Wood Magazine 158 2004 PDF

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October 2OO4,lssue 158
12 perfect-scoremarkinggauge
(xJ2
F;
38 top-drawer sawbladeorganizer
40 Arts& Craftsbed
50 tilting-bin
spicerack
63 mitershooting board ('
M go-anywhere toolcaddy G
72 kids'giratfebank
77 clamshellcabinetdoors
78 quick-to-makeclamprack 50
10 pointers
for router-table
starterpins
16 getthemostfroma marking gauge
34
48
fast,accuratetemplate
make-it-yourself
routing
missionfinish
,o/: /
thatproAlanNoelusesto
Trythesimpleformula
imitate
thefumedfinishes
of old.
60 theplanetruthaboutbetterioinerv
Discover
threehand-plane
methods
forcieatinq
seamless,
fail-safe
edge joints.
andmiter
70 success
withstaining
andfinishing
76 workshop
workover
Find
thecures ailsyourworkspace
forwhatever as
IheW00Dgangremedies
a reader's
messy shop.
86 guideto perfectglue-ups
project
Learnto makerock-solid assemblies. '"'
*'. dfj'
20 13bladeandbit cleaners
tested
80 6x48"belUdisc
sanders reviewed
Tenmodels
dukeit outfor besttoolandbestvalue.
s rated:fourshop-proven
products
6 editor's
angle
I soundingboard
24 shortcuts
28 shoptips
g2 askW00D Thissealisyourassurancethatwe
buildeveryproject,
verifyeveryfact,
110 what'sahead andtesteveryreviewed toolinour
t0 guarantee
workshop yoursuccess
andcomplete
satisfaction.
woodrnagazine.corn
Better llomes and Gardenso
2004
0clober
WffiOD. V o l2. 1 ,N o 5.
EDITOR-IN-CHIEF
No.158
lssue
BILLKRIER
Editor Managing
Executive Editor
JIMHARROLD MARLEN KEMMET
Editor ToolEditor
Desion
Senior
xrvlilnoYtr DAvE
cAMPBEIL
Editor
Editor Techniques
Techniques
DAVIDSTONE B()BWILSON
Editor
Editor Prolects
Prolects
()WEN DUVALL JANSVEC
Editor MasterCraftsman
Design
JEFFMERTZ CHUCK HEDLUND
Art Director
Art Director Associate Assistant
Art Director
KARTEHLERS GREG SELLEBS CHERYL A. CIBUTA
Manager AdministrativeAssistant
Production/0tfice
MARGARET CLOSNER SHERYL MUNYON
raphers
Photog
MARTYBALDWIN, MOATS,
LITTIE,BTAINE
SCOTT JAYWILDE
LETTHE
Owen builtthis missionend table
out of quartersawnwhite oak. lllustrators
TORNA
TlMCAHILL. ROXANNE
J()HNS()N. MIKEMITTERMEIER
LEMOINE,
SIJNSHINE
Technical
Consultants
DEANFIENE,JEFFHALL
JOHNCEBUHAR,
Contributing
Craftsman
JIMHEAVEY
Proofreaders
BARBARA
KrEtN, MllgllEljltlll!,,:_
JtMSAND,ERS, .>-
Senior B0BMATE
VicePresident
WILLIAM
VicePresident R. REED
MARKHAGEN
Publisher
ADVERTISING
OFFIGE:333N.Michigan lL 60601
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l['hc Minclc Skvliqht WOOD rnagazine October 2004
-
@ditoFtSangle
POBTER-CABLE@ continues to
proueits cutting-edge
anddesign
innovation
withlheselatesttools.
Doesyourshgp
;r Q>
belbng in rehaH
I Minedoes.Overtime it's
,{ becomeclutteredand cov-
eredin dust.And althoughI
alwaysmanageto somehow
7-114 MAG-SAW'" KIT get my projectsbuilt,I know
Change without
blades gears.
changing
first-ever
Thisaward-winning, Quik'Change" my shop needsreorganizing.
sawprovides
circular a fastandhassle-free lf yourshop needsa little
system blades
forchanging makingyoumore
onthejobsite.
productive help,too, you'llenjoythe new
modelswithor withouta brake.
andblade-right
in blade-left
Available
"WorkshooWorkover"feature
in thisissue. '\,i*
C;
From left, TechniquesEditor Dave Stone, reader
t
Jerry Mertens,and Senior Design Editor Kevin Boyle
in Jerry's worked-overworkshop.
VARIABLE.SPEEII DUAT ACTIOII
TIGER SAW.KIT
putsanend ow much moreefficientwould prettymuch what we werelooking for: not
backhandle
rotating
A revolutionary
you be in your workshopif you a completedisaster,but a working shopin
toturningyourbodyto getmoreleverage.
neverhad to hunt for a sharppen- big-timeneedof betterefficiency,storage,
Plusanextra-heavy-duty11.5AMPmotorfor
cil, track down a tapemeasure,or scrounge and organization.Tools and supplieswere
maximum powerfor allcuttingcapacities
and
up a missingfastener? What if you could hardto find amongfishing gearandtro-
bladeclampQuik-Changd forkeylessblade
simplymoseyfrom oneendof your shop phies.Soundfamiliar?
change inseconds.
to the otherwithout steppingover and And that'swhenSeniorDesignEditor
aroundobstacles? Would you enjoyyour Kevin Boyle andTechniques EditorDave
shoptime evenmore?We're bettingyou Stoneswunginto action.Armedwith pho-
would,andthat'swhy we're introducing tos andfloor layoutsof Jerry'sshop,they
our new series"WorkshopWorkover" on brainstormedwaysto betterit.
page76 to help you get organized. Now, it wouldhavebeeneasyto simply
We approached this articlequite differ- throw moneyandnew toolsat Jerry'sshop.
Fll{lSH BRAD
l'lAlLER/ ilAlLER ently thanour five IdeaShopsfrom the That wouldn'tbe especiallyhelpfulto most
COMPRESSOR COMBO KIT past12 years.In thosewe built a shinynew of you, so I gaveKevin andDavetwo
Haveeverythingonhandwiththisspecialedi- workshopfrom scratchand packedit full of restrictions:they were to spencino more
combo
tiontwo-nailer withboth
kitcomplete projectsand ideasyou could adaptto your than$1,000on materialsandbe in Jeny's
BradandFinisher and2 peakHE.8 HP
Nailers shop.A big undertaking,for sure,but one shopfor only two days.
running pancake
6-gallon Also
compressor. that provedworth it becauseof how much What theydid within thoselimitations
depth-otdrive,
anadjustable
includes iam- readersembracedthe results. wasremarkable, provingthatyou don't
releasemechanism nosetip.
andnon-marring But aftercompletingIdea Shop5 one haveto investa ton of time or moneyto
year ago we wonderedif we could takethe drasticallyimproveyour shop.
Formorecutting-edge shop-improvement conceptandmakeit And what did Jeny think of the entire
lromP0RTER-CABLE',
innoualions evenmorepracticaland affordablefor you. experience? He wasthrilledasyou cantell
visilporter-oable.com. After a lot of discussion, we decidedto in the photoabove.Not only washis shop
takeon the rehabbingof a reader'swork- madefully functional,but Kevin and Dave
shop.So in the Octoberissuewe askedyou evenfound spotsfor his fishing stuff.
to submityour shopsfor consideration. Not
surprisingly, a flood of submissions (397in
*S
total)ensued. r,$h.
From those,we selectedJeny Mertens'
shopin Forsyth,Missouri.His spacewas
iifi{H
Y^!A"W
WooD magazine October ZOOq
soundin boar,'C
boardforletters,
Ourbulletin andtimelyupdates
comments,
No lathe?No problem.Readersprtnrccreatirrc. Teachercountsthe ways

shop classeshelp stud-ents
I likedthedesignof your'TrivetPursuif' Your'TrivetPursuit'trivetsreallyintrigued As an industrialarts/technology education
project(issue154,page70),butldon't me,butsinceI don'thavea lathe,I teachertor32 years,I especially appreci-
havea lathe.So I mademine,below,by thoughtI wouldn'tbe ableto buildthem. atedyourinspirational storiesof teachers
scrollsawing ringsandgluing
the individual ThenI decidedto givethe projecta try andstudentsworkingtogetherto keep
thetrivethalvestogether usingthe usingmy newcircle-cutting jig for my highschoolshopprograms open.(See
'Workshop Revival,"issue155,page84.)
full-sizepatternsas guides. router.Aftergluingup mapleandcherry
Wash.
CharlieGilfoyle,Tacoma, blanks(l mademinesquare), I usedthe Toooften,theseprograms facebudget
patternsto lay cutsbecausethey'renotseenas critical
out pivot-pin for "gettingour kidsreadyfor college."
holes,then On the contrary,I believewoodworking
routedeach programs teachmanyvaluable skills.
circle.Finally, Herearejusta few:
I enlarged the I Mathskills.Woodworking requires
pivot-pin holes kidsto calculatefractions,layout parts,
usinga t/2" figureangles,andestimate material
Forstnerbit. needs.All of thesetasksdemonstrate
JohnL. Haase, practicalreal-worldwaysto applyabstract
Whiting,N.J. mathconcepts.
I Goalsetting.Buildingprojectsshows
kidshowto set a targetthenworktoward
it. Andtheygetconcretereinforcement of
theirgoalsas theycreatepartsandbring
the projecttogether.
I Motorskills.Usingwoodworking tools
helpskidsdevelopcoordination andskills
they'llneedto operateothermachinery-
fromcomputers to cars.
ProjectUpdate COVER
SEATSUPPORT I Teamwork.Groupactivities bring
AdirondackGlider(issue studentstogetherto accomplish tasks.
155,page34):Theseat I Communityinvolvement.Students
supportcovers(M)shouldbe
long.To layoutthe
1511/'r.^" I
51/e"
can learnthe valueof gettinginvolvedby
takingon projectsto improvetheirschool
andcommunity.
endangleson thesepieces,
as shownin Drawing 5 on
page37,adherethefull-size
patternsto yourworkpiece
l_ I Science.ln orderto successfully
workwithwood,kidsneedto understand
itscharacteristics.
New1rtord,Pa.Q
JohnSokolovich,
whereshown,rghf.
r Editorialquestionsandfeedback: W00D P.0.

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WOOD magazine October 2004

workshop saw!/
pinpointers
A router table starterpin putsyou
in controlof your work for smootherresults.
r{t
1t
}d.
With the workpiece

the starting point edge into
bit's bearings. Maintain even
both the pin and the bit as you begin routing
the edge.
flun.tioning much like a fulcrum, this as shownabove.Easeyour workpieceaway

F router table accpssoryis as valuable from the starterpin as the bearing takes
- as it is simple.Used in combination over, feeding the raw edgeinto the bit in a
with bearing-pilotedrbuter bits, a starterpin counterclockwisemotion, as shownbelow.
lets you brace your workpiece for more Instantly,you'll notice that a startingpin
precise and controlled freehandedgework. gives you addedconffol of your workpiece
You can buy metal and plastic starter during the critical point when the stock first
pins, suchas a brassversionfrom Eagle touchesthe spinningbit. For safety'ssake,
America ($4.99;eagle-america.com), but use a push pad for small workpieces.|l
it's easyto make one from a dowel or a
piece of steelrod. Pins shouldsnugly fit the Photographs: Scott Little
starterpin hole in the router table and
need only reach about an inch above
the table surface.
Stanerpins are bestmountedless
than 2" from the outside edge of your
bit. If you're using a homemade
router table that's not predrilled for a
starterpin, drill the pin hole slightly
in front and to the right of the bit on
the infeed side.
Brace yourself
Start your router and brace the
workpiece againstthe pin. Pivot the
starting corner of it firmly and
smoothly toward the cutter. Keep
your work pressedagainstthe starter Once your workpiece is firmly in contact with the
pin as the edge of your workpiece roller bearing, ease away from the pin for greater
comesto rest againstthe bit's bearing, freedom of movement.
10 WOOD rnagazine October 2004

pat-
t :i. ,i.;r-g9du7g1l1g1g have been a lVa"-deephole for a threadedinsert, as along its edges,where shown on the
using
sharp instrumentsto make laY- shown in PhotoA. tern and Drawing1.
Chuck a Vz" Fotstner bit in your drill
In fact, the first marking and mortising press, and position the fence to align Add a beam and bar
Cut the beam (B) to thickness and
gaugespredatethe developmentof mass- the bit with the holes, shown on the pat-
tern, that form the ends of the slot in the width but about 4" longer than the
producedpencils.Even with the availability
length listed in the Materials List' (The
of pencils, craftsmenstill scribe the most body (A). Drill the end holes, and then
most of extra length will be used to test the fit of
accurate layout lines on wood with the drill through the centerto remove
the slot. Clean up the the beam in the body slot.) Then cut a
sharp points of a gauge. Now You can the material from
slot with a chisel. groove for the bars (C, D) in one beam
make your own versionand experiencethe
Bandsaw and sand the bodY (A) to face, where shown on Drawing 1 and as
differencefirsthand.
shape. Then rout V8" round-overs shownin PhotoB.
Chuck a Va" round-over bit in Your
Laminate the bodY table-mountedrouter, and rout 1"-long
. To form the bodY (A), cut two
' z/ex2sAx44"faces(we used bubinga) round-overson all four edgesof the beam
core (we used (B). Test-fit the routed end of the beam in
and one Vqx2s/Bx4t/c"
maple).Apply glue, and laminatethe faces the body (A) slot, as shown in Photo C'
Make any adjustmentsneededfor a good
and core in the order shown on Drawing1,
fit. Mark the test end of the beam,and rout
keepingthe endsand edgesflush. With the
glue dry, trim one edge of this blank flush its entire length. Do not cut the beam to
finished length.
on your tablesaw,and then flip the piece
In the unmarkedend of the beam, use
and trim the other edge, leaving a 2t/2"-
a 5/tz"brad-point bit to drill a t/e+"
-deep
wide blank. Then, trimming both ends,cut groove,
counterbore centered in the beam
the blank to 4" in length.
Make a copy of the full-size body pat- where shown on Drawing 1. (The counter-
.tern on the oppositepage, and adhere bore must be deep enough to recessthe
head of a #16 wire nail slightly below the
it to the blank with spray adhesive. Adhering a maskingtape "flag" lo a3/e"
Transfer the 3/e"hole centerlineon the pat- Forstner bit to mark the depth, drill a bottom surfaceof the groove.)Then drill a
l/r0"hole centeredin the counterbore.
tern to the top edge of the blank, and drill 1rle"-deephole centered in the body (A).

12
E exploDEDvtEW
#4 x 3/a"brass
7o+"shank hole, F.H.wood screw #6-32xth"
countersunk brassknurled-head Fileflushto bottomof
thumbscrew adjustablebar atterassembly.
\ t/q-20x 1"
brass knurled-head
#16x1"wirenails
trimmedto e/e"
#16x1"wirenail
trimmedto t/2" 7se"counterbores /a" hole
Sharpenafter Toa"deep with
assembly. a %0"hole
centeredinside
7or"pilothole
s/o"deep t/a"round-overs
t/e"round-over
2"---------
I'I
I
21/2"
E fxeo BAR(topfaceshown)
Crosscuthere after
drillingall holes.
7o+"shank hole
countersun
--\---------,--fr*,
i---------------------7
i
ll \-f-G
T3/a"
i
,, _t----
l/__"_ _______-_i _i
|.-- T1/4, ----)<-
1/aq"
deep on bottom face with a
%0"hole centeredinside
Resawand plane a3Aex3/sx8"

..-,1$*the blank for
fixed bar (C) and adjustablebar
(D), testing it for a snug but moveablefit
in the beam (B) groove.
ffiTo make the fixed bar (C), drlrllal/u"
u*#'countersunk shank hole in one end of
the bar blank, where shown on Drawing 2.
Then on the face oppositethe countersink,
use a pilofpoint bit to drill a sAz" cotnter-
bore t/oc"deep, where shown. Centering a
Vro" bit in the counterbore, drill a hole.
Place the bar blank countersunkface up in
Tre"deep
the beam (B) groove with the holes in the length
Zero-clearance
beamand bar at the sameend. Align the bar insert
and beam ends, and using the countersunk
Install a zero-clearanceinsert in your With 1" of the edges of one end of the beam
shankhole in the bar as a guide, drill a5/64" tabfesaw, and cut a3/a" groove s/s" deep (B) rounded over, test-fit it in the body (A).
pilot hole 3Ae"deepinto the beam. centered in one face of the beam (B). The fit should be snug yet moveable.
woodm,agazine.com
13
!) For the marking points, sniP two
k+rcxt" wire nails to t/e" long and one
to Vz" long, and press them into the coun-
terbored holes in the beam (B), fixed bar A,foolproof way to avoid
(C), and adjustablebar (D), where shown screw disasters
It's easy to twist off a soft brass screw, as
on Drawing 1. (See page 16 for instruc-
shown below top, or strip its slot, as shown
tions on sharpeningthe Points.) betow center,when driving it into a hardwood
'l Thread a #6-32xV+" brass knurled-
part like the beam (B). And the smallerthe
r)neaO thumbscrew into the t/a" hole in screw,the greaterthe chanceof disaster.To
the adjustable bar (D). (The thumbscrew avoid these annoyances,pick up a few
will cut its own threadsin the wood.) File same-sizesteel wood screwswhen you buy
the threadedstud of the thumbscrew flush brass ones. Then, after drillingshank and
with the bottom of the bar. (See Sources pilot holes,drive in one of the steel screws.
for a kit that includes all the hardware for The strongersteel screw cuts threadsinto
To preventchipping,securethe bar blankin the marking gauge.) the wood with less chance.ofbreaking.Now
the marked(test)end of the beam(B)with 3/s" removethe steel screw and drive the brass
;[ Orive the threaded insert into the one. Store the steel screwswith the brass
maskingtape,markthe length,and cut the 'thole
in the body (A). (Use a 6mm hex
fixed bar (G)to size. ones and you'll alwayshave the right size
wrench to install the insert that comeswith steel screw on hand.
the kit.)
fifo prevent chipping or other damage f neferring to Drawing 1, screw the
llto the fixed bar (C), cut it to finished rJfixed bar (C) to the beam. (For help
length, as shown in Photo D. with successfullydriving brassscrewsinto
? ln a manner similar to cutting the fixed hardwood, see the ShoP TiP, right.)
I Uar (C) to length, house the remaining Holding the body (A) with the threaded
piece of the bar blank in the test end of the insert down, place a %"-thick 3/a"-diametet
beam (B), and trim the adjustablebar (D) nylon spacerin the 7s" hole where it inter-
to length. Then drill a s/zz"cotJnterborel/s" sects the slot for the beam. (The spacer
deep with a centered %0" hole near one protects the adjustable bar (D) from
end of the bar and a %" hole near the other thumbscrew damage.) Next insert the
end, where shown on Drawing 1. adjustablebar in the slot. Capturing the bar
Trimming off the test end, cut the beam to in the beam groove, slide the beam into
finished length. place. Finally thread a Vt-20x1" brass
knurled-head thumbscrew into the thread-
Finish and assemble ed insert. For tips on using your marking
I Finish-sandall the parts to320 grit. Do gauge,seepagetU.?
I not oversandthe edgesof the bars (C,
Written by Jan Svec withphuck Hedlund
D). Apply an oil finish. (We applied two Project design: Jeff Meftz
coatsof Minwax Antique Oil Finish.) lllustrations:Roxanne LeMoine
Gutting Diagram
A-body
e/tx3t/zx 12" Maple (.3 bd. ft.) bar

C-fixed {s' M1
*Plane or resaw to the thicknesses Va' M 1
D-adjustable bar 51/2'
listed in the MaterialsList. -Partsinitially
cut See
oversize. the instructions.
Materlals key: LMB-laminated mapleandbubinga,
B-bubinga, M-maple.
Supplies: Spray adhesive.
Blades and bits: %"andt/2"Forstner bits,stackdado
set,/a" andl/+" routerbits.
round'over
Sources
Hardware kit. #16x1" wirenails(3),#4x7a'brassflat-
headwoodscrew(1),#6-32xlc" andt4-20x1" brassknurled-
Vqx51/zx12" Bubinga(.5 bd. ft.) (1 ea.\,1+'20
hex'drive threaded insert
headthumbscrews
nylonspacer
(1),/ax/e"-diameter (1).Kitno.MG'2,$4.95
Seenmre ppd.Add$3.50foreachadditional
Woodworking. Call800/346-9663,
kit.Schlabaugh andSons
or goto schsons.com.
Collector's Series Wood and hardwanr kit. Thehardware listed
Tools abovepluswoodoftherequired thickness to makeone
gauge. Kitno.MG-2W, ppd.Add$9.50
$10.95 foreachaddi'
woodmagazine.com/furniture andSonsWoodworking,
tionalkit,Schlabaugh seeabove.
WOOD rnagazine October 2004

14
talking shoP
hovtrto
marking/mortising
gaugetowork
Vtltretherit's the Collector'sEditionmarking/mortising
gauge on page 12,or a commercially made one' here's
how to make good use of this traditional layout tool.
Use the single point to scribe the shouldersof a tenon...
hen you want a fast and eliminating "thicknessof line" errors.It

accurateway to lay out guide- alsoprovidesan accuratelyplacedgroove
lines for cuttingjoints, reach for the tip of your chisel.The main
for a marking/monisinggauge.The three disadvantageof scribedlayout lines is that
photos,right, show typical applicationsfor you can't erasethem, althoughin most
a marking gauge. cases,the lines are eliminatedor coveredup
Available in variationsfrom ordinary to , when cutting or assemblingthejoint.
ornate,all marking gaugeswork the same
way. A beamholding a single sharp i Sharppoints cut fine lines
marking point (marking gauge),a pair of i To scribeniurow, consistentlines, you need
points (mortising gauge),or both singleand , rhatp points. Most commercialgaugeshave
pairedpoints (combinationgauge)slides i conical,nail-like points, which scratchthe
throughthe body. The body has a device i surfaceinsteadof cutting it. Thesepoints
for locking the beamin place,fixing the leave fizzy lines when marking acrossthe
point or points a set distancefrom the body. grain and are likely to follow the grain
Why use a gaugeinsteadof a pencil?The when marking parallelto it. For best
line createdby a wood pencil changes results,file the points to form a two-sided
thicknessalong its length as the pencil knife edge,as shownbelow, /ey'.Make sure
point dulls. The point on a gaugescribesa the point edgeis parallel to the gaugebody.
much thinner and consistentline, Sharpenpairedpoints to the samelength. ... or scribe plywood to prevent chipping
Continuedonpage19 when cutting rabbets.
Knife
edoe
Surface
of stock
( ,4-
\< Travel I
\ \r--
RIGHT WRONG
Tilting the marking Tiltingthe marking
point away from point toward the
the directionof travel directionof travel
presentsits knife presentsits blunt
Remove the beam from the body, and clamp edge to the stock. side to the stock.
it to your workbench. Protect the beam with The point cuts a The point scratches
a couple layers of masking tape, and use a Set the paired points to the width of a
clean line. aluzzy line.
fine flat file to form a two-sided knife point. tenon, and scribe mortises on your stock.

