂƌĚ͘
dĞŶŽŶƚŚĞĞŶĚƐ͖ŶŽƚĐŚƚŚĞďŽƩŽŵ
Set up to cut the tenons using
scrap feeding the stock
ϐǤ
Making test cuts creep up
on the blade height until
cutting both cheeks achieves
ϐǤ
Then saw the long cheeks
on all four tenons Finish up
the tenons by adjusting the
blade height and cutting the
narrow edges of the cheeks
with the stock fed on edge
Next referring to the EŽƚĐŚƚŚĞďŽƩŽŵ͘
illustration on page tŚĞŶƐĂǁŝŶŐƚŚĞ
mark the corner notches on ĂƐǇƐĂǁƐĞƚƵƉ͘hƐŝŶŐĂ1Ш8ΗdZ ďŽƩŽŵŶŽƚĐŚĞƐ͕ƵƐĞ
the tray bottom measuring ;ůƚĞƌŶĂƟŶŐdŽƉĞǀĞůǁŝƚŚZĂŬĞƌͿďůĂĚĞ͕ ƚŚĞƐĂŵĞĨĞŶĐĞŽīƐĞƚĂƐ
outward from its center ǁŝƚŚƚŚĞĨĞŶĐĞƐĞƚ1Ш8ΗĂǁĂǇ͕ĂůůŽǁƐĐƵƫŶŐ ǁŚĞŶƐĂǁŝŶŐƚŚĞƚĞŶŽŶ
Readjust the blade height to ĞĂĐŚƚĞŶŽŶĐŚĞĞŬŝŶƚǁŽƉĂƐƐĞƐǁŝƚŚŽƵƚĂ ƐŚŽƵůĚĞƌƐŽŶƚŚĞƚƌĂǇĞŶĚƐ͘hƐŝŶŐƚŚĞĨĞŶĐĞ
reach the cutline and then ĚĂĚŽďůĂĚĞŽƌƐĂĐƌŝĮĐŝĂůĨĞŶĐĞ͘dŚĞďůĂĚĞ͛Ɛ ĂƐĂƐƚŽƉ͕ĨĞĞĚƚŚĞƐƚŽĐŬŽŶĞĚŐĞƵƐŝŶŐƚŚĞ
saw each notch as shown ƌĂŬĞƌƚĞĞƚŚŵĂŬĞĨŽƌĂƌĞůĂƟǀĞůǇŇĂƚĐƵƚ͘ ŵŝƚĞƌŐĂƵŐĞ͕ŵĂŬŝŶŐƚŚĞĐƵƚŝŶƚǁŽƉĂƐƐĞƐ͘

Bevel the ends and
ďŽƩŽŵƚŽĮŶĂůƐŝǌĞ
At this point the tray ends and
bottom are still oversized in
width They need to be marked
in place and then cut to size
beveling the edges of the parts
at the same time to match the
angles of the adjacent parts
Begin by installing the bottom ǆƚĞŶĚƚŚĞŐƌŽŽǀĞůŽĐĂƟŽŶ͘ Knife dƌĂŶƐĨĞƌƚŚĞŐƌŽŽǀĞůŽĐĂƟŽŶƐ͘With a tenon
into one tray side groove and ĂůŽŶŐƚŚĞƚŽƉĨĂĐĞŽĨƚŚĞƚƌĂǇďŽƩŽŵƚŽ ŝŶŝƚƐŵŽƌƟƐĞ͕ĐĂƌƌǇƚŚĞŐƌŽŽǀĞĞǆƚĞŶƐŝŽŶ
then extend the groove location ĞīĞĐƟǀĞůǇĞǆƚĞŶĚƚŚĞƚŽƉĞĚŐĞŽĨƚŚĞ lines from the sides onto both faces of the
toward the end of the side ŐƌŽŽǀĞŽƵƚƚŽǁĂƌĚƚŚĞĞŶĚŽĨƚŚĞƐŝĚĞ͘ ĞŶĚƐƚŽŵĂƌŬƚŚĞƉĂƌƚƚŽĮŶĂůǁŝĚƚŚ͘
as shown Repeat at all four
corners Next transfer those
knife lines onto both faces of
the tray ends Then rip the
necessary bevel on the edge
Dry assemble the tray and
trace the slope of the tray side
onto the end of the tray end Also
mark the tray bottom to width
ϐ
beveled edge width that s offset
about Τ from the top of the
tray side Note that the bevel Trace the side slope. ŌĞƌĚƌǇͲĂƐƐĞŵďůŝŶŐ DĂƌŬƚŚĞďŽƩŽŵƚŽǁŝĚƚŚ͘ Trace along
angles on the top and bottom ƚŚĞƚƌĂǇ͕ƚƌĂĐĞƚŚĞƐůŽƉĞŽĨƚŚĞƚƌĂǇ ƚŚĞďŽƩŽŵŽĨĞĂĐŚƚƌĂǇĞĚŐĞ͕ƚŚĞŶŵĂƌŬ
edges differ Finally bevel rip ƐŝĚĞŽŶƚŽƚŚĞƚƌĂǇĞŶĚƚŽĞƐƚĂďůŝƐŚƚŚĞ ĞĂĐŚĐƵƚůŝŶĞ1Ш8ΗŝŶǁĂƌĚĨƌŽŵƚŚĂƚ͕ǁŚŝĐŚ
ϐǤ ďĞǀĞůŽŶƚŚĞƚŽƉĞĚŐĞŽĨƚŚĞƚƌĂǇĞŶĚ͘ ǁŝůůĂƩƌĂĐƟǀĞůǇŽīƐĞƚƚŚĞďŽƩŽŵĞĚŐĞƐ͘
&ŝŶŝƐŚĮƌƐƚ͕ƚŚĞŶŐůƵĞƵƉ
ϐǡ Τ radius round
over on the outside faces of the tray
sides and lightly break all other
ϐǡϐǦ
sanding the entire tray through
grit Mask off all joint surfaces
and then apply several coats of
wiping varnish Glue up the tray
all at once Place a dab of glue at
the center of each groove before
inserting the bottom which will
keep the panel centered as it moves
seasonally Apply glue judiciously
to the tenons to minimize squeeze
out and use clamping pads to Keep out crooks. dŽƉƌĞǀĞŶƚĂŶǇƚǁŝƐƚŝŶƚŚĞƚƌĂǇ͕ǁŽƌŬŽŶĂĚĞĂĚͲŇĂƚƐƵƌĨĂĐĞ͕
ϐǤ ĂŶĚŵĂŬĞƐƵƌĞƚŚĞƚƌĂǇŝƐĂďƐŽůƵƚĞůǇƐƋƵĂƌĞƵŶĚĞƌĐůĂŵƉƉƌĞƐƐƵƌĞ͘

Southern Style (untboard
A simple take on a Southern classic BREADBOARD END Tenon
7
Ш8 × 23Ш4 × 183Ш4" 3
Ш8 × 1 × 161Ш2"
By David Traylor
DŽƌƟƐĞ
Ш8 × 1 × 163Ш4"
3
TOP CLEAT Tenon TOP BACK RAIL

Ш8 × 11Ш2 × 113Ш4"
7 3
Ш8 × 3Ш4 × 3Ш4" Ш8 × 11Ш4 × 371Ш2"
7
BOTTOM BACK RAIL

7
Ш8 × 23Ш4 × 371Ш2" Ш8" centered groove,
3
Ш2" deep
1
Tenon
3
Ш8 × 13Ш4 × 3Ш4"
17Ш8"
OUTER RUNNER
7
Ш8 × 4 × 101Ш2"
SIDE APRON
)
Ш8 × 111Ш2 × 14"
7
LEG
think huntboards are as much a part of the 17Ш8 × 21Ш4 × 39"
South as grits and barbecue First appearing in the
late th Century these tall serving tables were
used indoors and out as counters for informal
dining Over the years the simple slab board tables
became more sophisticated gradually evolving
into pieces better suited for formal dining rooms
My design was directly inspired by an
antique my brother and sister in law found
near Signal Mountain Tennessee Although the
simple construction suggested humble origins 11Ш4"
the piece had elegant lines and proportions
that ) knew could complement a hardworking
ϐǤ
As ) ve helped students build this huntboard over
at last count ) ve learned from them too and
adjusted the techniques to make this project builder
friendly and forgiving )n addition to receiving an
introduction to a host of woodworking skills the
students graduate with a piece of Southern history
A box with legs
For a major case piece
construction is surprisingly
easy and forgiving Start with
the legs and work your way in
dKW
Ш8 × 183Ш4 × 41"
7 Aside from the mortises in the
ZĂďďĞƚďĂĐŬĨĂĐĞ
ƚŽĮƚŐƌŽŽǀĞƐ͘ legs and breadboards most of
3
Ш8ΗŐƌŽŽǀĞ͕
3
Ш4" deep the work can be accomplished at
<WE> dĞŶŽŶ
1
Ш2 × 81Ш2 × 371Ш2" 3
Ш8 × 5Ш8 × 1" the tablesaw The biscuit jointed
cleats and drawer runners do
more than just save time they
#20 Pin 21Ш4"
Biscuit Ш4"dia.
1 also offer just enough wiggle
room to correct gaps and
DRAWER GUIDE
3
Ш4 × 1 × 121Ш4" facilitate drawer installation
Drawer Detail
EdZZhEEZ dƌŝŵƐŝĚĞƚŽĂĚũƵƐƚĮƚ͘
7
Ш8 × 5 × 101Ш2" EŽƚĐŚĐůĞĂƚ
ƚŽĮƚĐĂƐĞ.
ϭΗƌĂďďĞƚ͕
^d/>
1
Ш4" deep
7
Ш8 × 23Ш4 × 71Ш2"
ZtZ>d KddKD
Ш8 × 11Ш2 × 371Ш2"
7
Ш4 × 13 × 131Ш2"
1
dKW&ZKEdZ/>
7
Ш8 × 11Ш4 × 38"
<
5
Ш8 × 67Ш8 × 123Ш4"
dĞŶŽŶ KddKD SIDE

3
Ш8 × 13Ш4 × 1" &ZKEdZ/> 5
Ш8 × 73Ш8 × 131Ш2"
7
Ш8 × 23Ш4 × 38"
Ш4ΗŐƌŽŽǀĞ͕
1
&ZKEd
Ш8" deep
3
Ш8 × 73Ш8 × 133Ш4"
7
ůĞǀĂƟŽŶƐ
441Ш2" 163Ш4"
ŽŶƐƚƌƵĐƟŽŶ^ĞƋƵĞŶĐĞ
• DŝůůǇŽƵƌƐƚŽĐŬ͕ĂŶĚ
rough-cut the parts.
Ш4"
3
• DĂŬĞƚŚĞĂƉƌŽŶƐĂŶĚƌĂŝů
ĂƐƐĞŵďůŝĞƐ͕ƚŚĞŶĐŽŵƉůĞƚĞ
ƚŚĞďĂƐĞŐůƵĞͲƵƉ͕ůĞĂǀŝŶŐ
dĂƉĞƌƐƚĂƌƚƐ
13" from top. dĂƉĞƌ ƚŚĞďĂĐŬƌĂŝůƐĚƌǇͲĮƚ͘
397Ш8"
starts 13" • DĂŬĞƚŚĞĚƌĂǁĞƌƐ͕ŝŶƐƚĂůů
from top.
ĚƌĂǁĞƌƌƵŶŶĞƌƐ͕ĂŶĚŐůƵĞƚŚĞ
ďĂĐŬĂƐƐĞŵďůǇŝŶƉůĂĐĞ͘
• DĂŬĞĂŶĚĂƩĂĐŚƚŚĞ
ďƌĞĂĚďŽĂƌĚƚŽƉ͕ƚŚĞŶĮŶŝƐŚƵƉ͘
WŚŽƚŽƐ͗ZĂůƉŚ>ĞĞŶĚĞƌƐŽŶ͖/ůůƵƐƚƌĂƟŽŶƐ͗ŚƌŝƐƚŽƉŚĞƌDŝůůƐ Oct/Nov 2016 woodcraftmagazine.com 37