16
talking shop
Engaging the gauge

To usea markinggauge,setthe point the desireddistancefrom the
body usinga steelruler or the actualstockthat will fit thejoint, as
shownbelowtop, andlock the beamin placeby tighteningthe
knurled-head thumbscrew.To setthe distancebetweenthe twin
pointsof a mortisinggauge,usethe bit or tool you'll useto cut the
mortise,as shownbelowcenterandbottom.Then hold the body
tightlyagainsttheedgeof theworkpiece,tilt the gaugeslightly
awayfrom you to presentthe cuttingedgeof the point or pointsto
the wood, as shownin the drawingon page 16, andpull the gauge
towardyou. Use this methodto scribelinesparallelto the grain,
acrossthe grain,or on end grain.|l
L\
Positionthe pointswith the stock...
HawkPrecision
Scroll Saw""
performace
Vibration-fiee
1il;i.itiilffiil;r
hardwoods likebutter.
3-in-1 Woodphnero Cub wood,rnotal,
llo uttimatePlaner/Mdder/Gang plastic,gilassand
Saw.Plane
youroyrnlumb€r,cmatecustommoldings& rnorel
savethousands. Vadable
feedwith5homotor.
JointAbility'"
Createp€rfectfittingglu€
jointstim€aftertime!
. . . o rt h e b i t y o u ' l l
woodmagazine.com 19
CircleNo. 1678
blades and bits "/
/
.',7) t3
o
XJ -
blade and
bit cleaners
Which onesworkbest?
If cleaning your saw blades
and router bits sits near the
bottom of your "to-do" list, you
may be shortening the life of
your carbide cutters.We
tested eight products and
several home remedies to see
which work fastestand safest.
. .ii*',:i:..,':-,.r
After soaking one set of teeth for five minutes (5M) in CMT 2050, most of the buildup
he crud that inevitablybuildsup wiped away easily. Note the dark deposits left in the soaking cup from the action of
behind the carbideteethand cutters the cleanei alone.The "control" section shows the condition of the uncleanedteeth.
on your sawbladeand routerbits is
morethanjust an unwelcomenuisance.It For eachcleaner,we soakedone setof home remediesrun the gamutfrom mild to
affectsthe quality of your work by teethfor five minutes,and then gently dangerous. Pay specialattentionto those
requiring more feed pressureto make the wiped the teethwith a cleanrag and noted that are flammableand/orcorrosive:Those
cut andburningthe edges.In fact, cutters how much buildup was left behind.If the productscan causebigger problemsthan a
andbladeswith excessivebuildupare cleanerremovedall of the filth, we gradedit dirty bladeif mishandledor misused.Even
sometimesmistakenfor dull. A thorough with an "A" and stoppedtesting.If any if a productlabeldoesn'tspecificallyinstruct
cleaningoften canrejuvenatea cutter's residueremained,we soakedthe next you to do so,protectyour handsand eyes.
performancefaster(and cheaper)than sectionfor 30 minutes,wiped, and graded The fumes from someproducts,suchas
sendingit to the sharpening,shop. again.If needed,we then soakedthe next oven cleanerand SpraywaySaw Cleaner,
Keepingyour cutterscleanhas another group of teethfor 5 hours,wiped and are strongenoughto catchin the back of
lessobviousbenefit.Left unchecked,resins graded.The gradesfor all threesoaking your throat.With theseproducts,wear a res-
andpitch from wood and adhesives from times are shownin the chan on page 22. pirator and work in a well-ventilatedarea.
man-madeproducts(suchasplywood and After cleaningyour bladesand bits,
MDF) can corrodethe blade or router-bit Consider safety and speed inspectthe cutting edgesfor cracksor
body and deterioratethe carbide.Such Take a look at the Safetycolumn on the chipping, and discardany cutter showing
deteriorationhastensdulling. chart.and vou'll seethat thesecleanersand suchdamage.When in doubt,tossit out.
Continuedon page 22
Jobone:Making the mess
To ensurethat all cleanersin our test had to
deal with the samequality and quantity of Bear these tips
gunk, we got aholdof new FreudLU74M in mind for plloted bits
8O-toothcrosscutblades,installedeachone Bladeand bit cleanerscan rob router-bit
baclcwardon a tablesaw(to speedthe
bearingsof their lubrication, which leads
gunking-upprocess),and thenrippedequal
to prematurebearingfailure.Before
lengthsof pressuretreatedpine. To seehow
a factory-appliednonstickcoatingmight cleaningthe bit,spinthe bearingby hand
affect the performanceof the cleaners,we to ensureit turnsfreely.lf it spinseasily,
repeatedthe filthing on FreudLU74R removeit and set it aside;otherwise
blades(the nonstick-coated versionof the discardit and get a replacement. When
LU74M). Next, we markedeachbladeinto the bit is clean,reinstallthe bearingand
6-toothsectionsthat fit easilyinto shallow treat it with a high-speedrouter-bearing
cupsfilled with a cleaner,as shownin the lubricant,as shownat right.
photo,top.
20 WOOD magazine October 2004

w -,dt
d F
4
*/- .1
;l^
Finally, protectthem with a coatingof a i uncoatedblades.MoneYwell
rust-preventativeproduct,suchas those i spent,in our opinion.
reviewedrnWOODa magazine,issue 154. , I'esson #4: Two cleaners
Boeshield T-9 (boeshield.com,8001962- i removedall of the gunk after
1732)earnedtop honorsin that test. i only five minuteson uncoated
blades-SpraywaySaw
5 lessonslearned i Cleanerand Empire
Lesson #I.'Except for oven cleaner,none i BladeSaver. When You <i
"*"n-.
of the home remediesworked as well as the i factor in productsafetY, . i:,'
.*V
specialtyproductsformulatedspecifically i we have to go with
....jf!!
for cleaningbladesandbits. (We've heard l Bladesaver.which is virtu- &;*t'

kerosenesuggested as a bladecleaner,but ally harmlessand
in our tests,it had no effectat all, so we left canbe rinsedor
it out of the chart.) dumpeddown
Lesson #2: lf you're not in a big hurry, all the drain without
of the specialtyproductscleanedvery well dangerof polluting.
with a five-hoursoaking. Lesson #5: In a pinch,oven
Lesson #3.'On nonstick-coated blades,all cleanerwill do the trick, but
of the specialtyproductscleanedwell useit with cautionandPlentY These two blades demonstrate grades
enoughafter five minutesto put the blades of ventilation.Know, too, that A through D on the chart. An F grade
or bits backto work. For this luxury, you'll blade makerscautionthat it indicatesthat the cleanerhad no
may damageyour blade.Q apparent effect on the blade grime.
pay only $5-$10 morePerbladethan
I
CLEANINGEFFECTIVENESS tl
AFTERSOAKING(1)
' U ) O/
/r l-I
UNCOATED I NON.STICK oai
BLADE ICOATEDBLADE o -(U/
r-=/
{U/I
cl
.LEANER
SPECIALW PRODUCTS
/ MANUFACTURER'S
/ orrr?.uo9fffiLlortoo W/!/s/ 'AFETY

H :l
I
/ PRrcE(3)
F O RM O R E
INFORMATION:
Nonflammable. Eye and 8001962-1732

BOESHIELD Spravand let soakfor B skin irritant.Gloves .18 $9 for 8.5 oz.
www.boeshield.com
BLADEAND BIT 3G{b seconds.Wipe dry. recommended.
Sprayand allowto Biodegradable, non-toxic, 8881268-2487
CMT soakfora few minutes. and nonflammable. .48 $ 1 2f o r 1 8 o z . www.cmtusa.com
FORMULA2O5O Wipe with rag or sponge. Mildeve irritant.
Wet bladeand workwith soft Water-based. 866/700-5823
EMPIRE bristlebrush,if neccesarY. Eye and skin Protection .08 $ 1 7f o r 1 6 o z . www.empiremfg.com
BLADE SAVER Rinsewith waterand air drY. recommended.
Soaktoolsto removePitch. Nonflammable. 0
800/642-001
LENOXWOOD Alsocan applybeforecutting B B Eye protection .25 $3 for 8 oz. www.lenoxsaw.com
PITCHCLEANER to preventbuilduP. recommended.
Sprayor soakfor a few Eveand mildskinirritant. 800/594/9028
minutes,rinsewith water, B B N'onflammable. .91 $10 for 20 oz. www.oxisolv.com
oxtsoLv Lowflammability.
and wipe dry.
Soakbladeor bit in Biodegradable,and 7701680-0006
B nonflammable. .27 $ 1 3f o r 1 6 o z . www.aroundtheshoPi
nc.com
PITCHRX productlor 2-3 minutes.
Rinsewithwaterand drv. Mildeye and skin irritant.
Spravand allowto standfor Corrosive.WeareYe, .63 $ 5 f o r1 8 o z .
800/332-9000
SPRAYWAY 5'minutes.Wipewithdamp skin,and lungProtection. www.spraywayinc.com
SAW CLEANER cloth,sponge,or Papertowel.
'l6 153
800/225-1
Dilutewith 4 partswater. Mildskin irritant.Weareye 11 $10for oz.
WOODCRAFT Wipeon, brushon, or soak B- B- protectionwhen mixing. (makes5 pints) www.woodcraft.com
RESINREMOVER bladeor bit in cleaner.
O?HERCOMMONCLEANERS
CARBURETORCLEANER D .o G G-: "c B

Dangerousfumes.
Eveand skin irritant.
NOTES:
1. See photosfor examplesof grades'
Organicand biodegradable. " No furthertestingneeded.
CLEANER
CITRUS-BASED F D c- D. D B Slightlyflammable.
Nonflammable. 2. Basedon cleaninga 10"saw blade.
FORMULA409 c- c B. Eye and skin initant. Costper treatmentis affectedbY
appliiationmethodand cleaningefficiency.
Corrosiveand flammable. Wear
OVENCLEANER eye,skin,and lung Protection. 3. Pricescurrentat timeof article's
Biodeqradable, nontoxic,and production
and do not includeshipping,
SIMPLEGREEN G B B nonfla-mmable.Mildeye irritant. whereapplicable.

22
short world
Newsandnotesfromthewoodworking
cuts
Projectswith persondtty
If you're looking for a way to add life to your projects,
considerthe creationsmadeby StraightLine Designs
Incorportedin Vancouver,B.C. Designerandfounder o
E
JudsonBeaumontbeganthe companymore than 13 years o
o
ago for the purposeof designingand building customfur- o

o
niturewith an original,often unconventional twist. Says ?
on 'chil-
o
Judson, "Most of our pastprojects have focused 6
'the family,' so our initial approachis to incorpo-
o
dren' and
rate elementsthat make every one unintimidating,interac- 'o
tive, andfun!" .o
o
To seemore of the company'simaginativedesigns,visit
straightlinedesigns.com.
Big news:Black & Decker buys Pentair power tool group

The Black & DeckerCorporationof Towson,Maryland,has powertools);DeVilbissAir Power(compressors); and
movedto purchasethe power tool group belongingto Minnesota- OldhamSaw (saw blades). SaysNolan D. Archibald, B&D
basedPentairIncorporatedfor $775 million. The saleincludes Chairmanand CEO, "This acquisitionwill add well-respected
companiesthat manufacturewoodworkingproducts,specifically: brandsto our portfolio and expandour offeringsin product
Delta (stationarypower tools); Porter-Cable(benchtopand portable lines wherewe haverelatively low marketshare."More later.
Continuedon page 26
wauIoioinwood
tGst
UGGisG,r,
iustUotmotG
Beforejoiningyour projectwith the simplicitv
andstrengthof Pocket
HoleJoinervVoumustcut Vourworkpieces accuratelv.
lntroducing,KRECPrecisionMeasuring Svstems.Woodworking
machineaccessories that helpVouto cross-cutVourworkpieces with
morespeedandrepeatable precisionthan everbefore.Perfect
for the mitersaw,tablesaw,drillpress,andmore.
Visitwww.kregtool.com
todayfor moredetails
@fires
short cuts
Testyour workshop smarts A n s w e l sto thequesti ons

i n i ssue1,57, To removethe ring in old shellac,Bob
Raiseyour woodworkingIQ by trying the r True or false: Water rings on adviseslightly dampeninga rag in dena-
quick queriesbelow.Find the answersin furniture surfacesare in the layer of tured alcohol and wiping the affectedarea.
the next issueof WOODamagazine's furniture polish or wax above the finish. This causesthe finish to redissolve.loseits
ShortCuts,or go right now to False.Waterrings developin the finish, porosity,andbecome"compacted."The
saysfinishingexpertBob Flexner.Older result:a restoredclearfinish .
shellacor lacquerfinishesare most prone For old lacquerfinishes,Bob recom-
r What's the origin of "pennyr" the becauseof their porousnature. mendsTouch-UpSolutionsBlush Control
T
word used to define nail sizes? (availablein an 11-ounceaerosolcan for
$3.99)or LiberonRing Remover(a wipe-
r What woods were usedin the con- on productin a 125-mlbottlefor $ I 1.95).
struction of Civil War-era canteens? & Get both at woodfinishingsupplies.com.
sunnyside
r Can you name this denatwed r Can you name the bygone
obscure Victorian-era abolrclsohient tool pictured below and explain its use?
hand tool and According to antiquetool expertMartin J.
describe its use? Ctcars & ,,
I'igtnentt'd 'lirlr('
Donnelly,this No.1 "Odd Jobs"
[tl sHfor tRot CombinationTool was madein 1887as
part of the StanleyRule & Level line. It
includesa try square,level,mortis-
fls ing gauge,markinggauge,

compass,andT-square.
This late 1800sStanley t
tool served as the 3&r 'i:' 7
predecessor to ..$* E
o
o
today's ui
Remove rings in old lacquerand shellac combination
o
o
finishes by using the appropriate solvents. square.

o
=
You'REPnonnnrvJusr As AMgrTIous.
Whether youarea do-it- r What's the best way to rid mold from
yourselfer, a professional your lumber stack?
woodworker or somewhere Mold fungi forms in humid conditions.It
youhavea world appearsasblack or greenish-black discol-
in between,
orationon the surfaceof wood. While it
fullof projectsinthehome
doesn'tdamagewood, it may indicatethe
or i ntheshopthatw i l lbe presenceof decayfungi, somethingthat can
easier andmoreenjoyable to weakenwood structurally.
compl ete you
w hen use qual - To get rid of mold, you havetwo choices:
ityclamps, bench visesand 1) washthe wood with a 1:4bleaclVwater
miterboxes/saws fromthe solutionor 2) don a dustmaskandplane
Adjustable Clamp Company. the wood outdoorswith a thicknessplaner.
Lookforthemunder the Be awarethat mold sporescan setoff an
Jorgensen, Adjustableand allergicreaction.For this reason,sandingis
Ponybrandnames wherever not an option.As a furthermeasure,elevate
your lumber stackat leasta foot off the
fi netool saresol d.
groundto protectit from further
moistureexposure.f
"&t6ut tu".' "hn.g;

Agliustable-
Made in the USA by the AdjustableClamp Co.,
433 North Ashland Ave., Chicago, lL 60622,
Mold, such as this, can be washed off

with a water/bleachsolution.

T
-
sho youworkfaster,
Helping andsafer
smarter,
f
rrnottto alignment woes

CL
E
fust say To solvethese

o
.L
It'sa tricky,time-consumingbusinessto spacingconsistent. o
installoverlaydrawerfronts.Thetough problems, I usea verysimPleandfast ;

6
parts:aligning thefrontswitheachother technique-spacers. o
andanyadjacent doorsandkeeping the First,installthedrawerboxesin the a

o
tr
o
cabinet.Pre-drill thefastener holesin the

drawerbox,whereshown.Next,pre-drill dt
thecenter-pull boltlocations in thefalse

drawerfrontwitha s/sz" bit.Thesebolt At the last houseDennis Stratrleowned,
holesmustbe squareto thefront's he made all of the cabinetsin the
surface. (l usea drillpress.) kitchen and bathroomsfrom red oak
Startingwiththe bottomdrawer,set harvestedfrom property the housestood
theverticalspacerin place,as shown, on. "At the time,I ownedan old
andholdthefalsefrontagainstthe Belsawcircular sawmill with a 50"
faceframewithits bottomedgeparal- blade," saysour Top ShopTip winner.
lelto thefaceframe.Drivea 2" screw For their new house,he again built the
throughtheboltholeas shown,draw- cabinets,and installing all thosedoors
ingthedrawerboxtightagainstthe and drawer fronts inspired the award-
falsefront.Then,pullthedrawerbox winning np at left.
out,clampthedrawerfrontto thebox
at bothendsto keepit fromrotating, Dennis Strahle
receivesa 1-hp
andattachthefrontthroughthe pre' dust collector
drilledholes. (model DCl BXL-
Finally, removethe2" screwand CF) from Penn
installthe pull.lf the pull'sscrewis too State Industries
short,counterbore thescrewholefrom for sending in this
issue's Top Shop
the insideout.Repeatthistechnique Tip. Thanks,
Vertical spaoer f
':
.,::::..' forthe remaining drawerfronts,using Dennis!
aligns to door. Predrilled holefor' a horizontal spacer,as shown.
knob in drawer ftontg
-Dennis Strahle,Eagle,Mich'
Role reversal for sanding drum helps sleerrcsslip on

I grewtiredof tryingto slide
sandingsleeves
tight-fitting
overtherubberof mydrill- Describehow you've solveda work-
presssanding drums.To shopdilemma,and you'll earn$75 if it
loosenthefit for installation, appearshere.And, if your tip garners
I mounted thesanding drum Top ShopTip honors,you'll alsowin a
in mydrillpresswiththe tool prize worth at least$250.
drumloosened forchanging Sendyour best tips, along with photos
sleeves. Then,I laida flat or illustrations and your daytime tele-
sandingblockwith8O-grit phone number,to: ShoP TiPs, WOODa
paperagainst thedrumwhile MagazinerlTl6 Locust SL, GA-310'
it spunat a lowsPeed.ln Des Moines,IA 50309-3023.Or e-mail
onlya fewseconds, I took tips to: [email protected].
thedrumdiameter downjust Rememberto include your contact
enoughforthesleeveto info in the e-mail as well.
easilyslideoverthe loose Becausewe firy to publish only origi-
drum.Thedrumstilltightens nal tips, pleasesendyour tips only to
firmlyon thesleevefor WOOD magazine.Sorry, but submitted
sanding, andI don'thaveto materialscan't be returned.
struggleto changesleeves.
-Brent Hepker,1nida,S.D. Continuedon page 30

28
shop tips
Workbench table set for messy company Drop-down tools preserve

Keepingglueoff the workbenchis
workbench space
an ongoingproblemfor mostwood- In my smallshop,keepingtoolshandy-
workers.To preservemy benchtoP, and my workbenchclear-is a constant
I use an inexpensive vinyltable challenge. One solutionI developedis
coverfroma discountstore.Before thisdrop-downstorageplatformfor
doi n gglue- ups g o rk ,I
or f inis h i n w someof my busierbenchtoP tools.
coverthe benchtopwiththis heavY First,I attacha plywoodmounting
vi nyl .W it ht he glue- u pc o m Pl e te , plateto at leasttwo wall studsabove
the driedgluebrushesoff the vinyl the workbench. Next,I buildthe
with littleeffort,The tablecovers platform,as shownbelow,varyingthe
comein a varietyof sizesand theY widthaccordingto the tool beingstored,
lastlonger,storeeasier,and are I buildthe platformbasedeepenoughto
mo repliablet hanpolys h e e ti n g . accommodate dust-hoseattachments,
-Bill Martin,
Lewisburg, Tenn. and then add a bracethat clearsthe
tool'sfence.
A continuous hingeholdsthe platform
to the mountingplate,and J-hooksand
chainholdthe tool securewhileit's
stowedaway.Oncethe tool is boltedto
the platform,I don'tevenhaveto worry
aboutclampingit downwhenworking
with heavY'awkward
N.c.
,:;::-, Ashevi,e,
Wall studs
4
Mitersaw in
stowed
position
J-hook
Height of saw in
down and locked
position plus 1"

I
R e s a wq u a r t e r s a v \ r r , t o f i r " .
X?:
t.:il(tra putS gvg-
,r,il'.1
":..:r.:. Quartersawn stoek
', . ,:,
,1, r; ,+l,rC'U,glO.
. . ::t(')(. .l,t )
Core
Quartersawn stock
( rutltttLtt'tlrttl
ltLt,47'.il
MNT THIS?
A clean,sharp hole
every time.
Nochips,
nosplits,
;N
i r . . ) t . l
.*r,s l n0errors.
-:; -)a'
It takes skill
.
rC ill,;
a n da s h a r p
d r i l bl i t ,
Andfhat
*{t
takesthe
DrillDocforo
drillbitsharpener.
' ) ( ) ' . . ) :- tl \
,)aI
-rt-l,eS
-{
i t]
'' ll:ll-los
_Kl ,l i r ijKli. .:ii-tl
Restores
GETTru
bitsto factory
sharp
Fastandeasyto use
Sharpens
mosttwistbits* {
evensplitpoint .*
Diamondsharpening wheel
Powerful
20,000rpmmotor
;:1r';.;:: rff
l)t,l_l
A n t i - s x i ds t a i r , '
treadtape wrapped
- 1u u n G h a l r d l e s .
-[-/uti Iu-tl,
i,". ,'
'.'--'-
:l
1 rt
shop tips
Dovetait iiq does an

about-faie?s router grride
WhenI neededto cutdadoesfor a bookshelf I was
building I hit uponthe ideathatmydovetail
recently,
jig mightservedouble-duty as a dado-cutting guide.I
justturnthedovetail templatearoundso the
backside becomes a straightedgeforthe router
base.OnceI squaretheworkpiece to thestraight-
edge,thedovetail jig'supperclampholdsit securely.
Thissingle-clampsystem, whichtakesupto a
13"-wide board,worksmuchbetterthantryingto
edgewithtwoclamps.Forlong
aligna straight
boards,I supportthe backof theworkpiece to keep
it fromrackinganddistortingtheelevated iig.
-Martin StaebelL
Batavia,N.Y.
Everv qood bench vise