Start with the legs Leg Detail 1"
The original huntboard had Τ square legs that 3
Ш8" groove,
tapered down to Τ ) was able to replicate the 3
Ш4" deep
ͺΤͶ 21Ш2" 11" 81Ш2"
Use chisel to
ǯǤ ĮŶŝƐŚƐĂǁŶ
groove.
ǡǯ 13" Ш2"
1
track of the mortises and tapers Label the legs

ǡ
the mortises and a Τ square on the bottom 21Ш2" 5
Ш8"
ǤǦ 91Ш4"
ǡ
Ǥǡ
to groove the back legs as shown below
Tapering is the last step Rather than 13Ш4"
ǡ
Ǥ
ůůŵŽƌƟƐĞƐĂƌĞ3Ш8" wide and 1" deep.
ensure that ) m tapering the correct face DŽƌƟƐĞƐĂŶĚŐƌŽŽǀĞƐĂƌĞ1Ш2" in
from outside faces of legs.
Adjustable Tapering Jig
1" Washer
head screw
TOGGLE CLAMP
Pivot fence to CLAMP PAD

set taper, then 3
Ш4 × 23Ш4 × 4"
screw to base.
FENCE
3
Ш4 × 4 × 37"
Saw to the stop. Raise the 11Ш4"

blade to 3Ш4", and then mark
ƚŚĞĨƌŽŶƚƚŽŽƚŚ͛ƐůŽĐĂƟŽŶ
on your tablesaw. Set the BASE 31Ш4"
stopblock so that the lines Ш2 × 7 × 37"
1
touch at the end of the cut.
dĂƉĞƌƐĞƫŶŐŵĂĚĞƐŝŵƉůĞ͘Using the layout dĂĐŬůŝŶŐƚŚĞƚĂƉĞƌƐ͘Set the fence so that the blade grazes the
ůŝŶĞƐĂƐĂŐƵŝĚĞ͕ƉŽƐŝƟŽŶƚŚĞĨĞŶĐĞƐŽƚŚĂƚƚŚĞ base’s outer edge, and rip the tapers as shown. Taper all four
waste extends over the edge of the base legs, and then reset the fence and taper the adjacent faces.

Tenon two-step
All the tenons on this piece start long Τ
thick For speed and convenience ) cut the wide
cheeks at the tablesaw with my stack dado Apply
downward pressure to prevent lifting and test
ǤȌϐ
tenons on the side aprons and the narrow shoulders
on the rails ) switch over to hand tools Mark the
mortise locations on the tenons and then saw
and chop out the waste When chiseling simply
stay clear of the shoulder line Undercutting the
shoulder does not affect the strength of the joint
Transferring trumps a tape.ŌĞƌƌĂďďĞƟŶŐďŽƚŚĨĂĐĞƐŽĨ

ƚŚĞƐŝĚĞƐĂƚƚŚĞƚĂďůĞƐĂǁ͕ƌĞƐƚƚŚĞĂƉƌŽŶƐŽŶƚŚĞůĞŐƐ͕ĂŶĚ
ƵƐĞƚŚĞŵŽƌƟƐĞƐƚŽŵĂƌŬƚŚĞĞǆĂĐƚůŽĐĂƟŽŶƐŽĨƚŚĞƚĞŶŽŶƐ͘
^ĞƚĂƐƚŽƉĂůŽŶŐƚŚĞƚŽƉĞĚŐĞƚŽĂůŝŐŶƚŚĞƚŽƉĞĚŐĞƐ͘
Sawing out the shoulders. ŬĂƚĂďĂŵĂŬĞƐƋƵŝĐŬ

ǁŽƌŬŽĨƚŚĞƐŚŽƌƚĐŚĞĞŬĐƵƚƐ͘^ĂǁŽīƚŚĞƉĞŶĐŝůůŝŶĞƐ
ƚŽĐƌĞĂƚĞĂůŝƩůĞǁŝŐŐůĞƌŽŽŵĨŽƌĂƐƐĞŵďůǇ͘
Chipping out the waste.&ŽƌĂƐĞĂŵůĞƐƐũŽŝŶƚ͕ƚŚĞƐŚŽƵůĚĞƌƐĚŽŶŽƚŶĞĞĚƚŽďĞƐŵŽŽƚŚ͕ďƵƚƚŚĞŽƵƚĞƌĐŽƌŶĞƌƐ

ŵƵƐƚƌĞŵĂŝŶĐƌŝƐƉ͘,ŽůĚƚŚĞĐŚŝƐĞůũƵƐƚŽīǀĞƌƟĐĂů;ƟůƚĞĚƚŽǁĂƌĚǇŽƵͿ͕ĂŶĚƵŶĚĞƌĐƵƚƚŚĞũŽŝŶƚ͖ƚŚĞŶƚĂŬĞŽƵƚƚŚĞĐŚŝƉ͘
ŽŶƟŶƵĞĐŚŽƉƉŝŶŐƵŶƟůǇŽƵƌĞĂĐŚƚŚĞŵŝĚĚůĞ͕ƚŚĞŶŇŝƉŝƚĂŶĚĐŽŶƟŶƵĞĐŚŽƉƉŝŶŐĨƌŽŵƚŚĞŽƚŚĞƌƐŝĚĞ͘

Assemble in stages
)t s important to assemble the base in the
right order Glue up the front assembly
top and bottom rails stiles with the
Ǧϐǡ
at right Using the legs like clamping cauls
enables you to keep the side stiles perfectly
aligned Then glue each side apron to a front
and back leg The last step at this stage
is to glue the side assemblies to the front
ǡǦϐǤ
ϐ

of the project when you install runner
assemblies to guide and align the drawers
1
Use the legs to make the front. Using the legs as clamping
ĐĂƵůƐ͕ĚƌǇͲĮƚƚŚĞƌĂŝůƐŝŶƚŚĞŵŽƌƟƐĞƐ͘DĂŬĞƐƵƌĞƚŚĂƚ
ƚŚĞƚŽƉƌĂŝůŝƐŇƵƐŚǁŝƚŚƚŚĞƚŽƉĞŶĚŽĨƚŚĞůĞŐ͕ĂŶĚƚŚĂƚ
ƚŚĞŽƵƚĞƌƐƟůĞƐƚŽƵĐŚƚŚĞůĞŐƐ͘ŌĞƌƚŚĞŐůƵĞĚƌŝĞƐ͕
ĚŝƐĂƐƐĞŵďůĞĂŶĚĮŶŝƐŚͲƐĂŶĚƚŚĞĨƌŽŶƚĂƐƐĞŵďůǇ͘
2
Now assemble the sides. Glue the side aprons
ŝŶƚŽƚŚĞůĞŐƐĮƌƐƚ͘ŚĞĐŬƚŚĂƚƚŚĞĞŶĚƐŽĨƚŚĞ
ůĞŐƐĂƌĞŇƵƐŚǁŝƚŚƚŚĞĂƉƌŽŶƐ͛ƚŽƉĞĚŐĞƐ͘
Glue the front, not the back.

Glue the front apron between the two
ƐŝĚĞĂƐƐĞŵďůŝĞƐ͘dŚĞďĂĐŬƌĂŝůŝƐƐůŝĚ
into the grooves—without glue—to
facilitate assembly, and to allow you
ƚŽĐŚĞĐŬƚŚĂƚƚŚĞďĂƐĞŝƐƐƋƵĂƌĞ͘ 3
EŽǁĮůůƚŚĞĐĂƐĞ
(ere s where ) tell students to put their tape
Ǥ ǡϐǡ
ǡ
ǡϐǤȋ
ǯǡ
wooden wafers allow the runners to pop in
ǡǤȌ
ǡϐ Two fronts from one board. <ĞĞƉƚŚĞŐƌĂŝŶĐŽŶƟŶƵŽƵƐ
ĂĐƌŽƐƐďŽƚŚĚƌĂǁĞƌĨƌŽŶƚƐďǇƐƚĂƌƟŶŐǁŝƚŚĂƐŝŶŐůĞďŽĂƌĚ͘
ǤǦǡ ŌĞƌĐƵƫŶŐƚŚĞďŽĂƌĚŝŶŚĂůĨ͕ƉŽƐŝƟŽŶĞĂĐŚŚĂůĨŝŶŝƚƐ
ǡ ŽƉĞŶŝŶŐĂŶĚŵĂƌŬƚŚĞŽƵƚĞƌŵŽƐƚĞŶĚƐƚŽďĞĐƵƚ͘
Ǥ
ǡ ĂƐĞĞƚĂŝů 3
Ш8ΗŐƌŽŽǀĞ͕3Ш4" deep
Ǥ
ǡ 3Ш8ΗŐƌŽŽǀĞ͕1Ш2" deep
ϐǤ
BACK RAIL
sides position the drawers in
ǡǡ
ZtZ'h/
Ǥ
ϐǡ

Ǥ ǡ
Ǥ
CENTER RUNNER
ZtZ
CLEAT
FRONT RAIL
^ůŝĚĞƵƉƌĂŝůƚŽ
ŝŶƐĞƌƚƌƵŶŶĞƌƐ͕
ƚŚĞŶƌĞƉŽƐŝƟŽŶ
ƐŽĚƌĂǁĞƌ
ĨƌŽŶƚƐĂƌĞĐůŽƐĞ͘
>ŝŌƚŚĞďĂĐŬƚŽĮǆƚŚĞĨƌŽŶƚ͘hƐĞƚŚĞĨƌĞĞͲŇŽĂƟŶŐ Guides go in last. /ŶƐĞƌƚĂĨĞǁƚŚŝŶƐŚŝŵƐďĞƚǁĞĞŶƚŚĞ

ďĂĐŬƌĂŝůƚŽŵĂŬĞƚŚĞĚƌĂǁĞƌƐŇƵƐŚǁŝƚŚƚŚĞĨƌŽŶƚ͘ ĚƌĂǁĞƌĂŶĚŐƵŝĚĞƐ͕ĂŶĚƚŚĞŶƐĐƌĞǁƚŚĞŵƚŽƚŚĞƌƵŶŶĞƌƐ͘

Build a breadboard top
Breadboard ends are one of woodworking s Twin-Faced
slickest solutions for managing wood movement Tenoning Jig
The ends permit the top panel to expand
Drill holes
and contract across the grain in response to to suit top. FENCE
1
Ш2 × 8 × 30"
seasonal changes while preventing it from
cupping This detail also adds a classy touch
dƌŝŵďĂƐĞĂŌĞƌ KNOB
To start dress the rails and panel to assembly. Ш8-16
3
ϐǤǡ
on the rails and cut the mortise
BASE
This twin fenced routing guide can ensure 1
Ш4 × 8 × 30" CARRIAGE BOLT
that your tenon shoulders line up To make Ш8-16 × 31Ш2"
3
the jig temporarily tack two strips together

rip the strips so that the edges are perfectly Breadboard
parallel and then drill the bolt holes The End Detail
ϐȋ END
holes shows the exact location of the bit
To use the jig sandwich the top between the
fences and slide the base to the tenon shoulder
Elongate outer
line Adjust the bit depth so that routing from holes for wood
both directions yields a tenon that s a hair fat movement.
ϐͳ̶ǡͳΤ ̶
against the pass and make a second pass Tenon DŽƌƟƐĞ
ǡϐǤ 3
Ш8 × 1 × 161Ш2" 3
Ш8 × 1 × 163Ш4"
Shop-Made Pins, Done Safely

Commercial dowels are convenient, but they don’t a dowel from scratch, drill a hole (in this case,
make great pins. The problem is that they swell Ш4"-dia.) in a piece of steel or 1Ш8"-thick aluminum.
1
ƚŽŽŵƵĐŚƚŽĮƚƚŚĞŚŽůĞŽƌŚĂǀĞŐƌĂŝŶƌƵŶŽƵƚ Next, rip a strip of straight-grained wood slightly

issues that cause them to split as they’re tapped ŽǀĞƌƐŝǌĞĚ͕ĂƐƐŚŽǁŶďĞůŽǁ͕ůĞŌ͘ŚĂŵĨĞƌƚŚĞ
ŚŽŵĞ͘DǇƐŽůƵƟŽŶŝƐƚŽŵĂŬĞŵǇŽǁŶ͘dŽŵĂŬĞ end of strip, and drive it through the hole.
^ƚĂƌƚǁŝƚŚĂƐĂĨĞƐŝǌĞ͘To make grade-A dowel dĂƉƉĞĚƚŽƉĞƌĨĞĐƟŽŶ͘ŌĞƌĐŚĂŵĨĞƌŝŶŐĂŶĞŶĚ

stock, select a straight-grained piece of scrap with a pencil sharpener, set the dowel on the
ĨƌŽŵǇŽƵƌďŝŶ͕ĂŶĚƌŝƉŽīƚŚĞĐŽƌŶĞƌƐ͘ sizing plate and drive it through the hole.

Ш2Ηďŝƚ
1
1
Ш2ΗƐƉĂĐĞƌ
Tenoning the top. ^ĞƚƚŚĞĞĚŐĞŽĨƚŚĞƐĂĐƌŝĮĐŝĂůďĂƐĞĂŐĂŝŶƐƚƚŚĞƚĞŶŽŶ

ƐŚŽƵůĚĞƌůŝŶĞ͕ůŽĐŬƚŚĞũŝŐƚŽƚŚĞƚŽƉ͕ĂŶĚƐƚĂƌƚƌŽƵƟŶŐ͘dŽĐŽŵƉůĞƚĞƚŚĞ
ƚĞŶŽŶ͕ƐĞƚĂƐƉĂĐĞƌĂŐĂŝŶƐƚƚŚĞĨĞŶĐĞĂŶĚŵĂŬĞĂƐĞĐŽŶĚƉĂƐƐ͘
Trimming the
tenon. /ůĞĂǀĞƚŚĞ
ƚŽƉƉĂŶĞůƐĞǀĞƌĂů
ŝŶĐŚĞƐůŽŶŐƵŶƟů
ƚŚĞĨƵůůůĞŶŐƚŚ
of the tenon has
ďĞĞŶƌŽƵƚĞĚ͘dŚĞŶ
I use the waste
ƉŝĞĐĞƚŽƐƵƉƉŽƌƚ
ŵǇũŝŐƐĂǁĂƐ/ĐƵƚ Peg it together. Squeeze the
the tenon to its ďƌĞĂĚďŽĂƌĚƟŐŚƚƚŽƚŚĞƚŽƉ͕ĂŶĚƚŚĞŶ
ĮŶŝƐŚĞĚůĞŶŐƚŚ͘ ĚƌŝůůƚŚĞƚŚƌŽƵŐŚŚŽůĞƐĨŽƌƚŚĞƉĞŐƐ͘
Finishing and
ĮŶĂůĂƐƐĞŵďůǇ
Cherry doesn t need much help sunlight
and oxygen do a better job of adding
color than anything you can get from a
Ǥϐ
spot sanding ) brushed on four coats of
ǯǦǤϐ

both sides of the top but left the interior
ϐǤ
ȋϐǯ
Ǧϐǡǯ
want the drawers to smell or stick
Give the piece a few days to dry
before attaching the pulls and top see
photo right As a crowning touch ƩĂĐŚŝŶŐƚŚĞƚŽƉ͘ŌĞƌĂƩĂĐŚŝŶŐƚŚĞƚŽƉĐůĞĂƚƐƚŽƚŚĞĐĂƐĞ͕ĐĞŶƚĞƌ
apply a coat of wax to give the piece a ƚŚĞďĂƐĞŽŶƚŚĞƚŽƉĂŶĚƐĐƌĞǁƚŚĞƚǁŽƚŽŐĞƚŚĞƌ͘DĂŬĞƚŚĞĞŶĚ
little extra protection and extra pop ŚŽůĞƐŝŶƚŚĞĐůĞĂƚƐŽǀĂůͲƐŚĂƉĞĚƚŽĂůůŽǁĨŽƌǁŽŽĚŵŽǀĞŵĞŶƚ͘

Toy Trucks from × s
You could build just one, but that’s no fun. Turn your shop into an
ĂƵƚŽŵŽƟǀĞĂƐƐĞŵďůǇůŝŶĞĂŶĚĐƌĞĂƚĞĂŇĞĞƚŽĨĨŽƵƌǁŚĞĞůĞƌƐ͘
By Don Russell
W oodworkers don t have to go to the mall when

someone needs a gift We always have the opportunity
to create something special right at home That s
why ) ve come to love building these toy trucks
ǯϐǦ
produce all the parts and create my own assembly
line process ) ll share some of my techniques on
the pages ahead )t s great that the raw material
for this woodworking adventure is cheap and
ϐǤ
parts or head to the lumber yard for × stock
What ) like most about this truck project is that
it s fun to do as a group Round up your
ǡǦ
afternoon with your woodworking
guild Finished trucks are
great items to donate to toy
banks or charity auctions
Kids can get involved in the
construction process too
Who knows a child who
has a hand in building a few
trucks might just grow up
to be a great woodworker
Photos: Larry Hamel-Lambert Oct/Nov 2016 woodcraftmagazine.com 45

6 truck parts +
wheels & axles
You can create many variations
of this truck from stake side
pickups to oil tankers and tow
trucks See p But they all are
built on the basic cab and chassis
assembly shown below This
CAB
core vehicle requires a couple of
ready made components wheels
and Τ dowel rod for axles The
remaining six parts can all be
cut from Τ thick × stock
DASH
As shown on the facing page
you ll have an easy time mass
FRAME HOOD AXLE FENDER producing these six parts if you
BLOCK
set up different workstations
Basic Chassis
DASH CAB FRAME
Ш16 × 11Ш2 × 13Ш16"
3
11Ш2 × 17Ш8 × 2" Ш16 × 11Ш2 × 61Ш4"
9
ĂďWĂƩĞƌŶ
HOOD
11Ш8 × 11Ш2 × 11Ш4"
Ш4ΗŝĂ͘
3
3
Ш4"
Ш16"
7
5
Ш16 × 5Ш16"
ŐƌŽŽǀĞ
Ш4" AXLE
1
11Ш4" WHEEL
AXLE BLOCK
1
Ш2 × 1 × 15Ш8" Ш16"
3
FENDER
1
Ш2 × 1 × 31Ш2"
WŽƐŝƟŽŶďŽƩŽŵĞĚŐĞŽĨ
,ŽŽĚWĂƩĞƌŶ &ĞŶĚĞƌWĂƩĞƌŶ ĨĞŶĚĞƌŇƵƐŚǁŝƚŚĨƌĂŵĞ͘
Ш2ΗĐŚĂŵĨĞƌ
1
&ƵůůͲƐŝǌĞĚƉĂƩĞƌŶƐ
1 square= 1Ш4"
46 ǁŽŽĚĐƌĂĨƚŵĂŐĂǌŝŶĞ͘ĐŽŵ Oct/Nov 2016

ĂďŵĂƐƚĞƌďůŽĐŬ
;ďĞƩĞƌƚŚĂŶ
Set up for mass ĂƉĂƩĞƌŶͿ
ƉƌŽĚƵĐƟŽŶ
Straight square edged parts like
the frame and dashboard
can be mass produced
easily by ripping strips then ĂŶĚƐĂǁ
crosscutting them to length ĂŶĚƐĂŶĚ
Drill
To produce multiples of
other parts set up different Drill
1
Ш8Η^ĂǁĐƵƚ
workstations as shown
here ) found that it s best
to cut out the cab in pairs
starting with blanks that measure
Τ × Τ × Τ )f you ve got
STATION 1: Drill Press
inexperienced woodworkers on
your truck construction crew put Start with boring work. dǁŽĐĂďƐĐĂŶďĞĐƵƚĨƌŽŵĞĂĐŚďůĂŶŬ͕
them to work sanding parts or ĂƐƐŚŽǁŶŝŶƚŚĞĐƵƫŶŐĚŝĂŐƌĂŵ͘dŚĞĐĂďďĞŐŝŶƐǁŝƚŚĂƉĂŝƌŽĨ
painting them prior to assembly ƚŚƌŽƵŐŚŚŽůĞƐ͕ĂůŝŐŶĞĚǁŝƚŚĂĨĞŶĐĞĂŶĚƐƚŽƉ͕ĂƐƐŚŽǁŶĂďŽǀĞ͘
ZƵŶĨĂĐĞƐĂŐĂŝŶƐƚ
STATION 2: dĂďůĞƐĂǁ ĨĞŶĐĞƚŽƌŝƉĂ
ĐĞŶƚĞƌĞĚŐƌŽŽǀĞ͘
Tape, then cut. Tape a series of cab
ďůĂŶŬƐƚŽŐĞƚŚĞƌ͕ƚŚĞŶĂĚũƵƐƚƚŚĞƌŝƉ
ĨĞŶĐĞĂŶĚďůĂĚĞŚĞŝŐŚƚƚŽŵĂŬĞĂƉĂŝƌ
ŽĨǀĞƌƟĐĂůĐƵƚƐ͘ǆůĞŚŽƵƐŝŶŐƐƚƌŝƉƐĐĂŶ
ĂůƐŽďĞĐƵƚŝŶƉĂŝƌƐ;ĨĂƌƌŝŐŚƚƉŚŽƚŽͿ͘
dŚĞŐƌŽŽǀĞƐĨŽƌƚŚĞĚŽǁĞůĂǆůĞƐĐĂŶ
ďĞĐƵƚǁŝƚŚĂĚĂĚŽŚĞĂĚ͕ŽƌďǇŵĂŬŝŶŐ
ŽǀĞƌůĂƉƉŝŶŐŬĞƌĨƐǁŝƚŚĂƐƚĂŶĚĂƌĚďůĂĚĞ͘
STATION 3: ĂŶĚƐĂǁ STATION 4: ^ĂŶĚĞƌƐ

ZĞĮŶĞƚŚŽƐĞ Super simple
ŇĂƚƐĂŶĚĞƌ
rough edges.
^ŚĂƉŝŶŐĂŶĚ
ƐŵŽŽƚŚŝŶŐƚŚĞ
ĐĂďƐĂŶĚĨĞŶĚĞƌƐ
ĐĂŶďĞĚŽŶĞďǇ
ŚĂŶĚͲƐĂŶĚŝŶŐ͕
ďƵƚƚŚĞǁŽƌŬŐŽĞƐ
ŵƵĐŚĨĂƐƚĞƌǁŝƚŚ
ĂŶŽƐĐŝůůĂƟŶŐ
ƐƉŝŶĚůĞƐĂŶĚĞƌ
Cut curves for cabs and fenders.DĂŬĞƚŚĞ ĂŶĚĂŶĂƌƌŽǁ
ĮŶĂůĐƵƚƐƚŽĨƌĞĞƚŚĞƉĂŝƌĞĚĐĂďƐ͕ĂŶĚƌŽƵŐŚůǇ ďĞůƚƐĂŶĚĞƌ͘
ĐƵƌǀĞƚŚĞĐĂďƚŽƉƐ͘dŚĞŶĐƵƚĂďƵŶĐŚŽĨĨĞŶĚĞƌƐ͕
ǁŚŝĐŚŝŶĐůƵĚĞĂƐƚƌĂŝŐŚƚƌƵŶŶŝŶŐďŽĂƌĚ͘
/ůůƵƐƚƌĂƟŽŶƐ͗dƌĞǀŽƌ:ŽŚŶƐƚŽŶ Oct/Nov 2016 ǁŽŽĚĐƌĂĨƚŵĂŐĂǌŝŶĞ͘ĐŽŵ 47

Speed through
assembly with 3 jigs
On this automotive assembly line
yellow wood glue and a headless
pinner take the place of welding
gear and impact wrenches Your
truck factory should also include
the assembly aids shown here
because small parts slip around
when coated with glue These 111Ш16" JIG 1: Chassis
jigs make it easy to maintain &ůƵƐŚĮƚƐ͘dŚĞĮƌƐƚƉĂƌƚƐƚŽĂƐƐĞŵďůĞĂƌĞ
your manufacturing tolerances the frame and hood. This 2-piece jig keeps
ĞĚŐĞƐŇƵƐŚĂƐǇŽƵƉŝŶƚŚĞŐůƵĞĚũŽŝŶƚ͘
JIG 2: Cab Spacer