Seriousaboutpocketholeioinery?Startout right with deseir6s a dog
I likedyourShopTip in WOOb magazine
CMT's Pocket-Pro'"Starter Set issue152aboutmaking
faceto addfunction
a movable
to a dogless
jaw
vise.
However, my methodis fasterto setup
Uniqueadjustability andmoreversatile.
with 10 presetpositions
To attacha dogfor straight edge
clamping, drillthree3/e"holesin thetopof
Hardeneddrill guidesfor the movable jaw'swoodenface.Keepthe
accuracy& durability holessomewhat closeto the metaljaw in
ordernotto weakenthewoodenface.
Workswith stock from Usingdowelcenters, transferthe hole
112"to 1-5l8" thick locations to a removable visedogmadeof
3/qx3/c"
hardwood, anddrillthreematching
holes.Gluethreedowelsor metalrods
intotheremovable dog,andit willbe
readyto popintoplacewhenyouneedit.
"CMT's newPocket- Thedog'slongfacespreadspressure over
ProSystem isaneconom- a wideareaandreduces thechanceof
icalthoughquitecapable marring theworkpiece.
kitforwoodworkersinter- To clampsmall,irregular, or roundwork-
ested pocket
inadding pieces,
Ready aboutpocket
to getserious holejoin- drilltwosimilarholesin thestation-
holejoinery
totheirlistof aryface,as shown,andthenplacea
choices' ery?Thenchoose thejig getting
that's rave
reviews: fromCMT.Perfectfor combination of dowelsintoanyof thefive
thePocket-Pro jaw holesfor holding
Workbench, thosepieces.When
anyonewhowantsaneconomicalyet accurate
2003
December thedogsarenotin use,tapeoverthe
to thisfast,easytechnique
introduction for holesto keepsawdust fromfallinginside.
making incabinets
high-qualityjoints andfurniture. -Frank Penicka,MountPearl,Newfoundland
TheStarterSetis alsoan idealchoiceforwoodworkers who
wantto upgrade fromanother jig. lt includes
CMT'sunique
"Versatility
andeaseof two-piece moldedjig, toggleclamp,stepdrillbit,stopcollar,
usemakeeitherof these driverbit,samplescrews& a full colorinstruction book.Or
sJstemssurewinnersfor checkouttheDeluxeSet,withbaseplate, moldedcase,face
building
cabinetsand
clamp& more.
faceframesona regular
basis," AskyourCMTDistributor
for theirbest
you're
While
dealtoday! there, pickupa
ChrisMarshall,
Woodworker's
Journal, CMTProduct
new2004-2005 Catalog.

Bath towel
Towelson tools rub out rust problem

Afteryearsof frequentscraping,scouring,sanding,
rubbing,and waxingto maintainrust-freecast-irontool
tabl e sin m y s hopnea rh u mi dH o u s to nI,fo u n da v e ry
simpleway to keepthe rustfromformingin the first
place:Lay heavycottonbathtowelsoverthe tools.A
largebathtowelon my saw table,heldin placeby the
fence,and one spreadoverthe waysof my lathekeep
rustat bay and saveme countlesshoursof cleaning.
My wife has sewntowelsintofittedcoversfor my
planer,jointer,and othertools.Of course,they also
keepout dust.I startedout with ragbagtowels,but
now haveboughtnicefluffynew onesto keepmy tools
dust-and rust-free.
-Joe Marsh,Spring,Texas
Dri-l[ gride spaces f,oles,

and k-eepsth-em in line
BecauseI don'town a drillpress,I wasn't
lookingforwardto drillinga bunchof
e quallys pac edholesfo r s h e l fp i n si n th e
sidesof a cabinet.My prospectsbright-
e nedwhenI c am eup w i thth e s e l f-a l i g n -
ing,self-spacing jig for use witha portable
drill,shownbelow.
I madeit fromthreepiecesof oak,glued
togetheras shown,and two shortt/+"dow-
els. I laidout threet/+"holeson 2" centers
(thesizeand spacingfor my shelfpins)
alongthe centerline on the bottomof the
jig, withthe centerof the firsthole-the
g ui d ehole- 1" f r omt h e th i c ke n d .I u s e da
dri l lg uide( M c F eely 'psa rtn o . D G-3 6 3 7 ,
$39, 800/443-7937or www.mcfeelys,com)
to d ri llt he t hr eeholesp e rp e n d i c u lto ar
the base.
Aftermarkingand drillingthe firsttwo
holesin the series,I indexedthe jig'sdow-
el s i n t he c abinet - s idheo l e s a
, n d d ri l l e d
th e th ir dhole.I t hens i m p l ys te p p e dth e j i g
up one holeeac ht im eto d ri l lth e re s t.
-Jim Laine, Hillsborough, N.J.
3/qx2x21/2" hardwood
3/+x2x71/2"
Seea new \-,

Shoplip
of the Day at
,'rr,rdlx;f
ry1;gfrai He"corniti nd
woodmagazine.corn
develop your shop skills
f,ast.accurate
tempHe T
c
r
E n i .-o.)
HE
rH
{{
>F
routrng
m
v
z.
Frommachiningto bit selection,

here'sthe quick way to make
identicalparts.
hen you needseveralcopiesof Make the template your designincludescurvesthat are too
curvedparts,suchas the TemperedVq"hardboardmakesan tight for a bandsawblade.
corbelsfor the missionbed on economicaltemplate,but we prefer Vz" If you don't havean oscillatingspindle
page40, considerpatternrouting.Using a Baltic birch plywood. Both materialsare sander,install a sandingdrum with 8O-grit
pattern-basedtemplateand a routerbit free of voids-a vital featurefor smooth sandpaperon your drill press.Double-
designedto follow it, you'll speedthrough routing-but the extra thicknessof the checkthat you have a 90o anglebetween
the drudgeryof making duplicateparts Baltic birch plywood givesthe router's the drum and the drill presstable.Sandthe
without sacrificingquality. By keepinga bearingampleroom to roll along. curvedtemplateedgesto the paperpattern
batteryof templates,you also can save Spray-adherethe paperpatternto the lines,as shownin PhotoB.
time on projectsyou decideto repeat. rigid templatematerial,matchingthe
straightedgeswhereverpossibleto reduce Get ready to rout
Startthe job on paper the amountof cutting required. Tracethe shapeof the finishedtemplateon
The shapefor your templatecan come Bandsawthe patterncurves,as shownin your workpiece,aligning straightedges
from the WOOb magazinepatternpack, PhotoA. We useda Vz"blade,cutting tlo" whereverpossible.Rough-cutyour
a part from an existingpieceof furniture, outsidethe cutline.Relv on a scrollsawif Continuedonpage36
or a designyou draw. If you startfrom
scratch,work out the curve or curveson
paperusing a lead-core,flexible-curve
ruler (availablethroughart supply or wood
working stores);a Frenchcurve; an extra-
long profile gauge;a compass,or any
object that servesas a tracingmodel.
Of course,pattern-based templateshave
their limits. A router bit can't reproducea
sharpinside angleor insidecurve with a
radiuslessthan the radiusof the bit. Either
avoidthosedetailsin your designor plan
to completethem usingothertools,such
as a scrollsawor bandsaw,afterrouting
the rest of the shape.
Begin with a paperpattern.Cut out its
straightlines using a knife and straight-
edge.Use scissorsto cut curvesroughly
/2" outsideof the markedcurvedlines.

develop your shop skills
workpieceto t/ro-/s" from the edgeof its Next, temporarily adherethe templateto plate'sedgewith the bit's cutting edge
finished form to reducethe amountof the workpieceusingdouble-facedtape, spanningthe thicknessof your workpiece.
work vour bit will needto do. aligningstraightedgeswhereverpossible. Don't worry about cutting into the tem-
Whetherthe patternwill go on the top.or plate;the bit's cutting diameteris sizedto
bottom of the workpiecedependson match the bearing.
whetheryou're routing freehandor on a A starterpin placed as near as safely
tableand on your choiceof bits. possibleto the bit, as shownin PhotoC,
As seenon the chartbelow, you have will help braceyour work as you feed it
severalbit choicesfor patternrouting. On into the bit. For small pieces,use push-
flush-trim bits, the bearingmountsto the blocks to keep the templatefirmly against
end. On a patternbit, it's betweenthe the bearingwhile protectingyour fingers,
shankand the cutting body. as shown in the top photo on page 34.
Take advantageof your router table when You'll get the highestquality sand-free
working with small or nurrow parts.You edgeswith spiral- or sheer-cuttingbits.
can use a flush-trim or patternbit here,but Feed wood in a steady,fluid motion
we prefer the flush-trim's top-mounted along the piloted bit. By cutting the end
bearingbecausea patternbit exposesthe grain sectionsfirst, you can significantly
spinningcutter abovethe workpiece.For reducethe chanceof tear-outon the
piecesthat are too large or awkward for the remainingedgesof the workpiece.
router table, use a handheldrouter. After you're finished,cleanly peel the
templateand double-facedtape away from
Shapethe parts your workpiece.Removeany adhesive
Adjust the height of the router bit so its using paint thinner.Sandoff any fine
bearingrides on the centerof the tem- splintersor machinemarks if needed.i
Flush-Trim and Pattern Bit Sampler

f K {--_l
- l
ffi
G
a:&,
m
E
il;;
rGil
a rl I rl
-|
I T - --
t- !,
E
Flush-trim Spiralflush- Spiral flush-trim Downshear Gombination Double-bearing Pattern

trim (upcut) (downcut) flush-trim upcuUdowncut flush-trim
s/a-7/s"dia.; t/rlt/a" dia.; l/a-Vz" dia.; t/F/c" dla.; s/q" dia.; 't/F/q"
dia.i s/ra-2" dia.a
lz-2" cutling 3/r21h" cutting 7a-2" cutting r/r2" culling 11/r15/a" 1-11h"cutting rh-2" cutling
length length length length cutting length length length
Table: top Table: top Table: top Table: top Table: top Table: either Table: bottom
Handheld: Handheld: Handheld: Handheld: Handheld: Handheld: Handheld: top
bottom bottom bottom bottom bottom either
=
Adequate for Blades slice Steep spiral Blades slice at Slices through One bit works Top bearing
most work. As at an angle for makes smooth an angle for a thin veneers of on both hand- lets template
with all carbide a smooth cut; slices, smooth cut; plywood with held and table- be attached
rfiriiliiYl'] bits, look for upcut bits especially in downshear is less chipping mounted atop a work-
micrograin work best for laminated best for hand- on both routers for piece for hand-
carbide. table-mounted materials such held work faces.t either pattern held routing.
routers. as plywood; while available routing or
downcut upshear flush-trim work
versions work versions are such as
best for hand- best for table laminates.+
held routing.* work.
Hard+o-find bits: *from MLCS (800/533-9298); f from Woodhaven (800/344-6657); $ from Eagle America (8001872-2511)

great ideas for your shop
top-dnwer
blade o
org-rnuaet
It works great for
bottom drawers too.
I
s a
Bl z
T'
2t -{
F
rD
-.:-=-1}t/z',
o
his handy divider lets you TABLESAWBLADE

' 1/ax10lzx113/+"
organize and protect your HOLDER ,r*- g/0"
favorite saw blades. We hardboard divider
dimensionedours to fit into a drawer 7e"hole. centered
ffi-
in the sawing/routingcentershownon t/z" dowel
page62 of issue151of WOODa.Feel 3r/z" long
free to modify your organizerto suit a
draweryou have in mind.
To build your own, usethe drawing
at right to cut all the piecesto size, 1/ax83/qx113/q"
noting the locationsof the extending hardboarddivider e/q" dado

3/qxl" tabson eachdivider. For our 7e" deep, centered
10" bladeswe usedthe wider dividers
on the right; for our 8" dado set,the s/q"rabbet Ta"deep
narrow dividers are on the left. 3/cx 11 x 20" MDO
Drill two /2" holesin the basepiece
wheredimensioned,and glue a Vz"
dowel 3Vz"long into each.Next, drill
a 5/s"hole into each %" hardboard
divider. The dividers slide over the
/2" dowelsto separatesaw blades
while preventingthe teethfrom con-
tacting and damagingone another.
Mark the tab of eachhardboard
divider with the appropriateblade
description,and set that blade on top 23/+' Seemorcof
l--
of that particulardivider..l ldea Shop 5 at
Projectdesign:Jeff Mertz

Mltretheryou need a double, queen, or king,
this bed fills the bill, and does so in grand style.
tu
Stayhrned for the companion piec€s...

'\ ------**-*-Y7
'r"'.,''.-.,.^-,,..w
Interested in buiiding matching

I r l .
i,l pieces or a complete bedroom

,i ensemble?You'llfind plans for the
,[ nightstand (abovel in the November
2004 issue,the dresserand
mirror (/eff) in the December
2004 issue,and the blanket
chest (below) in the February
2005 issue.
w,"#'
40
his elegantproject is a dreamcome l[ uc DETATL Bevelededges
true. By simply changing the
dimensions of a few parts and 21/+'
the quantity of spindles,as specifiedin the
Materials List, you can build the bed in
double,queen,or king size.
You can rest easy about installing the
spindlesbecausethere'sno needfor repeti- 3/cx 21/2"mortise
tive drilling and chiseling of mortises. 1glro"deep
Instead,thanks to a simple indexing jig,
you'll cut notchedspindlestripsthat install
into the groovesin the footboard and head-
board rails, ensuringconsistentspindle fit
and perfect alignment.
E mcs 491/+"
Note: To display quartersawn white oak ray

fleck on allfaces of thefootboard and head- HEADBOARD
board legs, we mnde them by assembling LEG
)
four leg outer wraps (A, B) with splines(C, 21/2"
D) around cores (E, F) in the configuration
shownon Drawings 1 and 1a.As an option, 3/+x 21/2"mortise
you can constructfiguredlegswithout bevel- 1glro"deep
cutting long parts. Seethe Shop Tip onpage
31.Also, ifyouplanto useplain-sawnwood,
consider making solid legsfrom laminnted
FOOTBOARD
4/4 stock to the finished sizes listed in the LEG
MateriafsList. Thencontinuewith Step 7 to
lay out the mortisesfor the rail tenons.
3/qx 5" mortises
1glro"
deep
Vq" chamfer
1/-
t/q" chamter zrto'
)
Start lqy.*f"pplng up
someraDuloustegs
z/+"-thick stock, cut eight foot-
I From
I board leg outer wraps (A) to 2Vz" wide
and 32Vq" long and eight headboard leg
outer wraps (B) to the same width and
50V4"long. Angle your tablesawbladeto a
precise45", and bevel-ripboth edgesof the
wrapsfor a final width of 2V+".Ifyour stock
has any warp, use a featherboard clamped
to your rip fence to hold the stock firrr,ly
againstthe saw table.
)Witn your fence positioned on the
Er opposite side of the saw blade, cut
For the board feet of lumber and other angled %" grooves l/te" deep in the leg
items neededto build this project,see outer wrap beveled edges to receive the
page 46. footboardand headboardleg splines(C, D),
where dimensionedon Drawings 1 and la
and as shownin PhotoA.
QCut the footboard and headboardleg Keeping each leg outer wrap tight against
tf splines(C, D) and leg cores(E, F) ro the the saw table and fence, cut a /a" groove
sizeslistedin the MaterialsListbut 2" longer zAa"deep along each of the beveled edges.
woodrnagazine.com 41
't
El nrul rENoNDETATLS
Lay out the footboard and headboard
leg outer wraps (A, B) on Your work-
bench with the spline groovesfacing up. Footboardand
headboard
Startingwith a footboardleg, apply glue to
top rails@ 72:
the mating beveled edges (not in the
grooves)of two wraps (A). For a longer
opentime, usea slow-settingglue, suchas
Titebond Extend Wood Glue. Join the
J+
wraps togetherwith a spline (C) captured
in the mating grooves.Then apply glue to
the inside faces (not the bevelededges)of Footboard
the wraps, and press a core (E) in place. bottomrail@
Now placesplinesin the outer groovesof and
headboard
thejoined leg wraps.
centerrail @
f Clue togetherthe mating pair of wraps
rJwith a spline.Apply glue to the wraps,
as shown in Photo B, and join and clamp
the leg halves together,verifying that the
cornersdraw tight. For an easyway to do
this using minimum clamps,seethe Shop
Headboard^
tr
glueto the bevelededgesand inside
Tip,below.If you preferto only useclamps,
locate them 6" apart and alternateeach
bottomrail(!
Apply
facesof the leg halfwithoutthe core'Then direction to equalize the pressureon all
assemblethe matingleg halvestogether. sidesof the assembly.Repeatto assemble
the remainingfootboardleg and the head-
in length. (We cut theseparts extra long to board legs using leg outer wraps (B),
make it easy to assemblethe legs without splines(D), and cores(F).
keeping the ends of the parts aligned with Q nfter the glue dries, scrape off any
the wraps during glue-up.)To ensurethat lJsqueeze-out.Then crosscutone end of Next craft the rails for the
the legs assemble correctly, test-fit the each leg flush, and cut the other end to a headboardand footboard
32" stock
splines in the grooves and dry-assemble final length of 3lVq" for the footboardlegs I From 7t/2" or laminated
the wrapsaroundthe cores.While maintain- and49t/+"for the headboardlegs. I planedto |t/q" thick, cut the footboard
ing tight corners,allow the splinesandcores 7Lav out the 3hx2t/2"and3/qx5"mortises and headboardtop rails (G), footboardbot-
to movefreely without looseness. If needed, I in the footboard and headboardlegs, tom rail (H), and headboardcenter and
plane the parts to achieve the correct fit, wheredimensioned on Drawing1. Using a bottomrails (I) to the sizeslisted.Saveyour
reducing the thickness and width of the /+" Forstner bit, drill the mortises le/rt"' cutoffs for making testtenons.
coresequally to keep them square. deep.Then,using a sharpchisel,squarethe jlVityour tablesawwith a3/q"dadoblade.
Note: You'll need to work quickly when mortisesidesand ends. AThen cut a 3/q"-deepgroove centered
assemblingthe legs. To ensurethe process (!Using your handheldrouter, rovt a V+" along one edge of the footboard and head-
goes smoothly,read Steps 4' and 5 first so fJchamfer along the bottom edgesof the board top rails (G), footboardbottom rail
you understandtheproceduresand haveall legs. Now sandthe legs smooth with 220- (H), and headboardcenter rail (I), where
of theparts laid out and thesuppliesat hand. grit sandpaper. shownon Drawing2.
Inner tubes make handy

3'clampstt for special glue'uPs
Do you have some old bicycleinnertubes

hangingar ound?lf s o , h e re ' sa u n i q u e
way to get more mileageout of them.
When gluingtogetherlong multi-sided
assemblies,such as the Missionbed legs,
firstslicethe tube into one long length.
Then slicethis intotwo long strips.
Removethe valvestem.Clampa tube at
one end, wrap it aroundthe assemblY,
and clampit againat the otherend, as
shown at right.(You'llneed two tubes to
coverthe lengthsof the bed legs.)lf you
don'thave tubes,you can buy new ones Mission
for under$5-a fractionof the cost of leg assembly
buyinga lot of clamps.

@roe MoUNTING
DETATL
p exeloDED
vtEW
(Queen-size
bedshown)
t/q" dowel
>;i/,,
>iff"
r/q"chamter
t/a"dowel 2" long 1 t l 2 "a n g l e i r o n 621/t'

72" long
Bed-rail
fasteners
t/q" chamter
I #B x 1" panhead .A
?1
""r"*l-
I *Exactlengthequals
s/0"shankholewitha measured
lengthof mattressplus 1".
7o+"oilothole 1tZ"angleiron
z/a"d6epin part@ 72" long
?fo
form tenons on the ends of the rails,
'fllMark
the centerand endsof the arch on Time for the spindle strips,
lJwhere shown, lower the dado blade to the footboard bottom rail (H), where fillers, and spindles
/+". (We made test tenons on our cutoffs dimensionedon Drawing3. Then bend a
and verified their fit in the leg mofiises
I To mike the no?chedspindlesrrips(J),
fairing stick to thesepoints, and draw the I where shown on Drawing 4, cut two
before cutting the tenons on the rails.) Then arch. (For a free fairing stick plan, go to z/+x6x27t/q"pieces for a queen-sizebed,
make cheek cuts to fomr 3/+" tenons I %" ,' ,l o ti rrr. r!uzi n,-' .eonr/l ' l riBriandsaw
ng.) and two z/qx6x243/4"piecesfor a doublebed, or
long on the rails. For safety, support the rails sandthe arch to shape. two t/+x6x35t/,+"pieces for a king bed.
as shown in Photo C. Raise the blade to 3/+".
f Sand the rails (G, H, l) to 220 gnt. Make sure you cut the piecesto identical
With rails H and I placed on edge, trim the tJThen, to keep the rails matchedwith lengthso the spindles(L) will align correct-
tenons to 5" wide. For an easy way to fine- the footboardand headboardlegs, identify ly later.
tune the fit of the tenons, see the Shop Tip, the rail left ends and the left legs on the
on the next page. Dto cut preciselyspaceddadoesin the
front face using maskingtape. Etpieces to form the notchesin the spindle
El sprruoLE
sTRlpDETATL
(Fora queen-size
bed)
woodmagazine.com
43
Trim tenons with hand planes *
for an incredible shane and fit i
Adjustingyour tablesawblade heightto
removea whiskerof materialto get a precise- il
fittingtenon can be tricky.To avoid the risk of
removingtoo much material,cut close to the I
final thicknessof the tenon.Then use a rabbet I
block plane,as shown at right,to trim the I
tenon to the perfectsize. (A rabbetblock plane I
has a bladethat extendsthroughthe body I
sides,allowingit to trim tenonsflush with the I
shoulders.)Simplyadjustthe planefor a fine I
shaving,and take an equal numberof passes I
across both tenon cheeksas needed. i
ffiffi
Also. to ease insertionof the tenon in the i
mortiseand give extra room for glue squeeze-
out, slightlychamferthe tenon edges with a
block plane, as shown at far right.
strips, make a simple indexing jig. Screw a notchesfor a queen bed, 16 notches for a notchesin the spindlesrips. Sandlight cham-
zAx2x36" auxiliary fence to your miter double bed, or 23 notches for a king bed. fers on the endsof the slatsand spindles.
gauge, centering it with your tablesaw Repeatfor the other workpiece.
blade. Next, fit your saw with a 3/q" dado Enip six 7s"-wide strips from both work- Now let's check the fit of
blade. Raise the blade to /+", and cut a tJpieces, as shown in Photo F. To keep the parts wetvemade so far
notch through the fence. the correct orientationof the strips for spin- I Dry-assemble the footboard by posi-
dle alignment, mark the same end of each I tioning a center filler slat (K) and 36
QCut aVcxt/cx2"piece for an index pin.
fJUgtrtty chamfer the pin top edgeswith strip. Then plane the stripsto 3/q"wide to fit spindles (L) for a queen bed, 46 spindles
220-git sandpaper.Then, with the cham- the groovesin the rails (G, H, I). Set aside for a king bed, or 32 spindlesfor a double
fered edges up, glue the pin in the notch, four strips.You'll use them later as guides bed in the notchesin the footboard bottom
flush with the back face of the fence. to hold the spindles in alfgnment when rail (H). Make sure you position the spin-
Remove the auxiliary fence mounting assemblingthe footboard and headboard. dles with the quartersawnfacesto the front
screws,and move the fence exactly 3/q"to AWith the marked ends of the spindle and back. Using the four spindle strips (J)
repositionthe pin, as shownin Photo D. lJstrips (J) inside, glue and clamp two set aside for guides, align the spindlesand
3/a".Position a strips eachin the groovesin the rails (G, H, install the top rail (G), as shownin PhotoG.
.,[ naise the dado blade to
'lspindle-strip
workpieceagainstthe pin, I), where shown on Drawing 3. Position the Secure the assembly with a clamp at the
and cut a dado acrossthe piece. Now shift stripsflush with the shouldersof the tenons. center of the rails. Remove the spindle
the piece to locate the dado over the pin, ll Cttthe centerfiller slats(K) to size to fit strips. Then dry-fit the footboard legs
and cut again. Continue this Shift-and-cut I the spacebetweenthe spindle snips (J). (A/C/E) to the assembly, as shown in
process,as shown in Photo E, to form 18 Then cut the spindles (L) to size to fit the Photo H.
Shift the auxiliary fence to position the index Gut the needed dadoes in the spindle-strip With your tablesaw fence set 7e" from the
pin exactly {t'trom the dado blade. Then workpiece, shifting it over the jig index pin blade, rip six spindle strips (J)from each
reattach the fence to your miter gauge. after each cut. notched workpiece.

Withthe markedendsto the inside,position Dry-assemble and clampthe footboardlegs fnsertingthe s/qxg/qx6"
cauls betweenthe
the sparespindlestripson the frontand (NClEl to the endsof the footboardtop and spindles(L)and underthe top rail(G)in four
backof the spindles(L)to keepthem bottomrails(G,H),makingsurethe legs places(twoshown),clampthe top assembly
aligned.Thenadd the footboardtop rail (G). drawtight againstthe railtenonshoulders. (M/N)to the footboard.
that all of the parts fit together Spray-adherethe patternto a corbel. Now
)Venfy
El correctly. Then sand the center filler QRemove the masking tape. Then
bandsawthe corbel to shape,cutting just lfassemble the footboard top rail (G),
slat and spindtes.(We useda random-orbit outside the pattern line. Sand to the line bottom rail (H), center filler slat (K), and
sanderon the faces of the parts, and hand- using a 120-grit sanding drum in your spindles(L) asbefore.Now glue and clamp
sandedtheir edges.) drill press or an oscillating spindle the legs (NC/E) to the assembly.Use rub-
QDisassemble the footboard.Then trans- sander. Using this piece as a template, ber clamp pads or cardboardbetween the
lJfer the markings on the masking tape to mark the contour on the other corbels. clamp heads and the assemblyto prevent
the rail tenons and to the top of the legs, Cut and sand them to shape.For an easy marring of the finish. Repeat to assemble
and remove the tape. Sand the legs and way to make identical corbelsby pattern- the headboard.
rails. Repeatthe processto dry-assemble routing, seethe article on page 34. /l Cut four 2"-long piecesfrom a Vc" oak
'ldowel.
the headboardlegs (B/D/F), top rail (G), Note: Mattress lengthsmay vary by a cou- Also, ftem 3/+"scrap,cut four
centerand bottom rails (I), centerfiller slat ple of inches.To ensltrea correctfit in the 3/qx6" pieces for clamping cauls. Apply
(K), and spindles(L). bed, measure the length'of your mattress glue to two dowels, the top edge of the
and cut the side rails (P) to your rneasure- footboard top rail (G), and the top ends of
Fashion the tops. corbels. mentplus 1". the legs (NCIE}Insert the dowels in the
lide rails, andsipport
-and slits fFrom IVz" stockplanedto ltA", cut the rail holes. Then clamp the matched top
I Cut the sub tops (M) tops (N) to tfside rails (P) to size.Rout a V+"chatrfer assembly (MA{) in place, as shown in
I size. Rout a V+"chamferalong the bot- alongthe top outsideedgeof the rails, where Photo l. Repeatto assemblethe headboard
tom edgesof the sub tops,where shownon shown on Drawing3. Then, from 3A"stock, and its top assembly.
Drawings3 and 3a. Then glue and clamp cut the support slats (Q) to size. Sand the
RAppty glue to the backandtop edgesof
the tops centeredon the sub tops with a3/s" partssmooth. tf the corbels (O). Then clamp them in
overhangall around. place on the headboardand footboard legs
)Ontl /+" holes lVs" deepcenteredin the Head for the finish. underthe subtops (M). After the glue dries,
Er top edge of the footboard and head- and put it all together stain and finish the bottom face of the sub
board top rails (G), where dimensionedon
I Mask the top of the footboard legs tops, and touch up any areasthat needit on
Drawing3a, for /+" dowels. I (NC/E) and headboardlegs (B/D/F); the legs around the corbels.After the stain
Qhsert Vq"dowel centersin the holesin the tenons on the rails (G, H, I); the top dries, top-coat all parts, including the sup-
tlthe footboard top rail. Position a top edgesof rails G; the top and back edgesof port slats, with a clear finish. (We applied
assembly(MA{) on the footboard,centered the corbels (O); and the mating areaon the three coats of Aquazar Water-BasedClear
end-to-endand side-to-side.Press on the legs for the corbels.(Becauseit would be Satin Polyurethane, sanding to 320 gnt
assembly to mark the dowel-center loca- difficult to stain the headboardand foot- betweencoats.)
tions on the sub top (M). Remove the top board after assembly due to the narrow mount the bed-rail fastenersto the
assemblyand the dowel centers.Now drill Afo
spacesbetweenthe spindles(L) andlegs,we llheadboard and footboard legs and side
/+" holes 1" deep at the marked locations. maskedand stainedthe parts individually.) rails (P), lay out the mating left/right pairs
Mark the top assemblyto keep it matched
)Sand any parts that need it with 220- of fasteners,as specifiedin the instructions
with the footboard. Repeat for the head- Er grit sandpaper.Removethe dust.Then supplied with the hardware. Position the
boardand its top assembly. apply a stain to all of the bed parts except fastenerson the pzrts, where dimensioned
,1ll Cut the corbels (O) to rhe size listed. for the bottom face of the top assemblies on Drawing 5. Mark the mounting-hole
TThen photocopy the full-size corbel (M i) and the supportslats(Q). (We used locations. Then dnll 7/64"pilot holes 7,/s"
pattern on the WOOD Patternsa insert. Watco Danish Oil Finish, Dark Walnut.) deep,and screw the fastenersin place.
woodmagazine.com
45
n Cuttwo piecesof IVz" angleironto72" Using the holes in the iron as guides,drill support slats (Q) on the angle iron. For a
I long. DnlI3Ao" shankholes through the 7/u" pilot holes 7/e"deepin the rails. Now king-sizebed, mount a centerbed leg (see
iron, where shown on Drawing 3. Then screwthe iron to the rails. Sources) to the bottom of the center slat
(Q to preventsagging,as specifiedin the
position the iron on the side rails (P), flush tlWittr a helper, assemblethe bed, as
with the bottom and centeredend-to-end. lJshown in Photo J. Then position the instructions supplied with the hardware.
Now complete the bed with a box spring,
-E eeo-nALFASTENERDETATL Materials List mattress,mattresspad, linens, and comfy
(Headboard
shown) pillows, and climb aboard for a well-
deservedrest. I
Written by Owen Duvall
Projectdesign: Kevin Boyle
A-footboard Roxanne LeMoine
legouterwraps 3/qu 21/q' 311/c' O0 8 lllustrations:
B-headboard Note: To mnkeaking-sizeor double-sizebed,cut all

legouterwraps V+' 21/t' 491/t' Q0 I
of theparts to the sizesand in the quantitieslistedfor
C-footboard the queen-sizebed at left exceptfor the dffirences
legsplines ls' 3/t' 311/q' 0
specifiedbelowfor parts G throughN, P, and Q.
D.headboard
legsplines V8 3/"u 491/t' 0
E.lootboard
legcores Vc' 3/qu 311/q' 0 2
G footboard
and
toprails 11/q' 31/q'
headbd. 621/q' Q0 2 781/r' 561/q'
H footboard
rail
bottom 11/q" 61/z' 621/t' Q0 1 781/q'
I headboard
center
rails 1Y4'
andbottom 61/z' 621/q' Q0 2 781/q' co /4
J- spindle
strips 3/q' 27Vc' Q0 I 351/q'
K centerfillerslats Vt' 3Vc" 181/r' Q0 2 4Vr'

L spindles 3/"' 3/q' 171/z' Q0 72 92 64
Msubtops 31/z' 701/z' Q0 2 861/z' 641/2'
N tops s/cu 41/t' 711/c' 00 2 871/t' 65vi'

0 corbels 3/,' 23/q' 20" Q04
P siderails 11/a' 61/z' 80't Q0 2 7q'+
Q supportslats Vtn 4', 60%' c 765/a' 545/a'

-Parts
initially Seetheinstructions.
cutoversize.
tThelengths canvary.Ourqueen-size
ofmattresses mattressmeasured
79",Toensure a correct thelength
fit,measure ofyour
andadd1"to determine
mattress, ofthesiderails(P).
the'length
Materials key: Q0-quartersawn whiteoak,O-white of hardwood
oak,C-choice (2x4salsoaresuitable).
Suppfies: Spray oakdowel
adhesive,l/c" 10"long,
#8x1" flalhead
woodscrews(32),
#8x1'panhead (10),1tl2"
screws iron
angle
(2).
72"long
Blades and bits: Stackdadoset;7q"Forstner router
bit;45"chamfer bit.
Attach the side rails (P) to the footboard Sources

by engaging the bed-rail fasteners. Then Bed-rail fasteners.5ttlre" no.94K01.01,
bed-railfasteners, (setof4 prs.).
$6.20 CallLeeValley leevalley.com,
800/871-8158;
join the rails to the headboard. Center leg for king-size bed. Centerbedleg,no,68429, CallRockler
$12.99. rockler,com.
8001279-4441:
3/+x51/z
x 96" Quaftersawnwhiteoak (4 needed)(16 bd. ft. total) 3/cx71Ax 96" Quartersawnwhite
3 / + x 5 1 / zx 9 6 " O a k ( 4 b d . f t . )
3/qx71/+
x 96" Quartersawnwhiteoak (5.3 bd. ft.)
x 72" Quartersawnwhiteoak (2 needed)(6 bd. ft. total)

11/2x31/z
3/qx51/z
x 96" Quartersawnwhiteoak (2
*Planeor resawto the
thicknesseslistedin
x 72" Quartersawnwhiteoak (6 bd. ft.)
11/2x71/+ the MaterialsList. s/qx51/z
x 72" Quaftersawnwhiteoak (2 needed)(6 bd. ft. total)
11/2x71/qx 72" Quartersawn white oak (2 needed) (12 bd. ft. total) 1t/zx7t/t x g6" Quartersawnwhiteoak (2 needed)(16 bd. ft. total)
3/q x71/q x 96" whiteoak (5.3 bd. ft.) 3/qx51/zxT2"

Hardwood(5 needed)(15 bd. ft. total)
46
ffiaks*it-yourself
a o
mrssron
finish
Combiningcommonstainswith a
surpriseingredientyields a closecopy
of traditionalArts and Craftsfinishes.
hen it comes to Craftsman or movement in America through his maga- for coloring wood were sheergenius-even
Mission-style furniture, the zine, The Craftsman,and the widely copied if they were discoveredby accident.
name Gustav Stickley (1858- furniture he produced. His pieces were According to a history of Stickley, a
1942) always comes to mind. Stickley original, functional, and elbgant in their farmer noticed that raw oak planks in a barn
popularized the English Arts and Crafts simplicity, and the methods he developed had turned rich shadesof brown. Sticklev
Alan's stain formula uses nonfibered roofing Sand to at least 150 grit, and then raise the Add a half-pint of asphalt to one quart of red
tar-made with pure asphalt-mixed with grain with a damp cloth. Distilled water oak stain, a 4:1 ratio if you're mixing larger
Minwax red oak stain. Minwax natural stain works best because it contains no chlorine or smaller quantities. Use scrap from your
lightens the mixture as desired. Buy or impurities. After the wood dries, sand project to test the stain for color. For a
"nonfibered" roofing tar or you will have to with 180 grit just enough to remove the lighter look, add natural stain as a thinner.
strain the fibers out before mixing. A thicker raised wood fibers. Blow or brush off the For a darker colo[ sparingly add more tar
tar is available in caulking-style tubes and dust and sanding particles, making certain and test frequently.(Naturalstain mixed with
can be thinned with mineralspirits. you get all of the dust out of the pours. tar by itself makes a light stain.)

$hadesof the Past
i Alants Mission formula These sample boardsdemonstrate
i
I
the depth of color you can create by
layeringup to six coats of Alan's
stain.He recommendsthat the first
I stain applicationdry for at least 36
i g?,,}.$ hours beforeyou spray on added
l, sffi$ffiffi
layersof stain.You'llneed a spray
gun becausebrushingon additional
stain could reactivatepreviouscoats
and muddythe look. A clear topcoat
I Red Oak Stain can be brushedover a single stain
coat, but must be sprayedon if you
Non-fibered Fumed-looking
stain appliedmultiplestaincoats.
discovered that ammoniafumes,createdby Alants modern-day match tJVhite

Oak Red Oak
farm animalwastes,reactedwith the tannic To makecertainhis Missionfinish matched
acid found naturallyin oak. Stickleyused today'sagedoriginalfinishesas accurateas
that knowledge to develop an ammonia- possible, Alan borrowed examples of r
fuming processthat createda distinctive, iuthentic Stickley furnirurein their original
consistent tint in quartersawnoak. The I X
finishes from his next-door neighbor. "l
downsideis that ammoniafuming poses knew he had collected severalpieces of
serioushealthand safetyrisks. Stickleyandhad inheriteda few othersfrom
The challengetoday is to createa user- his fatheraswell. Fortunately,he washappy
friendly, safe-to-makefinish that closely to help," Alan says.
matchesthe Stickley look using materials One discoverywas that Stickley furnish-
readily availableat hardwarestores.
To meetthis challenge,we turnedto Alan
ings camein a rangeof shades,from natur-
al to a dark ebonizedfinish.(Seesamplesof
2x
Noel, a professional finisherin Atlanta.He comparableshadesat right.) Choosing a
sharedwith us his novel stain mix that's popular tint for today's furniture, here's
easy enoughfor a hobbyist, yet attractive how Alan duplicatedrhemedium-lightorig-
enoughto appealto professionalrestorers. inal Stickley finish on an oak chair.rF
3x
4x
5x
In a well-ventilatedspace, work the asphalV Let the stain dry completely before spraying
stain mix into the grain with a soft brush or additionalcoats of stain and topcoating.
rag. Work up from the bottom so that drips Protect the wood with an oil-basedsatin
or spills on surfacesbelow will do no harm. varnish-polyurethane in this case-applied
Let the stain stand for 3 to 5 minutes,then
wipe off the excess. For darker finisheslike
those shown far right, spray on light coats of
using a natural bristle brush or by spraying.
After the topcoat dries, rub lightly with 0000
steel wool. A buffed coat of dark wax
6x
the mixture without wiping them off. completesthe finish.
woodmagazine.com
tilting;bin
\-r#
ff ffikf
ffimffiffiffiffi
Reduce the jumble in
ur kitchen cabinets
by keeping a
dozen of your
most used spices
at your fingertips,
yet out of sight when
not being used.
With the bins No space on

ven if you don't cook, you can be
closed, your the counter? the most popul ar guy in t he
spices are No problem. kitchen with this weekend project.
neatly tucked This cabinet Designedwith expert input from the home
away and pro- also can hang economists in the Better Homes and
tected from on the wall.
sunlight,dust, Gardensa Test Kitchen, this handsome
and spatters. spice cabinet with tilrout bins is sure to

I exeloDED
vtEW
1/+"cove
t/q" rabbel t/q" deep along ends
t-
lz" rabbel
11/z'
t/+" rabbel t/+" deep /+" deep
alongfrontedge
/a" rabbet 1/2"F.H.

r/t" deep
1
t/a" dowels
I 13"
I
1/2"long t/q" dado
(bin stops) t/+" deep
,/
t/+" holes
1/4,,deep
t/z" rabbel
t/q" deep
along front edge
3e/q" -?--=---
I
t/2" rabbel t/+" deep
t/+"round-overwith t/a"shoulder )
bumper(optional)
\__--- Self-adhesive
SIDE
Note:Onlyonetilt-outbinis shown. Leftside,insidefaceshown)
Self-adhesivebumper-------z@
pleasethe most demanding chef,and you blade, cut /q" -deep dadoes along the rear 1/a"rabbel
t/q" deep
can complete it in a weekend.Use your edgesof the sides(A), bin tops (I), and bin
own 3Vz"-to 4Vz"-tallspicebottles that fit bottoms (J), where shown on Drawings 2
up to a maximum 2"-diameterhole, or see and 3. Make sure the sides are mirror
Source to order a matching set of bottles. images.To learn how to use an auxiliary
We even supply labels for 30 different fence when cutting rabbets,seethe sidebar
spicesyou can copy, cut, and pasteto iden- o n p a g e53.
tify both the bins and the bottles. Move the fence to expose t/+" of the
dadoblade.Then to steadythe partsand
Cut the dadoes and rabbets reducechipping,attachan auxiliary exten-
From Vz" stock, cut the sides (A), top sion to the miter gauge with its end t/ro"
. (B), shelf (C), bottom (D), bin tops (Ij, from the face of the fence. Now cut t/+"-
and bin bottoms(J) to the sizeslisted in rhe deep rabbetsin the upper ends of the sides
MaterialsList. Set the bottom (D) aside. (A) and both endsof the top (B) and shelf
Install a Vq" dado blade in your table- (C), where shownon Drawings1 and 2.
: saw, and attach
an auxiliary extension Move the fence to expose Vz" of the
to your miter gauge.Positionthe fenceas a dadoblade,and cut /+"-deeprabbetsin
stop, and cut Vq"-deepdadoesin the sides the lower ends of the sides (A), where
(A), whereshownon Drawings1 and 2. shown on Drawings1 and 2. Then cut the
Install a s/a" dado blade in your table- same rabbets along the front edges of
,, Sa.w:and attach a 3/+"-thickauxiliary the top (B) and shelf (C), where shown on
fence to the rip fence. Exposing Vs" of the Drawing1.
woodmagazine.com
51
Using a combinationsquare and a sharp Garefullydimplethe holecenterswith an Engagingthe tip of als" brad'pointbit in
pencil, mark the hole centers. awl or centerpunchat the markedlocations. the dimple,drillthe7+"-deepholes.
ffi trrtart<the centersand drill Vq"holes Va" bin tops (I). Then stick them together with your next larger size Forstner bit. Test the
1# deep in the sides (A) for the pivot and double-faced tape, keeping the ends and ftt of the bottle in the hole. Thendrtll holes
bin stop dowels,where shown on Drawing edgesflush. Mark hole centersfor the spice in the bin tops. The bin tops accommodate
2, and as shown in Photos A, B, and C. bottles, where shown on Drawing 4. Bore a maximum of 2"-diameter holes. The bot-
Make sure the parts are mirror images. the holes through both parts with a Forstner tles must be 3/2" to 4I/2" tall.
Finish-sand the inside faces of the sides. bit, and then separatethem. (! From Vz" stock,cut the cleat (E) to size.
Then cut four Vz"-longpiecesof W' dowel Note: Bore l3/t" holes in the bin tops (I)for *JGlue and clamp the cleatto the top (B),
for the bin stops, and glue them in place, the spicebottles listed in Source. To usethe keeping both parts flush at the rear and the
where shownon Drawing1. bottles that many popular spices come in, endsof the cleat flush with the shouldersof
ff Install a Vz" dado blade in your table- shownbelow right, measurethe diameterof the top end rabbets.
ffi su*, and cut a t/a"-deepgroou" in the the bottle, and bore holes in scrap with
Make the crown and base
#4 x s/a" bfdSS
roundheadwood screw -
--------_-
--!. t From Vz" stock, cut the crown (F) to
* size.Install aVc" covebit in your table-
@erru mountedrouter,and position the fenceflush
(twoneeded) z/o+"
shank hole with the pilot bearing. Using a follower
/2" PaPerstrip 13r/2"long
7er"pilot hole t/+"deep
I
I
57/e'
N
R
SN
/e" rabbets't/+"deep
\-tla" dowel 1tlro"long (bin pivot)

1/q"holes/q" deep, centered

-
i
II
block to steadythe part and reduce chip-
p erru
roe
II out, rout covesin the endsof the crown and t/+" rabbel *Note: Bore up to 2"-diameter
I
then along its front edge,where shown on /e" deep hofesfor largerbottles. *1e/+,hole
Drawing1. )
l"'l#From 7+"stock,cut the base(G) to size. T-Tr
**u$ Install a Vq" round-over bit in your ttl
table-mountedrouter. Again using a fol- tt,r'[
I |
l,
lower block to back the end cuts, rout
round-overswith %" shoulderson the ends tlr
ttlc
and along the front edgeof the base,where
-----r
shownon Drawing1. / l<-
1/zu/ 21/q"
E N DVIE W
Assemble
',lt
the bins
From Vz" stock,cut the bin fronts (K) to
.rr size.Draw the cutoutsin the top edges
of the bin fronts, where shownon Drawing
3, and bandsawand sand them to shape.
Then install a V8" round-overbit in your
table-mountedrouter, and rout their outside
endsand edges.
,r"f !fiff t/+"holes3A" deep,centeredin the
',i ':,edges of the bin fronts (K), where
shown on Drawing 3 and as shown in
Photo D. Then cut four l/+"-long piecesof
Vq"dowelfor the bin pivots, and glue them
in the holes. Using a s/te"-thickspacerto
guide a fine-tooth saw, trim the dowels,
leaving%0" protruding.
Glue and clamp the bin bottoms (J) to
'i..,.ths bin fronts (K), keeping both parts
flush at the ends and lower edges,where
Using a dowelingjig to center the drill bit on fnsert a2Vz"-widespacer between the bin
shownon Drawing1. Let the glue dry. Then the thickness of the bin fronts (K),drill 7a" bottom (J) and bin top (l),and glue and
glue and clamp the bin tops (I) to the bin holes 3/n"deep 7e" from the bottom edges for clamp the bin top to the bin front (K),
fronts,as shownin Photo E. the bin pivot dowels. keepingthe ends flush
Gut right-on rabbets the quick and safe rrnay .