Dashboard &
ĐĂď͘ Fasten the
dashboard to the
hood, then use a Ш16"
7
1
Ш2"-thick spacer 13Ш4"
block to align the
cab on the frame.
SIDE BACK
JIG 3: Wheels & Fenders 3
Ш4 × 33Ш8 × 7" Ш4 × 33Ш8 × 8"
3
25Ш8"
Base
Ш4 × 47Ш8 × 8"
3 Ш4"
3
9
Ш16" Spacer
hƉƐŝĚĞͲĚŽǁŶĂůŝŐŶŵĞŶƚ͘ Glue the wheels

ƚŽĂǆůĞƐ͕ƚŚĞŶƵƐĞƚŚĞũŝŐƚŽĞƐƚĂďůŝƐŚƚŚĞĐŽƌƌĞĐƚůŽĐĂƟŽŶ WƌĞƐƐƵƉ͕ŶĂŝůĚŽǁŶ͘ Make sure the wheel
for a axle housings on the underside of the frame. won’t rub on the fender before pinning it.
48 woodcraftmagazine.com KĐƚͬEŽǀϮϬϭϲ
ǆƉĂŶĚǇŽƵƌŇĞĞƚǁŝƚŚ
ĐƵƐƚŽŵŝǌĞĚĚĞƐŝŐŶƐ
The basic truck is just the beginning WŝĐŬƵƉdƌƵĐŬ
With a little imagination you can add
features to the core truck platform and dŽǁdƌƵĐŬ
create a number of variations Four
different examples are detailed here
For a truly over the top creation
ϐ
at the bottom of the page
Painting your truck parts
before assembly and
combining contrasting

other fun options
dĂŶŬĞƌdƌƵĐŬ
^ƚĂŬĞƐŝĚĞdƌƵĐŬ
Who’s got the best truck?

tĞ͛ǀĞŐŽƚŵŽƌĞĚĞƐŝŐŶƐ
ƚŽŝŶƐƉŝƌĞǇŽƵƌƚƌƵĐŬͲ
ŵĂŬŝŶŐĂĚǀĞŶƚƵƌĞ͘'Ž
ƚŽŽƵƌǁĞďƐŝƚĞ͕ĂŶĚĐůŝĐŬ
ŽŶƚŚĞŽŶůŝŶĞydZƐ
ĨŽƌƚŚŝƐŝƐƐƵĞ͘
Oct/Nov 2016 ǁŽŽĚĐƌĂĨƚŵĂŐĂǌŝŶĞ͘ĐŽŵ 49

^ŽŵĞƟŵĞƐŝƚƉĂǇƐƚŽŬĞĞƉƚŚŝƐ
ƉŽƌƚĂďůĞƉŽǁĞƌƚŽŽůƉĂƌŬĞĚ
By William Schneider
P ϐ
Ǥ
ǡǦϐ

Ǥ
ǯ
ǡϐ
ǯǦǤ

ǡǡ
Clever lever. Use this handy hold-down to keep your work Ǥ
ŇĂƚĂŶĚƐĞĐƵƌĞǁŚŝůĞĐƵƫŶŐďŝƐĐƵŝƚƐůŽƚƐŝŶĞĚŐĞƐ͘ ǡǦ
ȋǡȌǤ
ǡ
ǤǦ

Ǥ
ǡǤ
Ǧǯͷͷ͹
ϐ
ϐǤ
ǡǯǤ
ǡ
to center slots in Τ ̶ǦǤ
Miter mate. Slot mitered ends on stock up to ǯ
ϴΗǁŝĚĞǁŝƚŚƚŚŝƐĂĚũƵƐƚĂďůĞŵŝƚĞƌƐƚŽƉ͘ ϐǤ
Groovy 45. Slip the corner of your workpiece into the Handy holder. dŚŝƐdͲƐŚĂƉĞĚƉƵƐŚƐƟĐŬĐŽŵĨŽƌƚĂďůǇĂŶĚƐĂĨĞůǇ
groove under the fence to slot 45° corner joints. ŚŽůĚƐǇŽƵƌǁŽƌŬ͛ƐŽƉƉŽƐŝƚĞĨĂĐĞĂƐǇŽƵƉůƵŶŐĞƚŚĞĐƵƩĞƌ͘

Create bushing for Lever
Arm pivot pin by installing
Build the jig, then add the accessories 1
Ш4-20 threaded insert,
then drilling interior
threads out with 1Ш4" bit.
Start by routing a Τ × Τ groove
in the base The groove provides FENCE
clearance space for sawdust and 3
Ш4 × 3 × 9"
miter joint alignment )t also
FOOT
provides a straight shoulder for 3
Ш4 × 51Ш4 × 9"
aligning the MDF and biscuit
joiner fences After gluing the
base and subbase together
screw each MDF fence to its Groove
6"
foot then screw the fence foot Ш8 × 3Ш8"
3
assemblies to the base A pair of

cleats can be added as shown to BASE
ϐ 3
Ш4 × 24 × 18"
Ǥϐ SUBBASE
varnish or shellac for moisture CLEAT (one on each side)
1
Ш2 × 24 × 18"
protection and easier cleaning 1 × 3Ш4 × 8"
Ш4"-dia. Pivot Pin made from

1
WƵƐŚƐƟĐŬ Lever Arm Ш4-20 bolt (remove hex head)
1
61Ш4" 11Ш2"
Top view
Ш4"
3 3
Ш4"
Ш4-20 threaded brass insert
1
Nut
281Ш2"
Shape handle for Chamfer sharp edges. 12"
comfortable grip.
2"
3
Ш4"
1
Ш2"
ĸǆƌƵďďĞƌƐƚƌŝƉƚŽĨŽŽƚ
121Ш2" ǁŝƚŚĚŽƵďůĞͲƐƟĐŬƚĂƉĞ͘
ĚũƵƐƚƐƚŽƉƉŽƐŝƟŽŶ
with 1Ш4-20 threaded
Miter Stop knobs that screw into
10" threaded inserts in base.
1
Ш2" plywood
Ш2"
1 11Ш2"
1"
91Ш2"
2 Ш2"
1
51Ш2"
12"
2 Ш2"
1
Ш4"
3
Fence face
ŽŶƐƚƌƵĐƟŽŶ
sequence
• Make the base and subbase
• Make the fence and cleats
• Assemble the pieces Align joiner fence
with jig fences, and
• Make hold-downs and guides fasten joiner to base.
• Mount your joiner
6"
WŚŽƚŽƐ͗>ĂƌƌǇ,ĂŵĞůͲ>ĂŵďĞƌƚ͖/ůůƵƐƚƌĂƟŽŶƐ͗DĞůĂŶŝĞWŽǁĞůů Oct/Nov 2016 woodcraftmagazine.com 51
GREAT SOLUTIONS FOR
YOUR FINISHING NEEDS
generalfinishes.com
Whether you are a professional or
a DIYer, award-winning finishing
products from General Finishes will
help you with your next project.
Our products are consumer friendly,
designed for easy use with more
pigment and depth of color than
Pie Safe with RED Milk Paint any other finishes on the market.
Woodcraft Magazine:
Vol. 9, No. 50 - Dec 12 -Jan 13
Photo By: Larry Hamel-Lambert Available at

Awesome
Audio
ƵŝůĚĂďĞƩĞƌƐĞƚŽĨƐƉĞĂŬĞƌƐƚŚĂŶ
ǇŽƵ͛ĚǁĂŶƚƚŽƉĂǇĨŽƌŝŶĂƐƚŽƌĞ
By William Schneider
W ho says that you can t

build a set of loudspeakers that
your own shop you can make stout
cabinets that won t resonate when
design work is already done All
you have to do is assemble the
can sound better than those you the piano hits middle C )nside a parts per instructions The kit
can buy You ll discover that well designed crossover will blend featured here contains everything
most commercial loudspeaker low through high tones smoothly you need except for the wood
manufacturers take steps to While you may be comfortable Even though the kit requires
lower the cost of manufacturing tackling the cabinets you might soldering electrical components
and shipping their products feel uneasy about the electrical together supplied stick
Two places where corners are tasks But don t worry With kits on templates show where
cut are cabinet quality and in the like the Overnight Sensations each item goes )f you can t
electronic assemblies inside These from Meniscus Audio see Buyer s solder already assembled
impact sound quality Working in
ǡǤ͸ͶȌǡϐ crossovers are available
Opening photo: Morehead Photography Oct/Nov 2016 woodcraftmagazine.com 53
^ƉĞĂŬĞƌĂŶĂƚŽŵǇ͗ĂƐŝĐďŽǆ͕ďĞĂƵƟĨƵůďĂŋĞ͕ďĂůĂŶĐĞĚ
Audio expertise isn t required to
,ZtKK TOP
ϐǦǡ &&> 3
Ш4 × 41Ш2 × 81Ш4"
3
Ш4 × 6 × 91Ш2"
1
Ш8" thick × 1Ш4" wide
Ǥ ǀŝŶǇůĨŽĂŵƚĂƉĞ
ȋǲͳͲͳǳ

TWEETER
ǤȌ
Ǧ
ǡ

Ǥ

ǡ

D/ͲtKK&Z
Ǥ
Ǧǡ

ϐǤ
Ǧ
ǡ
ϐǤ
ŽŶƐƚƌƵĐƟŽŶƐĞƋƵĞŶĐĞ
• DŽƵŶƚĞůĞĐƚƌŽŶŝĐƐŽŶĐƌŽƐƐŽǀĞƌďŽĂƌĚ͘
• DĂŬĞƚŚĞďĂŋĞĂŶĚďƵŝůĚƚŚĞD&
ďŽǆ͕ƚŚĞŶǀĞŶĞĞƌƚŚĞďŽǆ͘
• ƉƉůǇĮŶŝƐŚƚŽďĂŋĞĂŶĚďŽǆ͘
• /ŶƐƚĂůůƐƉĞĂŬĞƌĐŽŵƉŽŶĞŶƚƐ͘
• ^ĐƌĞǁďĂŋĞƚŽďŽǆƚŽĐŽŵƉůĞƚĞƐƉĞĂŬĞƌĐĂďŝŶĞƚ͘
Port
ƌŽƐƐŽǀĞƌ Žŝů ůĞĐƚƌŽŶŝĐƐ dĞƌŵŝŶĂůĐƵƉ
boards and screws
EŽƚĞ͗DĞŶŝƐĐƵƐƐƉĞĐŝĮĞƐ1Ш2ΗͲƚŚŝĐŬ
ŵĂƚĞƌŝĂůĨŽƌƚŚĞƐƉĞĂŬĞƌĐĂďŝŶĞƚ͘
I adjusted cabinet dimensions so that
3
Ш4ΗͲƚŚŝĐŬƐƚŽĐŬĐĂŶďĞƵƐĞĚ͘
Just add wood. ƚΨϭϯϬ͕ƚŚĞKǀĞƌŶŝŐŚƚ

ĂŵƉŝŶŐ
ŵĂƚĞƌŝĂů ^ĞŶƐĂƟŽŶƐƐƉĞĂŬĞƌŬŝƚŝƐĂŐŽŽĚĐŚŽŝĐĞĨŽƌ
ƐŽŵĞŽŶĞǁĂŶƟŶŐƚŽƚƌǇƐƉĞĂŬĞƌďƵŝůĚŝŶŐ͘
dŚĞŬŝƚĐŽŶƚĂŝŶƐĞǀĞƌǇƚŚŝŶŐǇŽƵŶĞĞĚĨŽƌƚǁŽ
ƐƉĞĂŬĞƌƐ͗ĞůĞĐƚƌŽŶŝĐĐŽŵƉŽŶĞŶƚƐ͕ĚĂŵƉŝŶŐ
ŵĂƚĞƌŝĂů͕ĐƌŽƐƐŽǀĞƌďŽĂƌĚƐǁŝƚŚƚĞŵƉůĂƚĞƐ͕
ƌŝǀĞƌŐĂƐŬĞƚ DŝĚͲǁŽŽĨĞƌ Tweeter ƌŽƐƐŽǀĞƌ
ƚĞŵƉůĂƚĞƐ ƐĐƌĞǁƐͶĂŶĚĐĂŶĚǇ͘zŽƵƐƵƉƉůǇƚŚĞǁŽŽĚĂŶĚ
ĂĚŚĞƐŝǀĞͲďĂĐŬĞĚĨŽĂŵƚĂƉĞ;ǁĞĂƚŚĞƌƐƚƌŝƉƉŝŶŐͿ͘

ĞůĞĐƚƌŽŶŝĐƐ
Audio 101
• Port - A tube inserted
into the cabinet that
allows deeper bass.
Its size works together
with cabinet volume.
• ĂŋĞͲ,ŽůĚƐĚƌŝǀĞƌƐŝŶ
ƉŽƐŝƟŽŶ͘ĂŋĞǁŝĚƚŚ͕
ƚǁĞĞƚĞƌƉŽƐŝƟŽŶ͕ĂŶĚ
Maple
veneer driver spacing must be
maintained or sound will
ďĞĂīĞĐƚĞĚ͘ŚĂŵĨĞƌƐ
#10 biscuits
or round-overs on
edges can aid sound.
• ƌŝǀĞƌƐ - The components
DAMPING that actually produce
DdZ/>
sound. Small drivers for
high frequency notes are
called “tweeters.” The
<
3
Ш4 × 41Ш2 × 8" largest drivers for handling
bass are called “woofers.”
This kit has medium-sized
drivers called mid-woofers.
• ƌŽƐƐŽǀĞƌͲŝƌĐƵŝƚƌǇ
that splits the electrical
signal into high and low
bands and sends them to
the appropriate drivers.
ƌŽƐƐŽǀĞƌƐŝŶĐůƵĚĞ
coils, capacitors, and
^/
3
Ш4 × 81Ш4 × 91Ш2" resistors (see below).
• Coil - This crossover
component passes low
BOTTOM
Ш4 × 41Ш2 × 81Ш4"
3 frequencies and blocks
higher frequencies
DŝƌƌŽƌƚǁĞĞƚĞƌƉŽƐŝƟŽŶ
for matching speaker. in the signal.
KZEZ MDF PORT
1" 21Ш4" Z<d • Capacitor - Blocks lower
frequencies and passes
1"
13Ш4" higher frequencies
21Ш2"
• ZĞƐŝƐƚŽƌ - Impedes the
51Ш2" ŇŽǁŽĨĞůĞĐƚƌŝĐĂůĐƵƌƌĞŶƚ͘
• ĂŵƉŝŶŐŵĂƚĞƌŝĂů - Placed
inside the speaker cabinet,
this material blocks internal
sound waves that adversely
ĂīĞĐƚƐŽƵŶĚƋƵĂůŝƚǇ͘
• ŝŶĚŝŶŐƉŽƐƚƐͲŽůŽƌͲ
23Ш4"
coded connectors for
ĂŵƉůŝĮĞƌǁŝƌĞƐ͘
3" ZK^^KsZ BINDING POST
<ŝƚƉŚŽƚŽ͗tŝůůŝĂŵ^ĐŚŶĞŝĚĞƌ͖/ůůƵƐƚƌĂƟŽŶƐ͗:ŽŚŶ,ĂƌƚŵĂŶ Oct/Nov 2016 woodcraftmagazine.com 55

DŽƵŶƚΘǁŝƌĞ
the electronics
Some soldering is required to connect
the speaker s electronic components
)f you feel uncomfortable soldering you
can order pre assembled crossovers
from Meniscus for an extra charge
Skin the coat.ŽŝůǁŝƌĞŝƐĐŽĂƚĞĚǁŝƚŚĞŶĂŵĞůƚŚĂƚ Mounting components and soldering
ŝŶƚĞƌĨĞƌĞƐǁŝƚŚƐŽůĚĞƌŝŶŐ͘hƐĞĂŬŶŝĨĞƚŽƐĐƌĂƉĞƚŚĞ ϐǡ
ĐŽĂƟŶŐĨƌŽŵǁŝƌĞƚŚĂƚŶĞĞĚƐƚŽďĞƐŽůĚĞƌĞĚ͘ included templates you can glue to crossover
boards as shown in these photos
Plan how to mount the crossovers inside
the speaker cabinet ) cut Τ × strips of
hardboard and plywood to use as feet for
the crossovers The plywood feet are glued
to a cabinet wall but the hardboard strips
which are glued to the crossover board
and screwed to the feet can be removed
Soldering 101
To solder electrical components, you’ll need
a soldering iron and electrical solder. Pencil
irons begin at $15, but I use a $50 Weller
ĂĚũƵƐƚĂďůĞŚĞĂƚƐŽůĚĞƌŝŶŐƐƚĂƟŽŶ͘hƐĞϲϬͬϰϬ
Hot melt glue rosin core, 0.031"-diameter solder.
dŽƐŽůĚĞƌ͕ƚŽƵĐŚƚŚĞŚŽƚƟƉƚŽƚŚĞũŽŝŶƚĨŽƌĂĨĞǁ
ƐĞĐŽŶĚƐ͕ĂŶĚĨĞĞĚƐŽůĚĞƌďĞƚǁĞĞŶƟƉĂŶĚũŽŝŶƚ
ƵŶƟůŝƚŵĞůƚƐĂŶĚŇŽǁƐŝŶƚŽƚŚĞũŽŝŶƚ͘DŽǀĞƐŽůĚĞƌ
Follow the template. Glue the kit’s template to the to coat other parts in the joint. I spend about 5
ĐƌŽƐƐŽǀĞƌďŽĂƌĚ͕ƚŚĞŶƵƐĞŚŽƚŵĞůƚŐůƵĞƚŽĂĚŚĞƌĞƚŚĞ to 8 seconds per joint. A good joint should be
ƉĂƌƚƐ͘ĚĚǌŝƉƟĞƐƚŽƐĞĐƵƌĞŚĞĂǀǇĐŽŝůƐ͘&ŝƚƚŚĞůĞĂĚƐ ƐŚŝŶǇůŝŬĞĐŚƌŽŵĞ͕ŶŽƚŐƌĂŝŶǇ͘KĐĐĂƐŝŽŶĂůůǇǁŝƉĞ
ŝŶƚŽƚŚĞŝƌƚĞƌŵŝŶĂůŽƉĞŶŝŶŐƐďĞĨŽƌĞƐŽůĚĞƌŝŶŐ͘ ƚŚĞƐŽůĚĞƌŝŶŐŝƌŽŶƟƉĐůĞĂŶŽŶĂĚĂŵƉƐƉŽŶŐĞ͘
Once you learn to solder, projects
ůŝŬĞŇŽŽƌůĂŵƉƐ͕ƚĂďůĞůĂŵƉƐ͕ĂŶĚƉŽǁĞƌ
tool repair all become possible.
ŝƉƟĞƐ
Home-made
ƟƉŚŽůĚĞƌ
Soldering
ƐƚĂƟŽŶ
Terminal
DŽƵŶƟŶŐĨĞĞƚ
^ŽůĚĞƌĂĐŽŶŶĞĐƟŽŶ͘dŽƵĐŚƚŚĞŝƌŽŶ͛ƐƟƉƚŽĂĐŽŶŶĞĐƟŽŶ
ĨŽƌĂĐŽƵƉůĞŽĨƐĞĐŽŶĚƐ͘tŝƚŚŽƵƚůŝŌŝŶŐƚŚĞƟƉ͕ĨĞĞĚƐŽůĚĞƌ
Solder
ďĞƚǁĞĞŶƟƉĂŶĚĐŽŶŶĞĐƟŽŶ͕ŵĞůƟŶŐƚŚĞƐŽůĚĞƌ͘DĂŝŶƚĂŝŶŚĞĂƚ
ĨŽƌĂƐĞĐŽŶĚĂŌĞƌƐƵĸĐŝĞŶƚƐŽůĚĞƌŚĂƐŇŽǁĞĚ͕ƚŚĞŶƉƵůůƚŚĞ Soldering
iron
ŝƌŽŶ͛ƐƟƉĂǁĂǇ͘ůůŽǁƐĞǀĞƌĂůƐĞĐŽŶĚƐĨŽƌƐŽůĚĞƌƚŽƐŽůŝĚŝĨǇ͘
56 ǁŽŽĚĐƌĂĨƚŵĂŐĂǌŝŶĞ͘ĐŽŵ Oct/Nov 2016

dŚĞďĂŋĞŝƐƚƌŝĐŬǇ͖ƚŚĞďŽǆŝƐĞĂƐǇ͘
Assemble, then trim
Ǧϐ
ǡǤ
ϐǡ Τ ̶ϐǤϐ
ǡǡǦ
Ǥϐ
Ǧ
and a Τ ̶Ǥǯ
ǡǤ
ϐϐǡ
Ǥ
ϐǡ >ĂǇŽƵƚĞĂĐŚďĂŋĞ͘ Locate each
ǤǤ hole carefully. Use the compass to
ȋǤͷͲȌǤǡ ŵĂƌŬƚŚĞŽƉĞŶŝŶŐĂŶĚƚŚĞƌĂďďĞƚ
ϐϐǦϐǦǤ ƚŽŚŽůĚĞĂĐŚĚƌŝǀĞƌ͛ƐŇĂŶŐĞ͘
Extend pivot
pin through
ďĂŋĞĂŶĚŝŶƚŽ
ǁŽƌŬďŽĂƌĚďĞůŽǁ͘
ŽƩŽŵ
Top
ĂĐŬ
ZŽƵƚŚŽůĞƐĨŽƌĚƌŝǀĞƌƐ͘ƩĂĐŚĞĚƚŽƚŚĞďĂƐĞŽĨǇŽƵƌ 'ůƵĞƵƉƚŚĞďŽǆŝŶƐƚĂŐĞƐ͘Cut slots for #10 biscuits in box sides,

ƌŽƵƚĞƌ͕Ă:ĂƐƉĞƌũŝŐŝƐŝĚĞĂůĨŽƌƐƉĞĂŬĞƌĐŽŶƐƚƌƵĐƟŽŶ͘/ƚ ďĂĐŬ͕ƚŽƉ͕ĂŶĚďŽƩŽŵ͘dŚĞŶŐůƵĞƚŚĞďĂĐŬ͕ƚŽƉ͕ĂŶĚďŽƩŽŵ
enables you to rout circular recesses and holes from ƚŽŐĞƚŚĞƌ͘WůĂĐĞĂƐŝĚĞŽŶƚŚĞǁŽƌŬďĞŶĐŚĂƐ/͛ŵĚŽŝŶŐŚĞƌĞ͕ƚŽƵƐĞ
1" to 71Ш2" in diameter in 1Ш16" increments. Use a 1Ш4" ĂƐĂƉŽƐŝƟŽŶŝŶŐŐƵŝĚĞďĞĨŽƌĞĐůĂŵƉŝŶŐƵƉƚŚŝƐƐƵďĂƐƐĞŵďůǇ͘tĂǆ
ƐƉŝƌĂůƵƉĐƵƚďŝƚ͕ĂŶĚƚĂŬĞƉĂƐƐĞƐĂďŽƵƚ1Ш8" deep. ƉĂƉĞƌŬĞĞƉƐǇŽƵƌŐůƵĞͲƵƉĨƌŽŵƐƟĐŬŝŶŐƚŽƚŚĞƉŽƐŝƟŽŶŝŶŐŐƵŝĚĞ͘
Flush-trim the
ďĂŋĞ͘Doing this
before veneering
the box prevents
router bearing
ƚƌĂĐŬƐŝŶƚŚĞ
veneer. Tape some
cardboard (about
Ϭ͘ϬϯϬΗƚŚŝĐŬͿƚŽ
approximate the
ǀĞŶĞĞƌƚŚŝĐŬŶĞƐƐ͘
/ŶƐƚĂůůĐŽƌŶĞƌďůŽĐŬƐ͘ƵƚĐŽƌŶĞƌďůŽĐŬƐ
ƚŽŚŽůĚƚŚĞƐĐƌĞǁƐĨŽƌƚŚĞďĂŋĞ͘
Mount them about 1Ш16ΗďĞůŽǁŇƵƐŚ͘
WŚŽƚŽƐ͗>ĂƌƌǇ,ĂŵĞůͲ>ĂŵďĞƌƚ͕ĞǆĐĞƉƚƐŽůĚĞƌŝŶŐƐƚĂƟŽŶĂŶĚĐŽƌŶĞƌďƌĂĐŬĞƚƉŚŽƚŽƐ͗tŝůůŝĂŵ^ĐŚŶĞŝĚĞƌ Oct/Nov 2016 woodcraftmagazine.com 57