When faced with cutting rabbetsof the same depth but several widths, as in this project,save time and increaseaccuracy Dy
installinga dado blade that accommodatesthe widest rabbet and using an auxiliaryience with your tablesaw rip tence.
Step 1: Install a dado blade about 7e" wider than Step 2: Clamp the auxiliaryfence to the rip Step 3: Switch off the saw. Lower
the widest rabbet you'll be cutting. Then cut a fence. Make sure the clamps will not interfere the blade slightly,reposition the
piece of softwood, plywood, pafticleboard,or with the workpiece. With the dado insert in fence to expose the width of dado
medium-densityfiberboard that's at least 7a" place and the dado blade below the surface of blade requiredfor the first rabbet,
thicker than the dado blade to the same size as the table, position the auxiliaryfence over the and make a test cut. Make any
the face of your tablesaw rip fence. Mark the blade so about 1/ta"of the blade will protrude adjustments needed, and rabbet
depth of the rabbets you will cut plus Yta"tor beyond its face. Lock the fence in place, your parts. Then, repositioningthe
clearanceon the auxiliaryfence with a line parallel switch on the saw, and slowly raise the blade fence to expose the width of blade
to the bottom edge and centered on the blade. into the auxiliaryfence to the depth line. necessary rabbet the other parts.
woodmagazine.com
53
-t
Appty finish and assemble Gutting Diagrarn

S finistr-sand all parts and assemblies.
& Then apply the finish, as shown in
Photo F. (We used Zar Salem Maple stain
followed by three coats of aerosol semi- 1/2x51/z x 60" Oak (1.3bd. ft.)
glosspolyurethane,sandingbetweencoats.)
ffi Cut the bin backs (L) to size, and glue
ffix and clamp them in place, where shown
on Drawing3. 1/zx71A x 96" Oak (2.6bd. ft.)
ffi Working with the front edges on a flat
#surface, spreadglue in the dado and end
rabbets of one side (A), and position the
ends of the top/cleat assembly (B/E) and 3/qx71/qx 24" Oak (1.3 bd. ft.)
bottom (D) in the rabbetsand the shelf (C)
in the dado. Then position the two bin
assemblies (VJlKlL) facedown with the
pivot dowels in the holes in the side. Now
spreadglue in the dado and end rabbetsof
the other side,and add it to the assembly,as
shown in Photo G. Glue and clamp the
assembly,and check it for square.
/lCut the back (H) to size, and glue and
*tchmp
it in place. Then glue and clamp
the crown (F) and base(G) to the case,flush 1/ex 24 x 24" T empered hardboard
at the rear, and centered side-to-side.
f,Cut two Vzxl4" stripsof Ve"acrylic,and
tJarin centeredscrew holes in the ends,
where dimensionedon Drawing3. Position
the stripsin the bin top (I) dadoes,and using
the holes in the strips as guides, drill pilot
holes into the bin tops. A sides 37/a'
Covering the mating glue surfaces with Using a straightedge and utility knife,
ffi B top f2 3Tc' 14s/a' 0
masking tape, apply stain and then a clear
finish to allthe parts and assemblies. When %S cut two Vzxl3Vz" strips from white C shelf SVq' 14Ve' 0
the finish dries, remove the tape. paper. Then make a copy of the labels on D bottom 3Vq' 14Va' O
page 105. (We copied ours onto ivory-color E cleat Y2' 1V2' 141/s" 0
paper.)Now cut out the 12labelsyou need.
F crown 43/s' 161/s' 0
Arrange the labels in alphabeticorder, and
G base 4Ve' 161/a' 0
adherethem to the paper strips with spray
adhesive.Place the label strips in the bin H back 13' 14s/a'
top dadoes, cover them with the acrylic

I bintops t/zo
strips, and drive the screws, where shown 31/a' 14' 0
on Drawing 3. If you're using the spicebot- J binbottoms Vz' 31/a' 14' 0

tles listed in Source,make a secondcopy of K binfronts V2' 57/s' 14' 0
the labels,cut them out, and adherethem to L binbacks t/su 3u 14" H
the bottles. Cover the labels with clear tape Materials key: O-oak,H-tempered hardboard.
to prevent them from getting soiled. Supplies: %"dowel, double-facedtape,masking tape,
!f For countertop use, adhere four self- t/s"cleatacrylic,
#4x%"brassroundhead woodscrews,
* adhesivebumpers to the boffom of the #5xt/2"flatheadwoodscrews, sprayadhesive, cleartape.
base(G). For wall hanging,adheretwo self- Blades and bits: Stack dadoset;1%"Forstner bit(or
adhesivebumpers to the rear edge of the upto 2"tofityourspicebottles); /+"cove,t/e"round'over,
base.Then position a pair of keyhole hang- andtA"round-over routerbits.
ers lVz" in from each side (A) and centered Source
on the width of the cleat (E). Drill pilot Hardware. Glass spicebottles withplasticspoon-or'
place. shake lidsno.
12K82.01, $.90ea.(12);blindkeyhole
holes and screw the hangersin Next
hangers no.00510,11, $2.30 (package of 10);1Omm self'
install screw anchors in the wall to align adhesive bumpers no.00520.02, $4.80(package of43),
with the hangers,and drive #8xlt/2" flat- CallLeeValley 800/871-8158, orgoto leevalley.com.
head wood screws,letting the screw heads
protrude t/a". Position the spice rack with
With glue spread in its dado and end rab-
the hangersover the screwheadsand slide
bets, tip the second side (A) into place, Writtenby Jan Svec
simultaneouslyengaging the top (B), shelf the rack onto them. Fill the bins. and start Projectdesign:Jeff Mertz
(C), bottom (D), and the bin pivot dowels. spicing up your kitchen. .l RoxanneLeMoine
lllustrations:

lr
ffie
,j.Q
ii\
I.
Learnonecraftsman's !*\.
secretsfor creating
3 high qualityjoints
usinghandplanes.
r.rtoned, award-winning woodworker, RandyMillerhasa

I
I lshop brimming withpowertoolsyetmakesno bones
abouthisloveanduseof handplanes."Theygiveme better
qualitywithoutincreased effort,"he says.
In a recentvisitto hisworkshop in AlisoViejo,California,
Randywalkedusthroughhistechniques for hand-planingedge
jointsandmitersthatfit better,he says,thananything youcan
produce witha machine. Randyalsointroduced usto the
Japanese planeshefavorsbecause of the increasedcontrolhe
believes theyoffer.Of course,Randy's techniques willwork
equallywellwithWestern-style planestoo.
Using a small bronze-headed Randy built this seven-

mallet-the only adjustment tool drawer chest using hand
required-Randy Miller gently taps tools. He planed the
the iron on his Japanesesmoothing drawers to fit perfectly
plane to expose more of the cutting in the openings and to
edge and take a deeper cut. slide with ease.

Joint l:
Handplaning
an edgejoint
Most of us flatten and squareboard
edgeswith a jointer. Randy chooses
not to have a jointer in his shop
becausethe tool's rotating headcuts
the edge in little scallops. Instead,
he uses a hand plane to create a
smooth, flat edge that will later
yield an almost invisible joint.
Here's how he doesit: Align boards with their mating edges flush. A Make passes with the plane over the full length
Step 1. To make a hand-jointed large bench vise holds the boards best, but any of the boards. Keep the sole flat, and plane until
panel, start by carefully matching clamps that can secure the boards will do. you peel off two full-width shavings.
boardsfor consistentcolor and grain
patterns.Even with thesetechniques, STEP4: PAIRINGTHEBOARDSFORJOINTING
a joint won't appearseamlessif mis-
matchedboardsgive it away.
Step 2. Rip each board about Vto"
wider than necessaryat the tablesaw
to get the edgesparallel and relative-
ly squareto the face of eachboard.
Step 3. Arrange the boardsto form a
panel, and then mark the face with a
large carpenter'sV to preventmixing
up the board sequence.
Step 4. Clamp the boards back to When planing two-board panels, place them back to back. For panels with more than two
back, as shown, above, and in the boards, pair boards two and tllree face-to-face, then joint the mating edges. Pair boards three
illustrations, right. and four back-to-back, and so on across the panel.
Step 5. Plane both edgesat the same
time using controlled full-length
strokes.Planing both boards at once
offers a wider surfacefor the plane's STEP5: EDGEJOINTING
sole and ensuresthat the panel will WITHA HANDPLANE
go together flat, even if the edges
are out of square, as shown in the
drawings, right.
Note: Becauseyou rury not be able to
plane with the grain on both boards,
use a well-sharpenedplane iron set
for a very light cut to prevent grain
tear-out.
Hold the plane's sole flat on the
board edges and work the entire
length of the boards,as shown in the
photo, top right.
Note: Randy chose a long version of FLATPANELS
FROM
a "Hira Kana" or smoothingplane BOARDS
OUT-OF.SQUARE
about 18" .long for jointing .these Even if not planed
36"-long boards. If you use Westem- squareto faces,
paired edges will have
slyle planes, choosea Jack plane or o Workpiecesplaced complementary angles.
back face to
#5 benchplane. back face
(Anglesexaggerated
Step 6. After jointing the boards, for clarity.)
checkthe fit of thejoint. If necessary,
plane the boards further until the
edges mate seamlessly along the
entire length of the joint.
Angles"cancelout,"producinga flat panel.
woodrnaEazine.com 61
Joint 2=
The sprungjoint
After practicingRandy's methods,you'll
be able to create panels with almost
invisibleseams.While this might seemlike
the perfect joint, Randy thinks it can be
improved by-get this-creating a gap
betweenthe boards.This technique,called
a sprungjoint, producesa shallowconcave
arc in eachadjoiningedge.
Why? A board absorbsand shedsmois-
ture most easily through its ends,so those When ready to be joined, mating boards Tighteningthe clampspullsthejointtight,
at the ends and be leavingno traceof the gap.Thetechnique
ends may changein width more than the should fit togethertightly
separated by about 1/sz"to3/sz"in the middle. alsohelpsevenlyspreadthe clampingforce.
middle of the board.The sprung joint leaves
the endsof eachboard a hair wider, allow-
ing them moremovementbeforethey might smooth arc, as shown, below left. The arc Step 4. Tightenthe clampsto make sureall
shrink enough[o separateat the glue line. needn't be deep-about Vtz" rs enough. gaps close fully along mating edges as
Many old-school woodworkersknow this Note: Once you master control of the shown,aboveright. Fine tune any joints, if
technique,but thoseexperienced only with a plane, you can create the arc by planing the necessary, by planingthem againfollowing
jointer may not. Here'show it's done: entire board length in one or two passes Steps 1 and2.
Step 1. Startby planingthe matingedgesas while varying pressure on the plane. Place Step 5. Now glue up the panel.To ensure
explainedin the previous steps.Now you light downward pressure on the plane at good quality joints, either tighten the
can createthe arc in two ways. the beginning of the stroke, heavy pressure clamps working from one end toward the
Step 2. Make a light pass with the plane in the middle, then ease up at the end. other, or tighten center clamps first and
overjust the centertwo-thirdsof the paired Step 3. After planing all board edges, dry work outwardtowardeachend.To ensurea
boards' edges to hollow that area, Then assemble the panel and check the joints, as flat panel, make sure the boardsdon't slip
make a full-length passor two to createa shown, below right. out of alignmentas you tightenthe clamps.
A S PR U N GJ OIN T
C RE A T I NG 1/sz-3/sz"
gap at center
(ARCSEXAGGERATED FORCLARITY) (Exaggerated for clarity)
Firstpass removes
materialhere.
Secondpass removes
materialfrommost of SPRUNGBOARDS
boardedges.
FOR
JOINED
CLAMPING
Matingedges
Lessthan /sz"
Note: Gap betweenboardswill
be doublethe arc depth.
(
Adjoiningboardspaired Endsfit together
or faceto-face.
back-to-back, tightlywith no gaps.
Randyts top 5 reasons for using hand planes

r "Handplanesallowyou to 'feel'the wood as you cut,
Eandy'F top secret for whichmakesit easierto preventtear-outand otherproblems."
hand-plane success
r "Planedsurfacesdon't requiresanding.They'resmoothand
Learnto sharpen,and hone re a d yfo r fi ni shi ng."
your planeir onsan d c h i s e l s
l "Handplanesare quiet.I can work earlyor late,even o u t i n
everytime you use them. the yard,withoutdisturbinganyone."
This m ay s eem lik eo v e rk i l lb, u t Randy's award-
I "End grainsmootheseasilywith a hand plane
maintaining a sharpedge takes winning upright
(e s p e c ial lay l ow angl eversi on)." cabinet proves
l es st im et han r ebu i l d i n og n e
r "Planinga surfaceratherthan sandingit creates his hand-plane
th at ' sdull.
n o fi n e d ustthat gets i ntothe shopor your l ungs." techniques work.

Joint 3: a gap exists at any corner, remove those two
mating boards from the clamps.
Step 3. Place one of the two box sides on a
MITERSHOOTINGBOARD
Shootingfor a shooting board, like the one shown at right,

and make a couple of passes (removing
marvelousmiter very thrn shavings) over the appropriate
end, as seen. below center. Hold the board
Hand-planeswork equally well when firmly against the shooting board. Repeat
making mitered boxes.Here, Randy relies this for the mating board.
on a simple 45" shootingboardto guidehis Step 4. Place the boards back in the clamps
plane at the preciseangle. A block plane and recheck the fit, as shown, below right.If
will shavethe miterseffectively,but Randy the miter is tight and the corner square,
often uses the same smoothing plane he move to the next corner. Check each corner Once the sides fit together perfectly,
employsfor jointing. Here'swhat to do: and repeat Randy marks the joints clearly before tak-
Step 1. Rip the box sidesto width,andthen Steps 3 and ing the box apart again. Then he cuts the
miter them at the tablesawto a lengthabout 4 as needed box top and bottom to fit, usually fining
t/tz" longer than necessary. asyou work them in groovescut into the box sides.He
Step 2. Dry clamp the box sides together around the assemblesthe box, then cuts the lid free..l
and checkthe fit of all miters,belowlefr.If entirebox.
Written by David Stone Photographs: Ed Gohlich
Step 2: Randy assemblesmitered boxes Step 3: Randy'sshooting board consists of a Step 4: After planing at the shooting board,
using a picture-framingclamp. After check- piece of 8/4 oak with side fences. One end recheckthe joint. With just a few plane
ing the squarenessof one corner,he begins is cut at 45o.Placingpaper shims under the strokes,the joint fits tightly from top to
fine tuning the joint with the largestgap. workpiece allows fine angle adjustment. bottom and creates a square corner.
Planingon thepull stroke:Aquicklook atJapanese

planes
Japaneseplanesdifferfrom'Western well,whilethe softersteelhonesaway
planesin severalimportantways. easilyduringsharpeningand provides
First,they featuresimplewoodenbod- some cushionto reducebladechatter.
ies made of tight-grained Japaneseoak. To make sharpeningeasier,the face of
Second,the bladessimplywedge into the hard steelis hollowedout, leaving
the planebody.A chip breakerholdsthe just an edge that requiresflattening.After
iron in placeand breaksthe shavings multiplesharpenings, the flat edge gets
removedby the bladeto preventtear-out. worn away.When this happens,the
The chip breakerwedgesagainsta pin bladescan be "poundedout" by tapping
th at holdsit and t he iro ni n p o s i ti o n . them near the top of the bevelto flatten
Third,no mechanicaldevicesare used part of the hollowarea.
to adjustthe planeiron.Tappingthe lf you'relookingfor Japaneseplanes, from $50 up to hundredsof dollars.To
bladeor planebody movesthe iron. try The JapanWoodworker(japanwood- learnmore aboutthesetools,read
"Learningto adjusttheseplanestakesa worker.com;800/537-7820)or Hida Tool Japanese Woodworking Tools: Their
littletime, but the processgoes fast and HardwareCo. (hidatool.com; Tradition,Spirit, and Use, by Toshio
when you know how,"Randysays. 800/443-5512). You'llfind modelspriced Odate,availablefrom Amazon.com.
Fourth,the planesare designedto be
pul l ed,r at hert han pu s h e d ". Pu l l i n gth e JAPANESE
PLANE Flat Hard
Planeiron
planegivesbettercontrolthan pushing," edge steel
Randysays."Onceyou get usedto doing CUTAWAY
VIEW cutting
i t, pullingt he planef e e l sn a tu ra le, v e nfo r Hollowed edge
devoteesof Westernplanes,"he adds. out area
Eventhe irons,far right,are uniquein JAPANESE
Japaneseplanes.They consistof a hard
steelportion(aboutt/a"thick)that's PLANE
"welded,"throughhand-forging, to a soft IRON
steelbackerthat makesup the remaining
thickness.The hard steelholdsan edge
Keepfuquenflyusedtools
organized, protected,and
withineasyreachwherever
yougo by rolling thiscompact
cartright up to lrcurwork area.
Itsdrawers,shelves, top tray
anddoorscreatenrmerous
storageopportunities.
'
ts
/z.41.&
::i':'
?!
Thanksto its large 6"-diameterwheels and

easy-adjust,fully retractable, locking handle,
moving the caddy is a cinch.
lfere it is----ourversion of the tag- The top of the tool caddy flips up and Note: For a natural wood look and void-
H along tool tote that won Kevin Hall the doors swing open to provide accessto free edges,we used Baltic birch plywood
I I of Tremonton,Utah, the grandprize the items inside. Simple scrapwoodhold- for our tool caddy,and applied a clearfin-
in our 20(X "Rugged'n' ReadyTool Storage ers keep everything in place while on the ish. As a lessexpensivealternative,you can
Contest." Kevin's inspiration for the unit move, and removabledrawersand shelves use typeAC or BC plywood, particularly if
came from a rolling carry-on suitcase,like accommodate tools and hardware. The you plan to paint the unit.AIso, becausethe
those used by airline travelers.It provides photo above shows the unit with one thicknessof plywood varies,you may need
on-the-gostoragefor the tools and supplies drawer and shelf, but it can hold two of to slightly adjust the sizeof someparts and
you needfor fix-ups outsidethe shop. each if needbe. the mating dadoesand rabbets.