Iron on some veneer for an
easy appearance upgrade
While MDF takes paint well after a couple rounds of
shellac and sanding it s even easier to veneer The
iron on method using paper backed veneers and an
ordinary clothes iron is straightforward and simple
Coat both the cabinet and the veneer with Titebond
Original let the glue dry and iron on the veneer Once
dried the glue will still reactivate for up to seven days
The veneer doesn t stick until you apply
heat so it s fairly easy to position each piece
Map out your veneer.DĂŬĞĐĂƌĚďŽĂƌĚƉĂƩĞƌŶƐ Ǥϐǡǡ
1
Ш2ΗŽǀĞƌƐŝǌĞĂŶĚƉŽƐŝƟŽŶƚŚĞŵŽŶƚŚĞǀĞŶĞĞƌĂƐ sides and top After ironing on a piece of
shown. Allow at least 1Ш4" between the pieces. ǡϐ
ϐǦǤǤ
Once all sides are complete use the wood
ϐǤ
of General Finishes Arm R Seal satin
Iron on the
veneer. WŽƐŝƟŽŶ
the veneer as
desired. Place
ĐŽƩŽŶĐůŽƚŚ
;ƚͲƐŚŝƌƚŵĂƚĞƌŝĂů
works well)
over it. Using an
ordinary clothes
ŝƌŽŶŽŶƚŚĞĐŽƩŽŶ
Cut it out. Using scissors or a knife, cut groups of tracings ƐĞƫŶŐ͕ƉƌĞƐƐ
ĨƌŽŵƚŚĞƌŽůů͕ůĞĂǀŝŶŐĂůŝƩůĞĞǆƚƌĂŵĂƌŐŝŶĂůůĂƌŽƵŶĚ͘ ĮƌŵůǇĂŶĚǁŽƌŬ
slowly to adhere
the veneer.
Spread glue on veneer and cabinet. Tape the Flush-trim veneer overhang.hƐĞĂŇƵƐŚͲƚƌŝŵďŝƚŝŶĂƌŽƵƚĞƌ
edges of veneer to a table, then use a sponge ŽƌƌŽƵƚĞƌƚĂďůĞƚŽƋƵŝĐŬůǇƌĞŵŽǀĞƚŚĞĞǆĐĞƐƐǀĞŶĞĞƌĨƌŽŵƚŚĞ
paint roller to apply glue. Let the glue dry. ĞĚŐĞƐ͘dĂƉĞƌĞĚƵĐĞƐďĞĂƌŝŶŐƚƌĂĐŬƐŽŶĂůƌĞĂĚǇͲǀĞŶĞĞƌĞĚƐŝĚĞƐ͘

Mount the crossover board,
ŝŶƐƚĂůůƚŚĞďĂŋĞ͕ƚŚĞŶZŽĐŬKƵƚ
ϐǡǯ
ǡǡǤ ǡ
Ǥ

Ǥǡ
ǡ
Ǧ Mount assembled crossover boards.
Ǥǡ &ŝŶĚĂůŽĐĂƟŽŶŽŶĂƐŝĚĞǁĂůůǁŚĞƌĞ
Ǥǡ nothing will interfere with the crossover.
ǤϐǡϐϐǤ ^ƉƌĞĂĚǁŽŽĚŐůƵĞŽŶƚŚĞďŽƩŽŵŽĨƚŚĞ
ǡϐ crossover feet, and press them into place
Ǥǡ for a minute or two. Set aside to dry.
Ǥ

Ǩ

ǤǨ
Weather
stripping
ensures a
good seal on
the cabinet.
/ŶƐĞƌƚĚĂŵƉŝŶŐŵĂƚĞƌŝĂů͘ Cut to size and insert, but be careful not to block the port.
Sweet Spot Setup
Viewed from above, speakers ƩĂĐŚůĞĂĚƐƚŽĚƌŝǀĞƌƐ͘
and the listener should form Each driver has a “+”
an equilateral triangle. Most and a “-” terminal (plus
speakers sound best placed ŝƐƐŽŵĞƟŵĞƐĐŽĚĞĚ
at least a yard from large red). It’s important to
surfaces like walls or large use correct polarity
TVs. The listening seat should ƉĞƌŬŝƚŝŶƐƚƌƵĐƟŽŶƐ͘dŽ
also be in the open. While ĂƩĂĐŚǁŝƌĞƐ͕ĞŝƚŚĞƌƵƐĞ
real-world compromises are the included push-on
ŽŌĞŶŝŶǀŽůǀĞĚ͕ǇŽƵŽǁĞŝƚ connectors or solder
to yourself to listen to these the wires directly to
speakers at least once in the the driver terminals. Be
ŝĚĞĂůĐŽŶĮŐƵƌĂƟŽŶďĞĨŽƌĞ sure the driver gaskets
tucking them against the wall. ĂƌĞŝŶƉŽƐŝƟŽŶďĞĨŽƌĞ
ĂƩĂĐŚŝŶŐůĞĂĚƐ͘

Joinery Class
Tongue-and-Groove
Making Perfect Tongue-and-Groove Joinery
on the Router Table
By Andy Rae
Edge-to-Edge End-to-Edge
Solid wood paneling, Groove Web frames,
cabinet backs, frame-and-panel
ŇŽŽƌŝŶŐ assemblies
^ƟůĞ
Rail
Plywood
Tongue
Wood edging
Edging ŽŵŵŽŶĂƉƉůŝĐĂƟŽŶƐ͗
Shelving,
cabinet sides • Edging
• Web frames
• Cabinet backs
• Wall paneling
• Flooring
W ith its relatively short

ϐ

ǡ

ǯ
groove the tongue and groove Ǥ
ǯ ǡ ϐȄ
ǦǦǤ
ǡǯ Ǥ using a straight bit rabbeting
ǡ ǯǣǡ ǡ
Ǥ ǯǤ ǡ
ǯ Ǥ
ǡ ǡǡ With a tongue and groove bit
ϐ ϐ or bits in your router table
ϐȋ ǡ
ǡʹǦǡ ǡǯ
ǤȌ ǲǳ Ǥ
DŝůůƐƚŽĐŬ
ĂƐŝĐdΘ'ĞƐŝŐŶ ǁŝƚŚƐƚƌĂŝŐŚƚ
ĂŶĚƉĂƌĂůůĞů
ĞĚŐĞƐ͘
For strength and aesthetics the 'ƌŽŽǀĞĚŝŵĞŶƐŝŽŶƐ͗

tongue should slip snugly into
1
Ш4 Ͳ3Ш8ΗǁŝĚĞп1Ш4 Ͳ1Ш2ΗĚĞĞƉ
its groove whether the joint dŽŶŐƵĞĚŝŵĞŶƐŝŽŶƐ͗
is to be glued or not Making &ŝƫŶŐƚŚĞ:ŽŝŶƚ 1
Ш4 Ͳ3Ш8ΗƚŚŝĐŬп1Ш4 Ͳ1Ш2ΗǁŝĚĞ
^ŚŽƵůĚĞƌƐŵĞĞƚ
the tongue about one third ĂƚũŽŝŶƚůŝŶĞ͘
the thickness of the stock DĂŬĞƚŽŶŐƵĞĂƚůĞĂƐƚŽŶĞͲƚŚŝƌĚ
ensures that all parts of the ƚŚĞƚŚŝĐŬŶĞƐƐŽĨƐƚŽĐŬĨŽƌƐƚƌĞŶŐƚŚ͘
ϐǤ >ĞĂǀĞƐŵĂůůŐĂƉďĞƚǁĞĞŶƚŽŶŐƵĞĂŶĚ
ŐƌŽŽǀĞĨŽƌĂƟŐŚƚĮƚĂƚƐŚŽƵůĚĞƌƐ͘
ZŽƵƚĞƌdĂďůĞ ^ƉĞĞĚ
ĐŽŶƚƌŽůĚŝĂů
ƌĞƐƐǇKƉƟŽŶ
^ŽŵĞƌŽƵƚĞƌďŝƚ
^ĞƚƵƉ ŵĂŶƵĨĂĐƚƵƌĞƌƐŽīĞƌŵĂƚĐŚŝŶŐ
ďŝƚƐĞƚƐƚŚĂƚŝŶĐŽƌƉŽƌĂƚĞ
When routing tongue and groove ĂďĞǀĞůŝŶƚŚĞƉƌŽĮůĞ͘
joints consistency is key for dŚĞƌĞƐƵůƟŶŐsͲŐƌŽŽǀĞƐ
ϐǤ ŝŶƚŚĞĂƐƐĞŵďůĞĚƉĂŶĞů
For predictable results use ĂĚĚĂŶĂĞƐƚŚĞƟĐĞůĞŵĞŶƚ
the right tools accessories Dial it down.hƐĞĂǀĂƌŝĂďůĞͲƐƉĞĞĚ ǁŚŝůĞŚŝĚŝŶŐĂŶǇƐůŝŐŚƚ
Ǥ ǡǯ ƌŽƵƚĞƌ͕ĂŶĚŬĞĞƉǇŽƵƌƐƉĞĞĚĂƌŽƵŶĚ ŵŝƐĂůŝŐŶŵĞŶƚŽĨƚŚĞƉĂƌƚƐ͘
to use a powerful router with ϭϱ͕ϬϬϬZWDƚŽůŽǁĞƌǀŝďƌĂƟŽŶĂŶĚ
variable speed control to ensure ƌĞĚƵĐĞƐƚƌĞƐƐŽŶƚŚĞƌŽƵƚĞƌĂŶĚďŝƚ͘
ǡ
these big heavy bits Make sure your router table is equipped V-groove paneling
ǡϐǡǦǤ
Alternatively you can saw out an opening for the bit in a thick
ǡǤ
ǡ
pushsticks and pushblocks keep your hands safe Tongue and
groove bits create a lot of chips so dust collection is crucial
ĞĐŽƌĂƟǀĞs
dŚĞƌŝŐŚƚƐƚƵī͘&ŽƌƟŐŚƚ͕ĐƌŝƐƉũŽŝŶƚƐ͕ĞƋƵŝƉǇŽƵƌƚĂďůĞǁŝƚŚĂϭ1Ш2ŚƉ
;ŽƌŵŽƌĞͿǀĂƌŝĂďůĞͲƐƉĞĞĚƌŽƵƚĞƌ͕ĂƐƉůŝƚĨĞŶĐĞ͕ĂĨĞĂƚŚĞƌďŽĂƌĚ͕ĂŚĞŌǇ
ƉƵƐŚďůŽĐŬ͕ĂƉůǇǁŽŽĚƉƵƐŚƐƟĐŬ͕ĂŶĚƚŚƌŽƵŐŚͲƚŚĞͲĨĞŶĐĞĚƵƐƚĐŽůůĞĐƟŽŶ͘
WŚŽƚŽƐ͗ŶĚǇZĂĞ͖/ůůƵƐƚƌĂƟŽŶƐ͗ŚƌŝƐƚŽƉŚĞƌDŝůůƐ Oct/Nov 2016 ǁŽŽĚĐƌĂĨƚŵĂŐĂǌŝŶĞ͘ĐŽŵ 61

Joinery Class
Making the joint with a 2-bit set

Using a mating piece set of router bits is one of the most ZŽƵƚƚŚĞŐƌŽŽǀĞĮƌƐƚ͘͘͘
ϐǤ
ϐǤǯ
the front face of the fences and then center the cutter across
the thickness of test stock milled to the desired dimensions
Use a featherboard and a pushstick to make the cut routing the
groove in a single pass Rout the tongue next using the routed
groove to help set the tongue to the correct height and again
ǯǤ
ϐǡ
rout as before feeding smoothly with consistent pressure
Tongue ϮͲĐƵƩĞƌ
ĐƵƫŶŐďŝƚ ŐƌŽŽǀŝŶŐďŝƚ
Nut
Bearings
<ĞĞƉƚŚĞŐƌŽŽǀĞƐŵŽŽƚŚ͘
ĨĞŶĐĞͲŵŽƵŶƚĞĚ
Spacers ĨĞĂƚŚĞƌďŽĂƌĚĞŶƐƵƌĞƐ
Washer ĂŐƌŽŽǀĞƚŚĂƚ͛ƐƉĂƌĂůůĞůƚŽƚŚĞďŽĂƌĚĨĂĐĞƐ͘
DĂƟŶŐďŝƚƐĨŽƌĞĸĐŝĞŶĐǇĂŶĚĂĐĐƵƌĂĐǇ͘ This 2-piece set from hƐŝŶŐĂƉƵƐŚƐƟĐŬŬĞĞƉƐŚĂŶĚƐĐůĞĂƌŽĨƚŚĞ
&ƌĞƵĚĂĐĐŽŵŵŽĚĂƚĞƐƐƚŽĐŬƚŚŝĐŬŶĞƐƐĞƐĨƌŽŵ1Ш2" to 11Ш4". One ĐƵƩĞƌƐǁŚŝůĞŽīĞƌŝŶŐŵŽƌĞĐŽŶƚƌŽůĨŽƌĂ
ŽĨƚŚĞďŝƚƐĐƵƚƐƚŚĞƚŽŶŐƵĞ͕ĂŶĚƚŚĞŽƚŚĞƌƚŚĞŐƌŽŽǀĞ͘zŽƵĐĂŶ smoother cut. For consistency, make all cuts
ĮŶĞͲƚƵŶĞƚŚĞĐƵƚŽŶďŽƚŚďŝƚƐďǇĂĚĚŝŶŐŽƌƐƵďƚƌĂĐƟŶŐƐƉĂĐĞƌƐ͘ with the “show” face against the table.
ZŽƵƟŶŐŶĚƐ
Cutting tongues on the ends
of work is handy for rail
connections such as when
making web frames for drawers
and other case components
Narrow rails can be tippy
against the fence so you ll
want to back up the cut with
a pushblock for safe square
cuts Bonus The block prevents
tearout at the same time
ĂĐŬŝƚǁŝƚŚĂďůŽĐŬ͘hƐĞĂƐƋƵĂƌĞĚƉƵƐŚďůŽĐŬƚŽŬĞĞƉƚŚĞǁŽƌŬƉŝĞĐĞƐƚĞĂĚǇĂŐĂŝŶƐƚ
ƚŚĞďŝƚ͛ƐďĞĂƌŝŶŐĂŶĚƚŚĞĨĞŶĐĞƐǁŚŝůĞǇŽƵƌŽƵƚ͕ĂŶĚƚŽƉƌĞǀĞŶƚƚĞĂƌŽƵƚĂƚƚŚĞďĂĐŬ͘
62 ǁŽŽĚĐƌĂĨƚŵĂŐĂǌŝŶĞ͘ĐŽŵ KĐƚͬEŽǀϮϬϭϲ

...then tackle the tongue
WůǇǁŽŽĚƐƉĂĐĞƌ
Eyeball the height. Set the tongue bit’s Rout the tongue in one pass.<ĞĞƉƚŚĞƉƌĞƐƐƵƌĞƐƚĞĂĚǇďǇ
ŚĞŝŐŚƚďǇůŝŶŝŶŐƵƉŝƚƐĐƵƫŶŐĞĚŐĞƐ ďƵŵƉŝŶŐŽƵƚƚŚĞĨĞĂƚŚĞƌďŽĂƌĚǁŝƚŚƐĐƌĞǁƐĂŶĚƉůǇǁŽŽĚ
with the groove, and then make a test ƐƉĂĐĞƌƐƚŽĐůĞĂƌƚŚĞƚĂůůĞƌĐƵƩĞƌ͘hƐĞĂƉƵƐŚƐƟĐŬĂƐďĞĨŽƌĞ
ĐƵƚŝŶƐĐƌĂƉƚŽǀĞƌŝĨǇǇŽƵƌƐĞƫŶŐ͘ for a smooth tongue with a consistent thickness and width.
T&G for Less A Good Lookin’ Fit

&ŽƌĂƌŽƵŶĚΨϱϬ͕ǇŽƵĐĂŶďƵǇ A well-made tongue-and-groove joint presents a gapless seam
a single WoodRiver bit that ĂůŽŶŐƚŚĞƐŚŽƵůĚĞƌƐ͕ŽƌĨĂĐĞ͕ǁŝƚŚĂƚŽŶŐƵĞƚŚĂƚĮƚƐƐŶƵŐůǇ
will cut tongues and grooves ŝŶƚŽƚŚĞŐƌŽŽǀĞ͘dŽĞŶƐƵƌĞƟŐŚƚƐŚŽƵůĚĞƌƐ͕ůŽŽŬĨŽƌĂŚĂŝƌůŝŶĞ
in 3Ш4ΗͲƚŚŝĐŬŵĂƚĞƌŝĂů͘hƐĞďŽƚŚ ŐĂƉďĞƚǁĞĞŶƚŚĞĞŶĚŽĨƚŚĞƚŽŶŐƵĞĂŶĚƚŚĞďŽƩŽŵŽĨƚŚĞ
ĐƵƩĞƌƐƚŽŵĂŬĞƚŚĞƚŽŶŐƵĞ͖ groove. Some manufacturers build this into their bit design. If
ƚŚĞŶƵƐĞĂƐŝŶŐůĞĐƵƩĞƌĨŽƌƚŚĞ ǇŽƵƌƚŽŶŐƵĞďŽƩŽŵƐŽƵƚ͕ŵĂŬĞĂƉĂƐƐǁŝƚŚƚŚĞƚŽŶŐƵĞ͛ƐĞĚŐĞ
ŐƌŽŽǀĞ͘^ĞĞƵǇĞƌ͛Ɛ'ƵŝĚĞ͕ on the jointer or with a couple swipes from a hand plane.
Ɖ͘ϲϰĨŽƌŽƌĚĞƌŝŶŐŝŶĨŽƌŵĂƟŽŶ͘
Groovy joint. You
can make wide
panels, such as
for cabinet backs,
ďǇũŽŝŶŝŶŐĂƐĞƌŝĞƐ
of tongue-and-
groove boards
together. A good
ũŽŝŶƚƐŚŽǁƐƟŐŚƚ
shoulders with a
small gap visible
inside the joint.

Buyer’s Guide
Mini-Workbench (p. 24)
1. WoodRiver 10-piece Router Bushing Set with Case.................................................................... #144625, $42.50
2. Whiteside RU4900 Solid Carbide Spiral Upcut Router Bit, 3Ш8"D × 11Ш4"CL × 1Ш2"SH..................... #08K61, $55.99
3. #10 × 3" HIGHPOINT Cabinet Installation Screws (washer head), 100-count box...................... #618101, $18.99
Serving Tray (p. 30)

1. Over-Under Flush Trim Router Bit, 1Ш2"D × 1"CL × 1Ш4"SH............................................................ #147970, $26.99
2. Freud LU84R011 Perma-Shield Circular Saw Blade

10" × 5Ш8" Bore × 50 Tooth Combination (ATBR).......................................................................... #127241, $73.47
Southern Huntboard (p. 36)

1. Southern Huntboard wood package. Poplar, cherry, or walnut. $199-$499,
plus shipping. (Price varies with wood species. Packages will include overage.)
Contact City Hardwoods 205-777-3647, or go to cityhardwoods.com.
2. Razorsaw Kataba Saw 255mm No. 105 with Replaceable Blade – Gyokucho ............................ #155690, $40.00
3. WoodRiver Vertical Handle Toggle Clamp,

21Ш8 x 31Ш8", 100 lbs. Capacity ...................................................................................................... #144312, $12.59
4. WoodRiver Knob Five Star with Through Hole, 3Ш8"-16 Insert (4 needed) .................................... #142225, $1.99
5. General Finishes Enduro-Var Top Coat Semi-Gloss, quart........................................................... #151028, $32.99
Toy Trucks from 2×4s (p. 45)

1. Freud Precision Shear 3Ш4"D Forstner Bit ..................................................................................... #832875, $11.99
2. Magswitch Universal Magnetic Featherboard ............................................................................ #148442, $48.99
3. Birch Dowel, 1Ш4" Round................................................................................................................... #50D01, $1.25
4. Wheels, 11Ш4"D × 3Ш8"W with 1Ш4" Axle Hole (12 pack) .....................................................................#50S41, $3.98
5. Grex 23-Gauge 13Ш8" Headless Pin Nailer .................................................................................. #826278, $189.99
ŝƐĐƵŝƚ:ŽŝŶĞƌtŽƌŬƐƚĂƟŽŶ(p. 50)
1. WoodRiver Knob, Four Arm with 1Ш4"-20 × 11Ш2" stud (2 needed) .................................................. #27R15, $3.99
2. Porter-Cable Deluxe Plate Joiner Kit ......................................................................................... #813666, $224.99
3. Threaded Insert - Brass, 1Ш4"-20 8-pc. (4 needed) ..........................................................................#159290, $6.99
Awesome Audio (p. 53)

1. Overnight Sensation Speaker Kit ..............................................................................meniscusaudio.com, $130.24
2. Conformable Weather-resistant Vinyl Foam Adhesive-back

1
Ш8" thick × 1Ш4" wide × 17' long.........................................................................#93675K11, mcmaster.com, $1.68
3. Weller WLC100 40-Watt Soldering Station ...........................................................................amazon.com, $39.75
4. Alpha Metals #AM31605, 60-40 Rosin Core Solder ................................................................amazon.com, $9.15
5. Jasper Circle Jig, Small, 1"-71Ш2" ................................................................................................... #143735, $24.99
6. Whiteside Spiral Upcut Router Bit, 1Ш4"D × 1"CL × 1Ш4"SH ............................................................. #03K33, $20.99
7. WoodRiver Flush Trim Router Bit, 1Ш2"D × 1"CL × 1Ш4"SH............................................................. #129684, $15.99
8. Titebond Original Wood Glue, 16 oz. ...............................................................................................#08L21, $4.99
9. Maple 4×8' Veneer Sheet 10mil, Paper Backed .......................................................................... #404182, $74.38
Joinery Class (p. 60)

1. WoodRiver 1Ш4" Tongue And Groove Router Bit, 1Ш2" SH ............................................................. #140802, $59.99
2. Freud 99-036 2-Piece Adjustable Tongue And Groove Router Bit Set, 1Ш2" SH ........................... #825745, $79.97
3. Whiteside 3370 Wedge Tongue And Groove (2) Router Bit, 11Ш4"D × 11Ш4"CL × 27Ш8"OL.......... #818625, $128.99
4. Whiteside 3374 Vee Panel Tongue And Groove (2) Router Bit, 13Ш4"D × 1"CL × 23Ш4"OL ......... #814403, $154.99
5. Freud 99-191 V Panel Router Bit Set, 1Ш2" SH ............................................................................ #834291, $177.47
6. CMT 855.506.11 V-Tongue and Groove Router Bit Set,

1
Ш2"SH × 3Ш4" MinJT-1" MaxJT 1 × 3Ш4"D ...................................................................................... #822356, $179.99
Unless otherwise listed, items above available at Woodcraft stores, at woodcraft.com,

or by calling (800) 225-1153. Prices subject to change without notice.