I ennrsvrEW 17"-
T-
1/z'
1_
r
1 /q'
L
r
1/c'
13Y4'
251/2" 251/2"
rI
41/z'
I
1/+"I
-
.:-
Vr'I Locationof parl@
r -_ 4"___t-l
L E F TS I D E BACK
(lnsidefaceshown)
2ul"k-A::j (Outsideface shown)
For the items neededto build this r1l;r-

project, see page 69.
BRACE
Startwith the case will assemblecorrectly.Then,with the rab-
I Cut the sides (A), axle supports(B), betededgesof the top fixed shelf facing up,
I fixed shelves(C), and back (D) to the glue and clampthe top divider to itt/+" back
sizeslistedin the MaterialsList. from the front edge, where shown on
t) Usinga dadobladein your tablesaw,cut Drawing 2. After the glue dries, assemble
Cf seven /+" dadoes V+" deep acrossthe the case,as shownin PhotoA.
width of the sides(A) and a 3/q"rabbet Va"
deep along the back edge, where dimen- Add the fenders and brace
sionedon Drawing 1. Make sure they are
I To make the fenders (F), flust cut four
mirror-imageparts.Then, drill a Vz"holefor I pieces of 3/4" plywood to 5t/+x7".
the wheel axle through the sides, where Laminate the pieces together to form two
dimensioned. I Vz"-thrck workpieces.
QBandsaw at/zxVz"notchfor theaxlein a )Wake two copies each of the full-size
9corner of the axle supports(B), where Er fender and handlesupportpatternsand
shownon Drawing2. Then glue and clamp three copies of the pipe supports/pipe
the supportsto the sides(A), where shown, clamp pattern on the WOOD Patternsa
with the notchesalignedwith the %" holes insert. Set the handle support and pipe
in the sides. supports/pipeclamp patternsaside.Spray-
tablesaw,cut Vq"rabbetst/2" adherethe fenderpatternsto the workpieces.
'fllUsingyour
deepalongthe endsof the fixed shelves Then bandsawjust outsidethe outer radius
(C), leavingV+xVt"tonguesto fit the dadoes on the patterns.Now sandto the line using
in the sides(A). a 100-gritsandingdrum.
(E) to size,making Glue and clamp together the side
f Cut the top divider QNoting that the two fendersare mirror assemblies (A/B), fixed shelves (C, C/E), and
tf surethe lenethmatchesthe shoulder-to- tJimages of one another,useyour tableback (D). Make sure the rabbeted edges of
shoulderlengtliof the shelvesso the case mounted router and rout a Vz" rotJnd-over shelvesC face down and shelf C/E face up.
woodmagazine.com
65
DETATL
@roe PRoFILE @ exeloDEDvtEW
t/2"round-over
1" scr.eweye
s/q"O.D.
aluminumpi 3/ro"hole,countersunk
25t/q" long
t/e"round-overs
#8x11/z'F.H.
t/a"round-overalong 1213/'ra" wood screw
front and side edges Twisted-linkchain
1 5 "l o n g rh-20 x2"
1" hookand hangerbolt
,l
screw eye
161/z'
1" screw 7e"hole
eye
#8x11/q'F.H.
wood screw
z/o+"
pilothole
Ta"rabbets
Ta"deep 2Y4"
#8x 1"F.H.
wood screw
21/2"no-mortisehinge
103/q'
tZ" round-over
I t/2" steel
4" pushnut
r/z x 1/2"
t/2"round-overs
Draw catch
t/c" rabbel
t/2" deep
-:-ll
r z ^ uJ R
notch
!,
3/+tt t
t/2" Sleel rOd\
22" long N --
',/""
6"-diam.
with a
/2"-diam' hUb
llal washer
along a top outside edge of each work- To make the brace (G), cut two 2x4"
piece, where shown.on the pattern and
Drawing2, andas shown in Photo B. Then
bandsawand sand the inner radius of the bandsaw the beveled edges of the part,
fenders to shape. Remove the patterns where dimensionedon Drawing 1, and
using a solvent, such as lacquer thinner. sand smooth. Now glue and clamP the
Now glue and clamp the fenders to the brace to the bottom fixed shelf (C) cen-
sides(A), positioningthem where dimen- tered and flush with the front edge,where
sionedon Drawing1. shownon Drawing2.
An easy (and dottbly fast) way

to form drawer-pull openings
2l'Forstner
Here'show to quicklyand uit
simultaneously bore preciseradiused
openingsin a pair of drawerfronts,
such as those for the tool caddY.
Clamp the two frontstogethertoP
edge to top edge,and markthe
centerpointfor the openings.Then
placethe clampedassemblyon top of
a backerboardon your drill-Press
table.Usingthe appropriatesize
Forstnerbit, a hole saw, or a circle
cutterfor the desiredopeningradius,
Round over a radiused edge of each fender, bore a holethroughthe frontsat the
routing opposite top outside edges of the markedcenterpoint,as shown at right.
pieces to produce mirror-image parts.

p onnwen
,4,I
D
l-
31/a'
l-- "i
,A\ 7se"shank hole,
countersunk witha
) 7o+"pilothole
# 8x 1 "F . H . s/q"deeo
wood screw
Drill mounting holes through the bottom (J)

and into the drawer frame (H/l) at the
marked locations.Then drive the screws.
Slide into the drawers door on the outsideface and the otheron the Elsroe
I From %" plywood, cut the drawersides insideface,whereshown,so that the rabbets # 1 0 x 1 3 / qF' . H . SECTION
VIEW
f (D and drawer fronts and backs(I) to overlapwhen the doorsclose. machinescrew in a
s/0"shankhole,
the sizeslisted.From Vq"hardboerd,cut the Note: We used countersunk.with a
drawerbottoms/shelves (J) to size. #4xt/2" flathead #10 stopnut
)Cu %" rabbets.%" deep alongthe ends wood screwsto fas- 3/+"
O.D.aluminumpipe
Er of the frontsandbacks(I), whereshown ten the hingesto the 25t/q"long No round-overs
on Drawing 3. Using a circle templateor Baltic birch ply- 1 alongback edge
compass.mark a centered1" radiuson each wood case. If you
of the two fronts, where dimensioned. are usingtypeAC or 7o+"pilothole
Bandsawandsandtheopeningsto shape.Or s/q"deep in part
BC plywood, which Q!)
seethe Shop Tip, oppositepage, for a time may have voids
savingalternative. between the plies,
QCtue and clamp together the drawer use l"-long screws # 8 x 1 1 / z 'F . H .
lJsides, fronts, and backs,and check for wooo screw
to help ensure an
square.After the glue dries,placethe draw- adequategrip in the
ers on your workbenchwith the radiused plywood edges.
openingsfacedown.
QN,tount hinges
illMark the locationsfor mbunringholes tJon the front
Ton the two drawer bottoms (J), where edge of the sides
shown.(We markedthe locationson white (A) and on the top
tape so we could easily see them.) Then edge of the back
positiona bottomon eachdrawer,flush with (D), where dimen-
the outsidefacesof the front and back and sioned. Align the
centeredend-to-endwith a e/tz"overhangon hinges flush with
the sides,where shown.Clamp the bottom the inside face of 1/q-20x 2"
to the drawer. Now secureit in place, as the sidesand back. hangerbolt
shownin PhotoC. AFasten the rop
Z (K ) to rhe
Top it off, and add the doors hinges with the top
(K) and doors (L) ro size.
I Cut the top flush with the back
I Using your table-mounted router,rout of the caseandcen-
a t/8" round-over along the bottom front tered side-to-side
and side edgesof the top, where shown on with a t/2" over-
Drawing2a. Switchto a Vz"round-overbit, hang. Next attach
and rout the top edges. Now rout a V2" the doors (L) to
round-over along the long outer edge of the hinges with the
eachdoor on its outsideface,where shown doors flush with
on Drawing2. the case sides and aVt" gapbetween the top mounting-hole locations, see the Shop Tip
I nent your routerwith at/a" rabbetingbit. edge of the doors and the top, where shown on the next page. Now mount draw catches
Er Then rout a -%"rabbet3/a"deepalongthe on Drawing 4. For an easy way to hold the on the doors, where dimensioned, using the
long inner edge of each door, cutting one parts in position while you mark the hinge screws supplied with the hardware.
woodmagazine.com
67
Time for the handle
I From t/+" plywood, cut four 2Vqx9"
I pieces-two for the pipe supports(M)
and two for the pipe clamp (N). Laminate
the two piecesfor the pipe clamp together
to form a lVz"-thick workpiece.
!) Retrieve the pipe supports/pipeclamp
fr patterns,and spray-adherethem to the
three workpieces.Using a 32" Forstnerbit
in your drill press,bore holes through the
pieces,onepieceat a time, whereshownon
the patternand as shown in Photo D.
Q Bandsaw and sand the pipe supports
tf andpipe clamp to the patternline. Then
rout %" round-overs along the top and
bottom edges,where shown. Now drill a Using stopblocks to preciselyposition the Jam togethertwo 1/+20hex nutson the
pipe supports (M) and pipe clamp (N),bore hangerbolt.Driveit intothe pipeclamp(N)
centered/q" hole only through the clamp. s/4"holes through each part at the marked by turningthe nutswith a 7re"wrench.Then
illtJsing your tablesaw, rip the pipe
'fclamp centerpoints on the pattern. removethe nuts.
(N) along the cutline, where
shown. Next, using your drill pressand a From a 60"-long pieceof 3/+"O.D. alu- you wish. (We applied three coats of
twist bit, enlarge the Vq"hole in the con- minum pipe, hacksaw one SVz"-long Aquazar Water-Based Clear Satin
toured half of the clamp to 3/a".Then drill piece and two 25V+"-longpieces.Slide the Polyurethaneto the caddy and aluminum
the countersunkshank holes in the other two long pipesthroughthe holesin the two pipes,sandingto 320 grit betweencoats.)If
half, where shown.Positionthis half of the pipe supports(M). Align one supportflush you plan to paint the caddy, first fill any
clamp on the back (D), wheredimensioned with the ends of the pipes. Then drill voids with a paintable wood putty, and
on the backportion of Drawing1. Using the mounting holes through the support and sand it smooth after it dries. Then prime
clamp shank holes as guides, drill pilot pipes, where shown on Drawings2 and 4, and paint the unit.
holes in the back, where shown on and drive the screws. Do not fasten the j)From a Vz" steelrod 36" long, hacksaw
Drawings1 and 4, and drive the screws. other supportto the pipes. Aa 2T"-long piece for the wheel axle.
3/q"plywood, cut four 1Vzx2Vz" (f Capture the SVz"-longpipe in the 3/q" Insert the rod through the holes in the case
fFrom
rJpieces for the handle supports (O). {f holesin the sidesof the handlesupports sides(A), whereshownon Drawing2. Then
Laminate the pieces together to form two (O). Then position this assemblyon the install the flat washers,wheels, and push
IVz"-thickpairs. ends of the long pipes, where shown. nuts on the axle. (We used a 6"-diameter
Drill countersunk%0" holes through the lawnmower-typewheel with a steel hub.)
f Spray-adherethe handle-supportpatterns
lf to an end of eachpiece.Then bore a3A" supports and pipes, where shown on Use a hammerto drive the push nuts.
hole 3/q"deep in the parts, where shown on Drawing2, andsecurewith machinescrews 2fo attachthe handleassembly,drill two
thepaffern.Draw diagonalson thebottomsof and stop nuts. For safety,trim the ends of 9sAz" shankholes throughthe back (D),
the partsto find the centers.Now bore a cen- the screwsflush with the nuts usinga hack- where dimensioned on Drawing 1, for
tered3A"hole l" deepin the boffoms. saw, and smoothwith a file. mountingthe upperpipe support(M). Then
countersinkthe holes on the inside face of
lf Bandsaw and sand the hhndle supports
I to the pattem lines. Then, using your Head for the finish the back.Next, with the tool caddyfacedown
table-mountedrouter, rout %" rounci-overs I Removethe top (K), doors (L), and all on your workbench, install a V+-20x2"
along all of the edges. Now remove the I of the hardware.Sand any areasthat hangerbolt in the centerVc"hole in the case-
patternsfrom the handlesupports,pipe sup- need it with 220-grit sandpaper, and mounted part of the pipe clamp (N), as
ports,and pipe clamp. remove the dust. Apply a clear finish, if shownin PhotoE. Now positionthe handle
assemblyon the unit, as shown,and install
the contouredhalf of the pipe clamp, a flat
washer,and a four-arm knob on the bolt.
Double-faced tape makes securethe upperpipe support(M) to
'fAfo
hinge rnounting easy the back (D), positionthe handleto cen-
ter the support over the shank holes in the
Holdinga cabinetdoor or case top in
exactpositionwhilemarkingthe hinge back, and tighten the four-arm knob. Then,
mountingholes can be awkwardand from inside the case and using the shank
Here'sa simpleway to
frustrating: holesasguides,drill pilot holesthroughthe
avoidthe problem.Applya pieceof support and pipes, where shown on
double-faced tape to the hingeleaves Drawing4. Now drive the screws.
that attachto the door or top. Remove f Remountthe top (K) and doors(L). To
the tape backing.Alignthe part and rf install a chainfor holding the top open,
pressit firmlyin placeto adhereit to drill pilot holesfor 1" ,.."*-"y., iniholeft
the tape.Open the door or toP and side (A) and top, where dimensionedon
markthe mountingholeswith an awl,
Drawing 2. Install the eyes. Then, using
as shown at right.Removethe tape,
and drillthe holes. @, needlenose pliers, open the eyes,slip the
ends of a 15" lensth of twisted-link chain
68 UIOOD magazine October 2004

-t
Quick and easy ideas for mounting yorrr tools and accessories
The tool caddydoorsprovidea convenientplaceto keep cl earancearoundthe i temsfor easyhandl i ng. A l s o,keepin
fre quent lyus edt oolsa c c e s s i b l a
e n d o rg a h i z e dT. o h angyour mindthat becausethe fixedshelves(C) extendto the frontof
tool sa nd k eept hems e c u rew h e n mo v i n gth e c a d d y ,you don' t the case,you needto keepthe toolsat leastZs/e"belowthe top
needto s penda lot of m o n e yo n fa n c yh o l d e rsU . s i n gsmal l of the doors and St/z"from the bottom.Ensureyour toolsand
piecesof scrapwood,dowels,and aluminumbar, you can make holdersextendno morethan 1t/z"lrom the doorsso they'llclear
attractiveholdersin minutesthat custom-fityour tools,such as the drawersand shelveswhen you closethe doors.
the ones shownin the photosbelow. To allowfor easy rearrangement of your tools later,omit glue
Startby removingthe doors,placingthem on your workbench, and si mpl yscrewthe hol dersi n pl ace.l f someof yourt ools
and l ay ingout y ourt o o l so n th e m .Ma k es u rey o u l e a veenough havethei row n hol ders,you can mountthemto th e doort oo.
t/c" spacer
(**
\
Vex1V""
J
aluminumbar
maKea no10 A piece of t/ax1tl2"aluminum bar (available To create narrow slots, glue t/e"spacers
les, glue two at hardware stores) and two 1/ayil/2yl'r/2tl between strips of /q" stock. A notched
ill stopped h< wood spacers make a handy holder for T-shapedholder made from 1/q"stock keeps
-shank or to< items that have a spring clip. a slidingbevel securelyin place.
onto them, and close the eyes.To securethe

top when it is down, drill holes in the top
divider (E) and the top, and install a I " hook
Seemore
and screw eye, where shown. shop project sides 11t/z' 251/z' BB 2
ftStiOe
the drawers and shelves (J) in plansat B axlesupports 103h' BB 2
lVplace. Load the caddy with tools, hard- C fixedshelves 3/r' a 1r
BB3
ware, and supplies and you're ready to roll
gazine,com/sh0frtonIs
woodma t t
D back 3/^r 17', 251/z' BB 1

to your work site. For ways to hang tools on E topdivider 3/4' 161/z' BB 1
the inside of the doors, see the sidebar
F fenders 11/z' 51/i' LBB 2
"Quick and easy ideas for mounting your
G brace 11/z' lr
+ LBB 1
tools and accessories."above.lF
H drawer
sides Vz' 31/B'
I drawer
fronts
andbacks v|' 31/a' 163/e' BB 4
J drawer
bottoms/
snetves vi O1/^" 1 6 1 % 0 "H
Diagram K top 3h' 1213Aa" 19" DDI
L 000rs 3h' 91/a' 253/a' BB 2

M pipesupports 21/q' BB2
1/2x24x 30" Balticbirchplywood N PiPe
clamp 2,/q', LBB 1
O handle
supports11/z' 11/z' 21/z' LBB 2
Materials key: BB-Baltic birchplywood,

LBB-laminated Baltic
birch plywood, H-hardboard.
Su pp Ii es : Spray-adhesiv
e,2t/2"no-morlise hinges(6),
#4xt/z"
llalhead woodscrews (30),#Bxl flathead wood
(30),
screws #Bxlt/t" flathead (2),
woodscrews #Bx1 t/2"llal-
headwoodscrews (2),#10x1s/a"flatheadmachine screws
(2),#10stopnuts(2),draw catches (2),sh'O.D. aluminum
pipe60 long, paintable
woodputty, double-faced tape,
% steelrod36"long, 6"-diameter wheelswitha
t/a"-diameterhub(2),72"flatwashers t1r"
(2), steelpushnuts
(2),,h-20x2" hangerbolt,1/+20 hexnuts(2),t/a"flatwasher,
four-arm t/n"
knobwith insert, 1"screw eyes(2),twisted-link
chain15 long,1"hookandscrew eye.
Blades and bits: Dado-blade set,/e"and/2' round-
overands/e" rabbetingrouterbits,3/q"
and2 Forstner bits.
Writtenby OwenDuvallwithChuckHedlund
Projectdesign:KevinHall,Tremonton,
Utah,withKevinBoyle
s/qx 60 x 60" Balticbirchplywood 1/qx 24 x 48" Hardboard lllustrations:
Roxanne LeMoine
woodmagazine.com 69
TheWoodvuorkerts Guide to UnderctandingWood: A 4-Part Series
PartIV:SuCCeSSwittt
stainir -rnd
Mfinis
Becausethe majority of these fibers run
lengthwise in a board, the face or edge
surfacesreveal the sides of the fibers. The
end of a boardshowsthe fiber's openends,
often called pores.
A few fibers, mainly rays, run acrossthe
board. And lengthwise fibers get twisted
aroundbranches.This meansyou'll likely
encounteropen poreson all board surfaces.
( Why woodneedsa finish

Pigmentparticles Wood, even when dried into lumber, can
Wood fibers
magnified to lodgein poresand shed and absorb moisture. So we need to
show structure surfaceirregularities. seal it with a finish. Doing this slows, but
doesn't stop, the transfer of moisture into
inish quality can make or break a yourself with the following insights into and out of wood fiber walls. This, in turn,
project. Just as people desire to what happensat the wood fiber level, and minimizes seasonalexpansionand contrac-
touch an immaculate finish, they you'll better your chancesat staining and tion causedby changinghumidity.
also can immediately detect one that's finishing success,startingright now. Finish also helpspreservewood color by
flawed. Whether the color is not right or the slowingthe processof oxidation,which can
surfaceis rough, a bad finish can spoil your A review of wood structure darken woods such as cherry, and lighten
efforts at fine craftsmanship. We've describedwood as millions of tiny, others such as walnut. Some types of fin-
For this reason,many of us find staining tubelike fibers glued together, above, that ishesfeatureadditivesthat block ultraviolet
and finishing downright intimidating. And transportand store water in the living tree. (UV) light, the other main culprit
too often we don't understandhow wood They become dry and shrink when the in changing wood's color. Finally, finish
will react to the coatingswe apply. So arm wood getsprocessedinto lumber. protectswood from dirt and scratches.
We sanded half of the end grain on this

red oak board to a finer grit, and then applied
We sanded the cherry sample at left to 80 grit, and the other to 400 grit. Then we applied one stain. This reduced the amount of pigment it
coat of the same cherry stain to both boards, producing very different tones. could hold. The result:consistent color.

Two ways to color wood board, as seen,previous
In somecases,we want to changethe color page bottom right.
of wood to createa certainlook, to even out You can minimize
inconsistent wood tones, or to hide sap- color inconsistencies
wood. This alsocangive freshwood an aged by first coating the
look, or make one wood imitate another. wood with a stain con-
To do this, coat the wood with either ditioner to partially seal
pigmented stainsor dyes. While thesetwo the pores. Or choose a
substancesaccomplishthe samegbal, wood gel stain-wood pores
acceptsthem differently. can't acceptas much of
Stain. Pigmentedstains(usually called just the thickenedsolventin The center of this pine board shows the light-colored earlywood
"stain") consistof tiny pigmentparticlesand these stains, yielding a and dark latewood. The colors "reverse out" when stained because
more pigment lodges in the porous earlywood (left).Stain
binder suspendedin a solvent. Stainsbuild more-evencolor. conditioner (right),reduces this effect by partially sealing the pores.
up on the wood surface,as shown below. Dye. In contrast to
This means that the smoother the wood stains, dyes-typically
surface,the lessstainit accepts,asfine sand- aniline-contain pig-
ing removes scratcheswhere the pigment ments that are soluble
can take hold. See the difference,previous (dissolving). Dyes are
page, bottom left. usually sold as a pow-
Sandingdoesn't close pores,though, so der that dissolves in
pigment still accumulates in them. This either water or alcohol.
highlights contrasts in grain figure, espe- Rather than remain
cially in open-poredwoods and in species on the wood surface,
that have widely varying pore sizes,suchas dyes soak in. This lets
red oak and pine. You can see this in the the figure show through
photo, top right. Maple has small, dense pores, so it doesn't provide many places
because dyes actually for
stain pigment particles to lodge, as shown (left).A dye (right),
The ends of a board, too, are naturally changethe color of the colors the wood evenly,regardless of pore size.
porous.They stain darker than the face of a wood fibers. ratherthan
cover up the fibers with pigment particles, for stain pigments to lodge, as seenin the
HOWWOODACCEPTS
STAIN
ANDDYE as stain would. Plus, dyes producea more- photo, above.
even tone than do stains.For thesereasons, Dyes do tend to fade more than pigmented
dyes generally perform better on figured stains,though water-solubleversionsresist
stock becausethey don't obscurethe grain. fading betterthan alcohol-solubledyes.The
Dyes also excel for coloring densewoods, latter also can be trickier to apply. Learn
such as maple, that don't offer many places aboutusingdye in issue157,page42.
Pigment particles lodge in open pores,

sanding scratches, and nooks and crannies Glear choicesin topcoats Wood soaks up some topcoats, such as
on the wood surface without soaking in. If you don't want to color the wood, you oils. These penetrating finishes reduce
can skip straight to the topcoat. Though moisture exchangeand beautify wood, yet
Dye saturatesthe wood. many types of clear topcoatsexist, they fall protect the wood surfacelittle. You can see
into two broad groups based on how the an oil finish on the right-handboard,below.
wood acceptsthem. Many topcoats combine oil and another
ffi-i-:,-i Some topcoats, such as lacquer and
polyurethane, remain on the wood surface
substance,usually varnish, to createfinish
with both penetrating and film-building
rather than soak in. These film-forming properties. Called wiping varnishes or
When applied to the wood, dyes soak finishessealthe wood and createa shell that oiUvarnishblends, these are easy to apply,
into the walls of the wood fibers, actually thickensand developsa glossysheenasyou
changing their color.
and allow you to regulate how much film
apply more coats, as seenon the left-hand you create.You'll haveto apply many coats
sample,below. Film-forming finishes offer to form a thick, protective film. i
protectionfrom abrasionand liquids. Written by David Stone lllustration: Eric Flynn
Hov much sanding is enough? The film-forming
fn the WOOb magazineshop,we finish (lacquer)
generallysandthrough180 grit when used on one red
applyinga film{ormingfinish.We sand oak board
through220 to give a smootherfeel to enhancesthe
differences in
woodsthat will get penetrating oil finish. pore sizes. A
On projectsthat will be stained,we Penetrating
sand throughat least 180 grit usinga finish (tung oil)
random-orbitsander,and then proceed makes the
differences
through220 or 320 grit on end grain
in pore size
and areasthat requirehand-sanding. less obvious.
woodmagazine.com
;>.'"./,
v r-r
t Beginscrollsawing throughthe giraffe's
body by cuttingthroughthe centerof its
i mouthand then intothe view-slotarea.
Patternsa insert. Spray-adherethe body
{ pattern and two copies of the side pattern
Kidswillgoanimalasthe ( to 3/c"MDF. Then adhere the tail pattern,
coinstheyfeedthisfriendlY
creature downits
zigzag
a
{
two copies each of the front and rear leg
patterns,and four copies of the hoof pat-
tern to V2"IN{DF.
{) Using your scrollsaw with a no- 12
inthe
neckanddeposit e Cl-blade,cut the parts to shape,staying
outsidethe mouthon the body. (You'11cut
the mouth to shapeafter forming the coin
bank.
see-through { slot.) Then drum-sandthe edges smooth
a to 180 grit.
Qfo split the giraffe's body so that you
tlcan machine the coin slot, first scroll-
\ saw through the mouth and into the sinuous
view slot, where shown on the pattern and
I in Photo A. Continue cutting along the pat-
tern lines to form the view slot and bank
cavity. Then cut along the centerline for
the 1" hole at the bottom to separatethe
body. Drum-sand the view slot and bank
cavity edges smooth. Do not sand the
edgeswhere you'll rejoin the body halves.
Using a three-wing VB"slotting cutter
'f/
in vour table-mountedrouter, cutaVz"-
deepsiot in eachbody half for the coin slot,
as shown in Photo B. Keep the pattern side
of each half faceup to ensure the slots
align. Then, using five-minute epoxy (see
the Shop Tip, oppositepage,far right), join
the body halves together, being careful to
remove any squeeze-outfrom the coin slot.
f Rfter the epoxy cures, scrollsaw the
rJmouth to shape.Then drill a 3/tz"blade
start hole, where shown on the pattern,
and scrollsawout the nostril.
I
f ooking for a project that uses few acrylic for materials,you have what it takes QOritt a 3/32"blade start hole through
to build this whimsical kids' bank. It lJthe two side pieces,where shown on
I I materials and tools and will give a
tlchild an early start on saving? accepts all coins except a half-dollar. the pattern.Then cut the inside of the pieces
You've come to the right place. With only to shape,staying approximately Vr" inside
a scrollsaw, router table, and stationary Gut the parts to shape, the patternline. (You'11flush-trimeachside
belt/disc sander for tools, and a 12x24" and ass6mble the bo?y openingto match the body bank cavity con-
piece each of Vz" and 3/+"medittm-density I Make four photocopies of the full-size tour after epoxying the piecesto the body')
fiberboard (MDF) and a small piece of Vs" I giraffe patterns on the WOOD Refit your table-mountedrouter with a 7s"

72
l[ rnorurvrEW
Coin slot Epory: A quick and handy way
to join pafis without clamps
Evertriedto glue togethersmall,odd-
shapepartsand struggledwith how to
clampthem securely?Here'sa simple
way to fix the problem.Use five-minute
epoxyto adherethe partsand holdthem
togetherwith your handsuntilthe epoxy
sets (the parts stay in positionwhen you
let go of them).The epoxycreatesa
strong,gap-fillingbond.We used epoxyto
assemblethe giraffebank,makingit easy
to adhereits irregular-shape parts,such
Rear leg
as the hoovesand tail, as shownbelow,
Using a slotting cutter, cut a centered Va" withoutclamps.Avoidsqueeze-out-it's
slot 72" deep from the mouth to the bank difficultto clean up.
cavity opening in each body half.
20'bevel
I exeloDED
vrEW
Centera flush-trimbit bearingon the edge

of the body bankcavity.Trimone side,and
thenturn the assemblyoverand repeat.
View slot
round-over bit. Now round over one edge
of eachpiece,where shown on Drawing1, 3/a"round-over
making surethey are mirror-image parts.
f Remove the pattems from all of the
I partsusing a solvent,suchas lacqueror
paint thinner.
lQEpoxy and clamp the sidesto the body,
Iupositioning them flush with the body
bottom and centeringtheir undersizeopen-
ings over the body bank cavity. When the t/a" acrylic
epoxy cures, trim the side openings flush
with the cavity using a bearing-guided
flush-trimbit, as shownin Photo C. Bank cavity
Qnefit your table-mountedrouter with
!J a rabbetingbit. Then rout a Vs"rabbet
Vt" deep along the inside edge of each
side piece, where shown, to receive the
acrylic panels.
I 0il;"flI;";:T;il,:'"'i
[:filfi;
V+"-deepcounterborecenteredside-to-side,
where dimensioned on the body pattern,
using a lV+" Forstnerbit. Then switch to a
Note: Body and sides
are made from 7+"MDF.
All other parts are made
tromr/2"MDF.
,.-]:-*.?::H
1tla"counte(bore1/c"deep,
drilledafterassembly
woodmaEazine.com 73
the acrylic.) Using a no. 2 blade in your Sand any areasthat need it to 180 grit.
scrollsaw,cut the panelsto shape.Test-fit Prime and paint the giraffe. (We
the panels in the openings,and sand the applied three coats of Rust-Oleum grey
edges,if needed,to fine-tunetheir shape. primer, sandingto 320 grit betweencoats.
Then we sprayedthreecoatsof Rust-Oleum
Add the leqs. hooves, American Accents no. 7962 Buttercup
and tail, afid finish up Satin,sandingbetweencoatsasneeded.We
I Using a disc sander,sand a 20o bevel on found theseitems at a home center.)
I the hoof end of the front legs, where lf Epoxy /2" roundjiggle eyesto the body
shownon Drawings 1 and la and as shown I where shown. Then apply a few dabsof
in Photo E. epoxy around the rabbetsin the sides and
pressthe acrylic panelsin Place.
!) Epoxy a hoof to each front leg, where
fr shown on Drawing 1. After the epoxy QUsing a no. 4 round artist'sbrushsuit-
cures, draw a line for sanding reference (Jable for acrylic paint and contrasting
along the curved top edge of each teg Vs" paint colors of your choice,paint spotson
from the outsideface. Then, using your sta- the giraffe body, legs, tail, and hooves,
tionary belt/disc sanderwith its table at 0o where shown on Drawing 1 and the pat-
(perpendicularto the belt), sanda 20obevel terns. (We used Delta Ceramcoatacrylic
on the inside of the front legs, as shown in paints, Raw Siennafor the body and legs
Photo F. (Holding the hoof flat on the table and Burnt Umber for the hooves and tail.
anglesthe leg at20" to the belt.) See Sources. Find the brush at art and
Glampthe body/sidesin a visesuppoftedon supply stores.)
a 2"-widebackerboard.Drilla 1" through- 2 Apply epoxy to the leg beveled sur- crafts
holecenteredin the 1tla"counterbore. tlfaces. Then, with the body/side (lFinally, installa l" rubberstopperin the
assembly upright on your workbench, Vcoin-access hole. Now surprisea child
1" Forstnerbit, and drill a hole centeredin adherethe legs to the body, where shown, with the bank and some coins, and watch
the counterbore through the bottom, as keepingthe hoovesflat on the work surface. the fun and savingbegin! ll
shownin PhotoD. a sanding referenceline along
'flllDraw Writtenby OwenDuvallwithKevinBoyle
the inside face of each rear \eg t7t" Projectdesignandillustrations: MikeMittermeier
Cut the acrvlic Danels above its flat bottom edge, where shown
for the banlf cavity to shape on the rear-leg pattern, making sure they
I To make a patternfor the acrylic panels, are mirror-image parts. Then double-face- Supplies: Sprayadhesive, epoxy,
five-minute double'
I place an SVzxll" paperon your work- tape the end of a 3/qx2Vzx4"scrap to the facedtape,/ax6x8" no.4 round
acrylic, adist'sbrush.
bench,and position the body/sideassembly outsideface of a leg, as shownin Photo G. Blades and bits: No,2 andno.12scrollsaw blades;
t/e"slotting %"round-over,
cutter, bearing'
with a side facedown on the paper.Using a Using your disc sander with the table three-wing
guidedflushtrim,andrabbeting bits;1"and1/q"
router
short, sharp pencil inserted through the angled at 20", sanda bevel on the inside of bits,
Forstner
bank cavity, tracethe siderabbetedopening the leg, as shown. Repeatfor the other leg.
Sources
on the paper. f Epoxy the rear legs'to the body, where Hardware and acrylic paints. t/2"round jiggle
!) Photocopy the pattern. Then spray- Jshown, keeping the outside of the flat
eyesno.5608, $,59package of 10;1"rubberstopper
(r adhere the two patterns to the film bottom edge of the legs flush with the no.7830,$2.99package of 10;DeltaCeramcoat Acrylic
backing on a Vsx6x8"piece of acrylic. (We work surface.Then epoxy the hooves to no.02025
Paints BurntUmber andno.02411 RawSienna,
adheredthe patternsto the film to avoid a the legs and the tail to the body, as shown $1.99each.CallMeisel Hardware Specialties,
800/441-9870; meiselwoodhobby.com.
messy clean-up,which also could scratch in the Shop Tip photo.
end of
front leg
Tabb angled at20o

to sahding disc
With your disc sander table angled to 20o, Keeping the hoof flat on your belt sander Holding the scrap with attached rear leg flat
sand a bevel on the hoof end of each front table, sand a 20' bevel on the inside of the on your disc sandertable, sand a 20' bevel
leg. Make sure you form mirror-image parts. front leg, stopping at the marked line. on the leg insideface to the marked line.

$r()rBrr_sul
ii'Ollfr0uIrB
In two days we cured a reader's shop of its clutter and transformed it into a fully functioning
workplace bursting with simple, adaptableideas.Take what you need to give your shop a boost.
he newsis shockingbut true:Our
shopsarein cluttercrisis.Most are GornerA
so stuffedwith tools and supplies
that little spaceremains for projects.
So we've been hard at work on cLlres. Hadial-arm r*-l
sawll
To prove they work, we asked you to (a
submit your shops for a field trial. From

hundreds of replies, we selected Jerry
ffi],
I nt t.s
Dust\
collector
Mertens' shop in Forsyth, Missouri. llll* Bouter table

His place showed all the symptoms of a Tablesaw
sick shop. visible in the "befbre" photos and elitension
wing with
and f-loorplan. Durin-qollr visit, we cured
his shop with simple solutionsthat you can
Llseto work over your work space.
Shoplavout
THESICKI{ESS:
hinders workflofi
Like most shops, Jerry's evolved over
tirne. As new tools and jigs entered,they
were positionedwhereverthey'd fit.
THEGURE: Rearranqinq
- - GornerB CornerG GornerB GornerC
does the trick
We relocated Jerry's tools and supplies Beforethe workover began,Jerry's shop was crowded and inefficient.Afterward,the shop is
where they belon-9,instead of wherever effectivelyarrangedand the walls hold cabinets instead of dust-coveredpackagesand tools.
space allowed. The "after" floor plan,
riglt, shows that tools for breaking down
boards-radial-alnt saw. jointer. and
planer-reside on one end of the shop.
Tools for machinin,g parts, handwork.
and assembly live on the other end. Jerry
now has easy accessto everything. New prefab cabinet
4#:'--//'\
Everyshop wall was filled with an overload

of disorganizedhooks and hanging items.
76
Wallhooks
hold often-
used items
,F
I
More prefab
cabinets
l.r -
lr
ilhe bandsaw
has a home!
THESIGI$IESS:faltering-
finish storage.
Jerry's storagefor finishing suppliescon-
sistedof a setof simpleshelves(seeCorner
A-Before photo). They swallowed stain
and finish cans, and gobbled up loads of
dust and clutter. Jerry's shop now spotts a clean countertop and loads of enclosedcabinet space. Using a
combinationof shop-built and store-boughtunits allows easy customization.
TtlEGURE:
A fast facade CLAMSHELL
CABINET (twooptions)
DOORS
createsa cabinet Door skin
't/2"
birch plywood
Two t/2"-plywooddoors hinged to a face Door skin t/2"birch plywood
frame madeof scrapstockput this problem #16x 1" wirebrad
Door tops s/q"pine,
underwraps.Securedby wood turn buttons, 3t,/2"wide
the doors keep dust out, and cans in (see
CornerA-After photo).
IHESlGlfilESS:
Lack of
enclosedstorage Door edges
Perforatedhardboard offers versatile stor- s/+"pine
age;but in Jerry'sshop,this storagesystem 31/z"wide
was hooked on clutter. One wall was
packedwith hooks that held rnostanything #6x 1"F.H.
you could think of, much in its original wood screw
packaging(seeCornerA-Before photo). \-.
IHEGURE:Prefabcabinets Keeperstrip
t/2"birchplywood
createa guick solution 1t/+"wide
To provide storage,we hung four ready-to-
assembleprefab cabinets purchasedat a
home center (see Corner B-After photo).
\
These units install quickly and-at $50 )
and $75 apiecedependingon size-prove # 1 6x 1 "
wire brad
economical when compared to building
your own cabinets.
t/z"plywood
spacer
THESIGIIIIESS:
A sinqle Door bottom
3/q"pine
t/a"perforated
hardboard
cabinet getscramfred-full -t--
7/a+"pilol hole g/a" deep
3t/z" wide
Jerry had built one four-door wall cabinet \ -- s/32"
shank hole, countersunk
(see Corner B-Before photo). It proved +g x 1t/2"F.H. wooo screw
suitablefor holdingjars of screwsand a few
supplies. But at only about 4" deep, it THEGURE:Deepshop-built andCorner B-After photo).Insideonepair,
couldn't accept much else. This cabinet doorshold more perforatedhardboardoffers effective hang-
location near the bench proved ideal, We turnedthis space-impaired cabinetinto ing storage.Another option: Add shelves
though,for turning the cabinetinto a home a storage superstarby equipping it with inside the doors. Jerry plans to load this
for hardwareand handtools. clamshell doors. (See the drawing, above cabinetwith morehardwareandhandtools.
woodmagazine.com 77
You can never have enough clamps, or rack
space to hold them. The drill press,which was
crammed into a corne[ now can be used anytime
and is surroundedby plenty of work space.
Toolshave no
THESIGI$IESS:
place to call home
When we arrived in Jerry's shop,we found the bandsawand drill hung a few tablesawjigs on the wall (in a locationnot handyto the
press shovedinto a corner due to lack of open floor space(see saw) and parkeda rolling toolbox in front of it.
Corner C-Before photo).Both machineshad to be pulled out into
the room for use.
Wall racks cradle clamps
THEGURE:
Enclosinghalf of the doorwaywith a 4'-wide wall givesthe shopa
At least those tools could be used. Jerry's benchtoptools that
finishedlook and providesthe backdropfor a bevy of clamp racks
resideon his long built-in counter(seeCornersA and B-Before
(see Corner C-After photo). The clamps used to hang on the
photos)had gottenso buriedthat they were tough to even find.
oppositeend of the shop,a long way from Jeny's workbench'
THEGURE: Reclaimedareas give tools space We moved what clamp racks he had, plus built a few more'
Pushingthe bench and tablesaw together andremoving unnecessary like the ones shown in the drawing below left. Both styles are
items, such as a foot locker, extra scrapbins, and loadsof lumber constructedthe same way. The difference lies in the size and
cut-offs,freedup about20 percentmorefloor spacein Jerry'sshop. spacingof the slots.One rack holds pipe clamps,the other keeps
This meansthe bandsawand drill pressnow get their own corners rapid-actionbar clamps.
wherethey're easyto usebut out of the way. (Seethe floor plans.)
We evenfound spaceto bring the portableplanerin from the garage. THE SIGI${ESS: An unmovabletablesaw
Solving the on-wall storageissuesover the long counter also doublesas a dumping ground
mademore usablespaceavailablefor Jerry'sbenchtoptools. Jerry's 3-hp cabinet saw with a 52" fence earns its keep at the
center of the shop. But positioningit there effectively chops the
THESIGI${ESS: Iigs and clamps workspaceinto two separaterooms.At leastthe tablesawbecamea
sit in the wronf camps convenient tabletopand workbench-meaning it easilygot buried!
As shownin the Corner C-Before photo,Jerrybuilt his shopwith
an 8'-wide doorway leadinginto his garage.He neverusedhalf of
the opening,though, and simply coveredit with clear plastic.He
-2"
Top -*
1/zx 41/2"plywood
QUICKCLAMPRACK
# 1 6x 1 "
wire nails
4Vz"
Cleat
,- 3/ex 3tZ" pine
7sz" shank hole, ?

c o u n t e r s u n k Secureto studswith
# 8 x 2 t / z "F . H .
wood screw TechniquesEditor Dave Stone adiusts the new mobile base that
makes Jerry's massive tablesaw moveable.
78
Ditching the freestanding router table made
space for a tool box. The dust collector tucks
tight to the wall and turns on by remote control.
Tablesawjigs hang on the wall within reach.
IllE GURE:
Making the saw
mobile cuts out hassle
Mounting a universal mobile base under the saw allows Jerry to it interfered least with other shop tools. Then we sunounded the
move this heavy machine by himself if the need arises.That way toolbox with Jerry's many tablesawjigs. They now hang on screws
he can position it for cutting big boards or get it out of the way where they belong, on the infeed side of the saw where Jerry can
altogetherto increasefloor space. reachthem easily as he works (seeCorner D-After photo).
IHESlGlltlE$S:
A router table wastesspace The final diagnosis
In the Corner D-Before photo, you'll see that one wall on the So, did our curesrid Jerry's shopof its sickness?Here's what Jerry
infeed sideof Jerry's tablesawwas consumedby clamps.Someof had to say: "I knew that I wasn't very organized,but I didn't
the longer clampsforced him to position his router table away from realize what a difference more storageand mobility could make. I
the wall in the alreadyinadequatefloor space. find it hard to believe how much better the shop functions, and so
doeseveryonewho comesby to seemy workshop workover."
IllE GURE:An all-in-onesawincrand Jerry has learned that anyone can get his or her workshop
routing stationworks wonder6 organized.It just takesforethought,a few well-spent dollars, and a
We got rid of the stand-alonetable and replacedit with a router- little help from woodworking friends.Who knows, your shopmight
table-equippedextensionwing for the tablesaw.This full-function be next. If you're interested,send a letter (200 words or fewer)
table atethe biggestsingle chunk of our budget(detailedin "Where explainingwhy your shopneedsa workover, along with a floor plan
the money went" at bottom rigfut),but upgradedboth Jerry's table- sketch,and up to five photos.Seeour addressonpage 8.Q
saw and his routing capabilitiesin addition to opening up space.
Written by David Stone with Kevin Boyle,
Of course,we didn't let the spacewe createdgo to waste. We Chuck Hedlund, and Jeff Mertz
parkedJerry's rolling tool box along the newly clearedwall where Photographs:Gayle Harper, In-SightPhotography
Wherethemoneywent
We set out to make major improvementswithoutspending
more than $1,000.You can see that had we not needed
two big-ticketitems-the routertable and tablesawmobile
base-we could have cut our budgetin half. Here'show
we spent our money,roundedto the nearestdollar.
Tablesawmobilebase $ tao
Router-tableextensionfor tablesaw $ 347
Cabinets (three 24x30", one 24x36") $eto
4" lockingcasters $28
Sheet goods $es
Lumber $80
Hardwareand supplies $42
TOTAL $ e88
An integratedrouter table makes the tablesaw multi-task.Senior
Design Editor Kevin Boyle makes sure it sits flush with the saw table.
rvoodmagazine.som 79
-rl
6x48"belt/disc
What can STRAIGHTENEDGES
you do with Sand a bandsawn edge

straight,then ease its
cornersby "rolling"the
oneof these workpieceon the belt.
babies?Take EI o
\1ill lr-u
.. -.
t| ,/ . sMoorH TAPER'
a look! u Ihelongsurface
x
makes quick
work of sanding
all four faces of a
I
1 tapered leg.
TRIM
INTERLACED
JOINTS
Box joints and CLEAN UP
dovetails,typically CURVES
cut a little oversize, Sand inside
becomeflush fast on curved cuts
a belt sander. withoutthe
need for a
dedicated
spindle sander.
EASE
CORNERS
Cut project parts
square on a
tablesaw,then
radiusthe corners
with precision.
MAKE
BETTER
BEVELS
Bevelpiecesup
to 6" wide using
the tiltingtable.
SAND PRECISION
CIRCLES
Bandsaw a disc to
rough shape,then
perfect it using a
s i m p l ej i g .
q (Findthe jig at
CHAMFER
DOWEL ENDS
Break the TUNE MITERS
edges of a Adjust miter cuts in
dowelto make pictureframesor
easier to insert moldingfor gap-free
80 into a hole.
-l
BELT.SANDING
POWER
sanders
Underthe same sandingpressure,some belts provedmore aggressive
than others.This chart showsthe amountof materialremovedfrom
8/4 x 3" red oak end grain in 30 secondsusinga new 10O-gritbelt.
These machines, priced the test and makesit the most