“American Made for the American Woodworker”
NEW! Whiteside CNC Router Bits

Make your designs come to life with Whiteside CNC router
bits available in two sets – Starter Set and Ball Nose Set
– and individually. Each router bit can be used in a variety
of CNC carving applications such as stock removal, signs
and intricate detail work. Solid carbide. Made in the USA.
161278 (A) 1/16" Ball Nose Bit 24B71 (F) 90° V Bit
161279 (B) 1/8" Ball Nose Bit 24B81 (G) 60° V Bit
161280 (C) 3/16" Ball Nose Bit 161282 Ball Nose Set, 3-Pc. (B, C, D)
161281 (D) ¼" Ball Nose Bit 161283 Starter Set, 5-Pc. (A, B, E, F, G)
818081 (E) ¼" Up Cut Spiral Bit
(A) (B) (C) (D) (E) (F) (G)
Available at • Visit woodcraft.com Or Call 800-225-1153.

Whiteside Machine Co., Claremont, North Carolina • 800-225-3982 • whitesiderouterbits.com
Ad Index
PRODUCT Website Page
Adhesives WŽǁĞƌĂƌǀŝŶŐ dƵƌŶŝŶŐ^ƵƉƉůŝĞƐ
Satellite City .......................caglue.com ....................................................18
King Arthur’s Tools .............katools.com ................................................... 20 Berea Hardwoods ..............woodcraft.com ..............................................13
Titebond .............................titebond.com .................................................26
Fred Wissen Designs ..........ptownsubbie.com..........................................70
ŝƚƐ͕ůĂĚĞƐ͕ΘƵƩĞƌƐ WŽǁĞƌdŽŽůĐĐĞƐƐŽƌŝĞƐ
Ring Master ........................ringmasterlathe.com ....................................70
Forrest Mfg.........................forrestblades.com .........................................11 Kreg ....................................kregtool.com ................................................ 22
Robert Sorby ......................robert-sorby.co.uk .........................................64
Freud ..................................woodcraft.com/Freud...................................IFC WŽǁĞƌdŽŽůƐ
Teknatool............................teknatool.com ...............................................52
Whiteside Machine ............whitesiderouterbits.com ...............................65 CR Onsrud ..........................cronsrud.com ...............................................12 tŽŽĚΘsĞŶĞĞƌƐ
Clamps and Hold-downs
Digital Wood Carver ...........digitalwoodcarver.com .................................70 Cook Woods .......................cookwoods.com ............................................21
Blokkz .................................blokkz.com ....................................................70
Epilog..................................epiloglaser.com .............................................10 Northwest Bamboo............nwbamboo.com ............................................71
ƵƐƚŽůůĞĐƟŽŶ
Kutzall .................................kutzall.com ....................................................19 West Penn Hardwoods ......westpennhardwoods.com ............................71
American Fabric Filter.......americanfabricfilter.com .............................23
Woodfinder ........................woodfinder.com ............................................71
Karcher ...............................woodcraft.com ..............................................13 Laguna Tools.......................lagunatools.com ........................................OBC
Oneida ................................oneida-air.com ..................................... 11 & 66
tŽŽĚǁŽƌŬŝŶŐ^ƵƉƉůŝĞƐ
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Finishing
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General Finishes.................generalfinishes.com ......................................52 Brand First ..........................brand-first.com .............................................70
Rikon...................................rikontools.com................................................. 1 Harbor Freight....................harborfreight.com...........................................7
Howard...............................howardproducts.com ....................................13
Touch-up Solutions [email protected] ...................70 SuperMax ...........................supermaxtools.com.......................................14 PS Wood .............................pswood.com ..................................................70
Hand Tools Wagner Sprayers...............wagnerspraytech.com ............................... IBC Royalwood Ltd....................royalwoodltd.com .........................................70
Thomas Flinn & Co. ............flinn-garlick-saws.co.uk.................................11 Rustoleum ..........................rustoleum.com ..............................................67

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The American Woodshop ....wbgu.org/americanwoodshop .......................22
National Hardware.............natman.com ..................................................71 Tanos ..................................woodcraft.com ..............................................18
CT Valley School of WW .....schoolofwoodworking.com...........................23
DŽŝƐƚƵƌĞDĞƚĞƌƐ Woodcraft Franchise ..........woodcraftfranchise.com .................................9
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Wagner Electronics ...........wagnermeters.com ......................................17 DMT....................................dmtsharp.com ...............................................21 Woodpeckers .....................woodpeckers.com ...........................................5

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WoodSense
Spotlight on Elm
WŝĐŬǇŽƵƌĨĂǀŽƌŝƚĞŇĂǀŽƌĨŽƌǇŽƵƌŶĞǆƚƉƌŽũĞĐƚ
By Joe Hurst-Wajszczuk
Red Elm White Elm
A century ago Dutch Elm

Disease DED decimated
ǣ ǡ
ǯǦ
creamy white to darker brown
the darker heartwood can
millions of elm trees many be easily confused with red
of which adorned American Ǧϐ White elm may show some
city streets Fun fact Elm Ǥǡ staining but this does not affect
is the th most common the wood s integrity Red elm
street name in the USA The under normal conditions elm remains in the darker red
encouraging news is that these
fast growing trees are enjoying contact with water This unusual
a comeback Elm lumber still ϐ Ǥ
isn t as readily available as ǡǡ ǡ
other domestic hardwoods ǦǤ mindful of the grain The wild
ϐ days elm is best reserved for ϐ
tricky but it s worth the hunt ǡ ȋǦϐ
This striking hardwood Ǥ due to alternating grain are
is affordable and easy to enchanting but elm s working
Ǥ Where the wood comes from
Elms grow east of the Rockies
are often intermixed in kilns from Southern Canada to
and lumber racks Two of the northern Florida Although
Elm Quick Take
most common varieties Ǧϐ White Red
White Ulmus americana and in where old elms have fallen DENSITY ϯϱůďƐͬ͘Ō3 ϯϴůďƐͬ͘Ō3
Red Ulmus rubra share
HARDNESS ^ŽŌ Medium
many characteristics but to DED As a result researchers
STABILITY Low
Ǥ disease resistant hybrids These ROT/INSECT Low
new trees blend characteristics RESISTANCE
the best stock from the stack ǡ TEXTURE Coarse
ϐǤ TOXICITY Low
History in Woodworking
How to select the best stock Chair spindles and seats,
ǡ USES ďŽĂƚƐ͕ĐŽĸŶƐ͕ƐƉŽƌƟŶŐ
ĞƋƵŝƉŵĞŶƚ͕ĚĞĐŽƌĂƟǀĞ
ǡ ƚƵƌŶŝŶŐƐ͕ǀĞŶĞĞƌ
attributes lending themselves to names White ranges from
Red Elm
&ůĂƚƐĂǁŶǁŝƚŚďƵƌů ZŝŌƐĂǁŶ
ϐ ǡ
ϐǤ ǡ
White Elm
Ǧǡ Ǥ
ǡ ǡ
ǯǤ ǡǤ
ǡ ǡ &ůĂƚƐĂǁŶ
ǡǯ
ǤǦ Ǥ

ǡ

Ǥ Ǥǯ
ǡ
Ǧ
ϐǤ Ǥ

Working elm in the shop
ǡ ǣ
Ǥȋ Ǩ ZŝŌƐĂǁŶ
ϐǤȌ
ǡϐ Finishing
ǡǡǦ
Ǥ ǡ
Ȁ
Heartwood
ǡ ǡ
Ǥ ǡ
Ǥ
ǡ
Ǥ Ǥϐ
Ǧ Ǥ
Ǥ ϐǡ
ǡ
ǡ Ǥ
Ǥ
WŚŽƚŽƐ͗>ĂƌƌǇ,ĂŵĞůͲ>ĂŵďĞƌƚ Oct/Nov 2016 woodcraftmagazine.com 69
The Market
D A B LY
A F F O R
C R E AT E & C A R V E
projects
FOR HOME & PROFIT
GREAT FOR Custom Engravers

Woodworkers/ Craft Makers
Artisans Sign Designers
[email protected] 317- 409-1450

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DIMENSIONAL LUMBER,
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The Market
Contact: Vic Lombard
30 issues packed with projects and detailed at (304) 865-5262
ŝŶƐƚƌƵĐƟŽŶƐŽŶŚŽǁƚŽďƵŝůĚƚŚĞŵ͘WůƵƐ͘͘͘ or e-mail at:
Vic_Lombard@
• Techniques ǁŽŽĚĐƌĂŌŵĂŐĂǌŝŶĞ͘ĐŽŵ
• Tool reviews
ͻ:ŝŐƐΘĮǆƚƵƌĞƐ
• Workshop projects
• Tips
Volume
Issue 32-61 2
To order product #161370 visit www.woodcraft.com or visit your local Woodcraft store.

Since 1928, Woodcraft has been committed to providing quality tools, supplies and advice to
our customers. From providing in-store classes and demonstrations to funding educational
woodworking programming, Woodcraft has remained steadfast in our commitment to the
beginner, intermediate and experienced woodworker for over 80 years running.
The American R OB
COSMAN
Woodshop “YOUR HAND TOOL COACH”
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The American Woodshop with Scott and the EmmyÆ Award-nominated public television series Rob Cosman,“Your Hand Tool Coach,” featured
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auctioned to help fund the Furniture Bank of Central showcasing some of the home shops of some of the motivational and educational way. Hand-tool dem-
Ohio and The Rio Grande Woodworking scholarship. country’s top woodworkers. Featured woodworkers onstrations are Tuesdays and Thursdays, and power
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For A Free Catalog Or To Find Your Local Woodcraft Store, Visit woodcraft.com Or Call 800-225-1153. 16WD11P

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Projects, Techniques, and Products

French Door Premier Adjustable Entry & Interior

Item #98-318 Item #99-762 Item #98-300

UNLEASH YOUR CREATIVITY WITH

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2 woodcraftmagazine.com Oct/Nov 2016 ŽǀĞƌƉŚŽƚŽ͗ZĂůƉŚ>ĞĞŶĚĞƌƐŽŶ

18• ATips & Tricks

4 woodcraftmagazine.com Oct/Nov 2016

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Bill Schneider still remembers the giant

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“After 30 years in the travel

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© 2016 Forrest Manufacturing

Oct/Nov 2016 woodcraftmagazine.com 11

Wood, steel, concrete…what’s next? Enter the California

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Please include your full name, address,

12 woodcraftmagazine.com Oct/Nov 2016

• Onboard Power Tool Outlet

NEW! Franklin Ballpoint Pen Kits

Oct/Nov 2016 woodcraftmagazine.com 13

dŚĞĨĂďƵůŽƵƐ;ĂŶĚĮŶĂůͿ>ŽŚƌĨŽƵƌ͘ƚĞƌƌŝĮĐƚĞĂŵ Now available on

After building his business for years

Photos: Randy O’Rourke Oct/Nov 2016 woodcraftmagazine.com 17

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/ůůƵƐƚƌĂƟŽŶƐ͗ŚƌŝƐƚŽƉŚĞƌDŝůůƐ Oct/Nov 2016 woodcraftmagazine.com 19

The Nick Agar Signature Series includes custom designed accessories,

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Oct/Nov 2016 woodcraftmagazine.com 21

Drilling sheet metal

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22 woodcraftmagazine.com Oct/Nov 2016

A traditional workbench provides a solid

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Photos: Paul Anthony, courtesy Taunton Press Oct/Nov 2016 woodcraftmagazine.com 27

2.ƐƉůŝƩĞƌŽƌƌŝǀŝŶŐŬŶŝĨĞ͘A properly aligned 5. A shoe-style pusher. For best control,

Resawing in a single pass

28 woodcraftmagazine.com Oct/Nov 2016

Flip and repeat. ZŽƚĂƚĞƚŚĞƉŝĞĐĞĞŶĚͲĨŽƌͲĞŶĚ͕ǁŝƚŚƚŚĞƐĂŵĞĨĂĐĞ Smooth follow-through. &ŽƌƐĂĨĞƚǇ͛ƐƐĂŬĞ͕ƵƐĞĂƉƵƐŚĞƌƚŽ

Oct/Nov 2016 woodcraftmagazine.com 29

W hen some good friends got married recently

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See Handle Detail

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