from $400to $800,tackle a aggressive,removing tV32",
followed closely by the
range of sandingtasks with Craftsman/Fischand Jet JSG-
both power and finesse. 6DC's sAs".By contrast,the
slow belt speed of the Shop
And thoughthey look Fox W1712 preventedit from
similar, we found big removingmore than t/re".
performance differences D Sn aV, accurate tables.
A Loads of power doesn't
among the tested models. mean much if it's not paired
with precision. In fact, when
f you've never had the pleasure of touching up a bevel or miter,
usinga big combinationsanderlike the accuracy and table stability
onestestedfor this article,you're miss- under pressureare paramount.
ing out on one of the most versatile Belt and disc tablesthat mount
machines in the shop. Compared to a with cast-iron trunnions (see
portablebelt sanderclampedupside-down photo, below left) provedrock-
in a vise, it's like the differencebetween solid in our tests. Such
using a long bedjointer and a handplaneto machines also have separate Shop FoxW1712
put a straight edge on a board-it can be tables for the belt and disc,
done, but the large, flat surfacemakes the saving you the inconvenience
job easier and faster. These sandersalso of switchingone tableback and forth. disc, which reducesthe sanding capacity
sport large-diameterdiscs,allowing you to The tablesof two sanders-the Jet JSG- when the table is tilted, as shown in the
sandwider workpiecesthan less-expensive 96 and Shop Fox W1676-mount to the photo belowright.
benchtopbelt/discsanders. machineby meansof a steelpost.We found tlnat disc and plafen Again, it's a
two disadvantages to this design:First, the tJquestion of accuracy.So far as the disc
five ctualities that count single stamped-steeltrunnion tends to goes, its constant turning minimizes the
in a belt/disc sander deflect and can even rotate on the post effect of any high spotsand low spots,and
I Power. Don't expecta machine'srated under heavy sanding pressure.Second, the worst runout of the test, .008" on the
I horsepowerto tell you how fast it'll hog these tables pivot near the center of the Shop Fox W1676 disc, didn't affect its
away wood-we found little'relationship table, insteadof at the edge closestto the accuracyin the slightest.
between the two. To uncover their true
power, we testedthe sandersin two ways.
To gaugedisc power, we sandedred oak
end grain using identical 80-grit abrasive
discswhile applyingfirst 35 lbs of pressure,
then again with 12 lbs. Under the heavier
pressure,the Delta 31-300, GeneralInter-
national15-035DC,ShopFox W1676,and
the similar Craftsman 22606 and Fisch
BDS-612001didn't bog down a bit. The
other sandersslowed or stalledunder heavy
pressure, but performed well under the
lighter load.
Next, we moved to the belt portion of the
sanders.After equippingeachmachinewith
a new 100-gritbelt, we againapplied35 lbs
of pressureand measuredhow much red
oak end grain each sandercould remove in
30 seconds.You'll find the results in the
Belt-Sanding Power chart, above right.
Although the motors on all of thesesanders
Cast-iron trunnions, such as on the Grizzly G1276 (left), locked tight and didn't deflect a bit,
turn at about 1,725rpm, Delta's large belt- even when we reallybore down on them. When the post-mounted
table (right)is tilted, the
drive roller givesit the highestbelt speedin leading edge moves up and away from the disc, narrowingthe availablesanding area.
woodmagazine.com 81
Easy belt changes and adjust-
ments, Changing belts on a combo
Sanderswith art sanderinvolvesremovingparts,suchas the
belt table, guards, and/or dust collection
innovative edge ports,and thosethat don't requireany tools
Combination sandersas a grouphave for the task earnedan "A" gradein the chart
changedlittleover the last few years, on page 84.
so we'reglad to see some thoughtful All of the sandershave a quick-release
innovationin the tools we tested. systemto relax the belt tensionwhen belt-
Besidesthe onboarddust collection changingtime comes, and on most units,
on the GeneralInternational the mechanismlocks in the untensioned
15-0 35DCand Cr af ts m a n 21516, Areasuntouchedby the belt (white)pointto position.This freesboth handsfor changing
here are two other featuresnew to a low spoton the platen.Bluechalkindi- the belt, and allows you to detensionit to
combinationsanders: cateswherethe abrasivegrit madecontact. prevent stretchingwhen the sanderwon't
Brownareasshowhighspotson the platen.
I Oscillatingbelt. The abrasive belts be used for awhile. The tension-release
on some largecommercialedge lever on the Gnzzly and Jet JSG-6DC must
sandersgo side-to-side whilethey go If you sandthe face of a wide workpiece be held down with one hand while you slip
around.The extramovementhelps on the belt, though, can you trust the the belt off with the other, and on the Jet
the abrasivelast longerand reduces machine to make it truly flat? That quality that takesa lot of strength.
burningfrom sandpaperloadedwith originates with the platen-the supporting QEfficient dust collection. These
dust and wood pitch.You'llfind this surfacebehind the belt. To quantify platen rf machinesremovea lot of materialfast,
same oscillatingactionon the flatness,we fired up eachsanderand placed and without properdustcollection,the shop
Craftsman/Fisch sanders.With the a weighted piece of melamine-coated air quickly becomeshazy with super-fine
oscillation featureengaged,the belt particleboardon its belt for 10 seconds,and wood particles.Most of the sandersin this
tracks left and right s/+". then noted the consistencyof the scratch test performed adequatelywhen connected
I Oscillating spindle sander. Talk pattern.The photo, above,shows the best to a dust collector. but two machinesdid
aboutyour do-it-allsandingmachine, and worst of the testedmodels. very well withoutan externaldustcollector.
Craftsmanplacedan oscillating Six of the sanderscame from the factory Both the Craftsman21516 and the General
spindlesandersmackbetweenthe with a graphite pad adheredto the platen, International (shown below) have dust
bel tand dis con it s 2 1 5 1 6m o d e l ,a n d which the manufacturerssay makesthe belt blowers and filter bagsbuilt in, so you can
threw in variablespeedto boot.With run smoother and quieter. We didn't usethem anywherewithout worrying about
the oscillatingspindle,you can sand observeany significant difference between making a dust-collectionconnection.Of the
insidetightcurves,and even smooth graphite-paddedplatens and nonpadded remaining sanders,we favor those with a
the edgesof a hole.Thoughnot quite platens in that regard. We did find, how- single 4" dust-collectionport that draws
as powerfulas the best sandersin the ever, that sanding end grain on a graphite from both the belt anddisc versusunitswith
test, it performedat or above average pad tends to compressit at the table level, two ports that require switching the hoseor
on belt,disc,and spindle. creating a pronounceddip in the graphite. hooking up a wye.
The oscillatingspindle sander on the The low tables on the Graftsman/Fischsander

Generallnternational'sinternaldust
Craftsman 21516 has a Te" stroke and
collector has its own motor, power switch, can test your back, especiallywhen tilted
oscillates60 times per minute.
and a S-micronfiltration bag inside. down for sanding miters.

hrerything you needto know aboutthe testedtools
Highpoints Highpoints
I Thismultifunctionmachine alsoincludesan I Themostpowerful andaggressive
oscillating
spindle
sander. sander in thetest.
I Built-in
dustcollector
workswellon I Notoolsneeded to makeall
belt,disc,andspindle,
andanintegral routineadjustments, including
blastgatedirectssuctionto thesanderin use. switching thebelt-arm orienta-
I Variable-speed allowsyouto choose
control the tion.And,unlikemostmachines in
bestbelVdisc/spindle
speedforthetask. thistest,the31-300helditsbelt
I Beltsander armchanges easilyfromhorizontalto vertical
andback. trackingaftertheswitch.
Low points Low points ;

t Although youcanshutoffthespindle sander
whenusingthebeltor disc,youcan't ? Cast-ironbeltarmis heavy,
stopthebeltand/or discwhenusingthespindle sander. andrequiressomestrength
? Discsander bogsdownunderheavy pressure,
butdidfinewithlighterpressure. to movefromhorizontalto
? Nobeltguardonendroller, youunprotected
leaving withthebeltarmhorizontal. vertical.
I lncluded mitergaugeis insubstantial,
andmiterslotsintablesaretoosmallto I Paintwearsoffplatenand
accepta standard mitergauge(say, 'r
fromyourtablesaw). causesbeltto bounce
I lt'sa longreachfromthediscto themachine'spowerswitch. againstplaten.(Replacing
thebeltremedied mostof
Morepoints thebouncing.) F"
) lt weighsalmostasmuchassomestationary sanders
in thetest.Addtheoptional
standfor$40. Morepoints
) Threesandersin oneforthisprice,andwithgoodpedormance onallthree,makes ) Mitergauge notincluded,but%"-wide miterslotaccepts
a
it ourTopValue. standardtablesawmitergauge.
) Power takeoffcanbeusedwithoptional flapsanderor
pneumatic drum.
) A strongperformer
in virtually
everyareamakes the31-300
ourTopToolforthistest.
Highpoints
I Oneof themoreaggressive belt
sanders,andthemotordoesn't
stallunderheavypressureon
thedisc.
l Notoolsneeded to change Highpoints
thebelt. I Nearlyaspowerful astheDelta
I Beltcanbesetto oscillate
%" 31-300whensanding onthe
I Sturdymitergaugewitheasy- disc,withanaverage stock-
to-readscaleandadjustable removal rateonthebelt.
stopsat 0o and 45o. I Built-in dustcollectorwith
S-micron filterbagdoesa
Low points superb jobonbothbeltanddisc,
? Changing thebeltorienta- andmakesit anattractive choice
tionnecessitatesremoving for userswithouta dedicated
andreplacing thedustport dust-collection system.
andbeltguard, and i Inaddition parallel-
to thetypical
requires anopenend running miterslot,thedisctable
wrench (notsupplied). alsohasa slotperpendicular to
? Nobeltguardontheend thediscfacefor usewitha circle-
roller,
whichcancatchonclothing withthebeltarmhorizontal. sanding jig.
9 Lowdisctablecauses stooping
for average-height
woodworkers,especially
withthetabletilteddownto 45o,asshownin thephotoat teft. Low points
I Wefoundit ditficultto calibrate
theanglecursorontheCraftsman'sdisc-sanding ? Thebeltarmmustbeheld
table(butnotontheFisch). whileyoutighten
horizontally it
because there'snostopto prevent
Morepoints it fromovenotating,
andit secures
) Exceptforcosmetic differences,
thesesandersarevirtually
identical. witha hexheadwrench.
I Dustcollection
is effective
onthediscandbeltin eitherhorizontal
or vertical
orientation,
butdusthoseinterfereswithsandingoperations,andwheninstalled
onthebeltport,thehosecovers thepowerswitchontheCraftsman.
woodmaEazine.com
83
Highpoints Hishpoints |iffi{t
l Cast-iron
trunnions onthebeltand 1' Goodpowerwhen onthedisc,
sanding
EtiF
disctableslocksolidly. stockremoval
andanaverage rate f I
I Beltsander changes from
easily onthebelt. - i
horizontal andback.
to vertical I Accurate ,
miterslotaccepts -",,*-Bf
Lowpoints
I Underheavy sandingpressure on ;:::sizemitersause
thedisc,wewereableto stallthemotor. I Belttension releasemechanism u.^,,
tukes
# _-T
I Tension-release
mechanism mustbe lotofstrength andmustbeheld
tooperate,
I
heldopento removethebelt. open to removethebelt. 'i
portonthedisc,andthe3" portonthebeltis an
I Nodust-collection I Graphite padonplatenworeunevenlyfrom " ,'r,/
G { I
oddsize. end-grain sanding, a dipinthepad
leaving
justabove tableheight E t
I Belt-tracking
adjustmentinstructions Usingboth
aren'tclearin manual.
knobsproved
tracking-adjustment cumbersome, andwewerejustas iil "
onlythefrontknob.
adjusting
successful ;L,
ltfilffi'lliupr.no.,orpneumaticdrum- ,at
Morepoints to thismachine.
addsversatility "a
is oneof onlytwobenchtop
) Thissander in thetest.
models ) A performer
good price.
at a premium r
MOrOR I Speeo(t) IBELTSANDER

Highpoints
I Gooddustcollection witha single4" portandblast
gatesto directsuction to thesanderin use. .n/ | '
I Lower discguardis a hinged door,making thisthe
Ft I l^/o€
/s/F H-is
€'I ^"ts
Fs
easiestsander forchanging abrasivediscs. li
i Inaddition to thetypicalparallel-running /s
".fI A"t7
miterslot.thedisctablealsohasa ao
slotperpendicular to thedisc
facefor usewitha circle-
af s"nlF
21516 11lz 110 643-3,675488-2,780 6x91lz T
sanding jig. CRAFTSMAN
22606 2,306
1 1 l z 110t220 1,802 6 x1OI/s T
DELTA 31-300 1 1 l z 1101220 2,204 3,162 7 x163la T
Low points
FISCH BDS-6120011 1 l z 1 1 0 2,298 1,800 6 x101/e T
I Whenplacing heavysanding pressure
GENERAL 15-035DC 13lc 110t220 1,791 2,335 613h6x12s11 T
onthedisc,wewereableto stall INTERNATIONAL
themotor. GRIZZLY G1276 1 110t220 1 , 7 8 4 2,327 7 x163le T
? Posfmounted disctabledeflected JSG-96 3lt 110 1,787 2,342 51lzx11 T
undersanding pressure
and,when JET
JSG.6DC 11/z 110/220 1,794 2,324 751rcx1431rcT
tilteddownto 45o,reduced the w1676 1 1101220 2,402 1,912 61lax123la P
capacityof thesandingdisc(see SHOP FOX
w1712 11lz 110 1,794 1.114 8 x121la T
photoonpage81),already the
smallestinthetestat 9". 4. (c) Cast iron
1. Measuredunderno load
with phototachometer. (c/G) Cast iron with graphitepad
Morepoints (s) Stampedsteel
(P) Post (s/G) Stampedsteelwith graphitePad
discrotation
) Clockwise of most
is opposite (r) Trunnions
andtakessomegettingusedto.
discsanders (A) Aluminum Built-indust collector;no external
version
for$400. dust collectionports
in anopen-stand
) Alsoavailable (c) Cast iron
(1) Singleportpullsfrom beltand disc
(1..) Singleportpullsfrom beltsanderonly
(2) Seperateportsfor each sander
Written by Dave Gampbellwith John Gebuhar
youropinion
Sharc Put your money on these sanders
of these sanders in Becausethe belt and disc of the Delta 31-300 proved unstoppable
our InteractiveTool in our tests, and becauseall routine adjustmentscould be made
Review at without tools, we namedit Top Tool. True, it doesn't come with a
woodmagazine.com/combosander miter gauge-an accessorythat's found on every other sanderin
this price range-but its standard-sizeT-style miter slot readily

Highpoints Highpoints
i Closedbasehasshelfforextrastorage
of i Largest
disctableintest,andthelongest beltplaten.
sandingsupplies. quieter
I Noticeably thantheothertestedmachines.
I Theleastexpensive
combination sanderin mitergauge
I Easy-to-read marked in 1oincrements.
thetest.
Low points
Lowpoints ? Slowbeltspeedmakes thistheleast
I A single tablemustbemoved
discandback.Post-mounted
undersanding pressure
downto 45o,reduces
frombeltto
tabledeflects
and,whentilted
thecapacity of the
J.K,
.jsQF
aggressive
I Plastic
sander
guards
wetested.
onbeltanddisctendto
dragontheabrasive.
l0dd-size dustports.
sO+
limitedat 10".
sanding disc,already
I Withbeltremoved andarmhorizontal, idler
al## Morepoints Fw
(end)rollercanfallontothefloor. ) Dualsteel lockonbothsides,
trunnions and $tl7l2
I Tightquarters to geta
makeit difficult deflected
lessthana single trunnion,
steel but
wrench onthearm-locking boltformoving "rlff
beltto horizontal
fromverticaland ) ff itpivots
i,1Xl]f,i;rion
tabres, rromW
vise-versa. thecenterandreduces capacity rF
whentilteddown.At
{7 0dd-size dustportonbelt. 45' downwardtilt,edgeof tablenearestdiscmoves%0"awayfromdisc.
/9 /-e Et! i / g 'i/g- , l(t /A-
rtIEttt
(+
/s
-r /.t
tEt,
f,ls
.f-tg
S'/.5/
ilFli {lF /"f, o
t#t, i"s
FA
ar /4.
F-9
./la
'/o
/"s/.8 16t I \r/ < /_g
tEgtt
Flu'l #Fli
e5 o/ a
os/ c
.ooS/ ,togA F
(t, 8/S d
7 x 161/a
91/ex 161/a
7 x'161/e
1 0 x1 2
9x 163/ro
6.t Excellent 7. Averageof belt and disc underno load, 9. (LIFE) Lifetimewarrantyagainstfactorydefects.
tr Good
measuredfrom 12" away.
u Average (CS)
(M)
Closedstand
Mitergauge
10. (C) China
E Belowaverage (MB) Mobilebase
(T) Taiwan
M Sanderdoes not come

with this accessory.
(OS)
(PS)
Open stand
Pneumaticdrum sandersand extensionshafts 11. Pricescurrentat timeof article's
(RS) Additionalrubberspindlesfor spindlesander productionand do not includeshipping,
(W) Work stop whereapplicable.
acceptedthe miter gauge from the tablesaw in our shop, and You'll also find effective on-board dust collection-and an
should do likewise with any tablesaw miter gauge (except for oscillating spindle sander-on the Craftsman 21516, for
Craftsman,which are typically a little undersize).The General $180-$330lessthan the Delta and GeneralInternational.At that
Internationall5-035DC fell short of Delta's power and user- price, it may not be suitable for day-in, day-out use in a
friendliness, but its built-in dust collector makes it mighty professional shop, but it's perfect for the space-starved(and
attractivetoo. budget-conscious) home shop.The21516 is our Top Value. |l
woodmagazine.com 85
-l
"1r
',,d.*"
',;
i\,
:11
FT.r. I .+"r
Siuingot ihi;
Risers
clampingsquaresto ensure'99qsngles.
assembly off the workbench, allowing space for clamps.
k;k **-
hether your next woodworking Stage 2z After the initial milling, give the
task is a major production stock another24 hours to acclimateagain.
or just a lO-minuteskit, every Following this secondrest, inspect your
project that gets rave reviews includes piecesto see if you'll need to flatten or
successfulglue-upsas part of the script. otherwiseadjust your stock before assem-
When you're gluing and clampingyour bly. When satisfied,mark up your stock
partassemblies,first readyyour stock.Only accordingto the specification in your plans,
by working with straight,stablestock can set up your tools,and machineyour work-
you preciselyalign partsin a glue-up. piecesto size.
Start by acclimating your stock to the
humidity and temperatureof your shop. Planning the production
Here'show to proceed. Preparingto glueup milled stockeliminates
unpleasant, last-minutesurprises.Use this
Acclimation stages scriptto ensuresuccess:
Stage1: Allow roughstockto acclimatein y' Gatherthe necessaryclampsfor the proj-
your shop for 24 hoursbeforemilling. Aim ect. (In most edge-to-edgeglue-ups,figure
To prevent post glue-up warping, acclimate about 10" spacingbetweenclamps.)Need
for a 6- to ll-percent moisturecontent. your project stock to your shop. Do this by
Then mill piecesto rough dimensions,as standing it on edge, or resting it on stickers more?Borrow or buy clampsas neededto
shownin PhotoA. (wood spacers),allowing air to surround it. providefull bondingalonga gluejoint.

-l
y' y'^reyour clamps long enough? If not, clamp blocks make an adequatesubstitute, WOODamagazineshop,we like the roomi-
couplersor pipe extensions,suchasthe one but you may have trouble juggling them nessthat 4x4s afford, as shownin the photo
shown in Photo B (about$2.50),will save duringthe glue-upprocess.One solutionfor on the previous page.You may needto run
you the expenseof buying more clamps. pipe clampsis shownin Drawing1. them through the jointer to make them
y'Inspect the heads and bars of each squareand flat.
clamp. Remove dried glue globs, grit, or Enter the supportingcast y'L-shape corner clamping squares.These
oily substancesthat dent or contaminatethe The gluing processis more than clamps.In simple accessoriesguarantee90o sides.
projectsurfaces. supportingroles,be sureyou haveon hand: r' X dead-blow mallet and cushioning
(fo avoid marring your finely sanded y'Riser blocks to hold your project a few block to coax togethertight-fittingjoints.
stock, each clamp surface needs a clamp inches above the benchtop,creating plenty y'Extended open-time glue-ideal for
pad (about$5 a pair in catalogs).Hardwood of room for clamp heads. Around the working with largeor complexassemblies.
If you can't find a local supplier, call
Titebond at 800/347-4583.
y' Cauls-stiff, sturdy boards-distribute
pressure between clamps. As shown in
Drawing2, woodworkersrely on a slightly
bowed caul for even pressuredistribution.
Seethem in action in Photo C.
y'Waxed paper and masking tape to
shield wood surfacesfrom clampsor drip-
ping glue. We prefer blue (painter's)
masking tape becauseit leavesbehind no
adhesiveresidue.
y'Plastic putty knife or rubber kitchen
spatula,rags, and clean water to remove
glue squeeze-out.
Add extensions to your pipe clamps for extra-long glue-ups. The blue painter's tape helps The dressrehearsal
protect the wood from damage by the pipe clamps and glue. Before you open the glue bottle, you'll
want to uncover every joinery problem,
script the assemblysequence,and decide
where and how to clamp.
Dry-fit your assembliesand document
the steps,imagining you're applying glue
1lqx 11/qx 13/q"hardboard
1lqx 3lqx 13/q"hardboardspacer
Note:Smallwoodpieces
help securepad to head.
TAPERED
CLAMPINGCAUL
Joint or sand a 1/sz"taper from

middleof caul to both ends.
2x2 clampingcaul
Note: Taper is shown

exaggeratedfor clarity.
When the center of an assembly is beyond
the reach of your clamps, a caul with a slight
convex edge helps distribute pressure.
87
along the way. Clock your time. Did your
run-through last longer than the open time
for your glue? (Even for extended open
time glues, the maximum is 20 to 25
minutes.) If so, consider theseoptions:
I Split up the gluing processinto smaller
subassemblies.
I If necessary,call in exffa handsto share
the assemblyand clamping roles.
I Rehearsethe assemblyprocessagain to
reduce the time. You'll be amazedat how
a second or third run-through speeds
assemblytime.
As you dry-fit parts, you'll quickly dis-
cover problems. You shouldn't need
Herculean strength or a sledge hammer to
snug up a mortise-and-tenonjoint. If you
can't arive at joint perfection with light
clamping pressureor a couple of light taps
with your dead-blow mallet, plan to
remake ill-fitting parts. Clamping can't
correct loose joints or mis-sized and
warped parts.
With your tape measure, confirm that
Dry-assemble your project pieces so you can double-check, and maybe even shorten, your your assemblyis square.The measurement
clamping routine. Even when using glue with an extended drying time, you don't want any last- of your diagonals should be equal as
minute surprises from tight-fitting ioints or mistakes.
shown in Photo D. If not, try adjusting
your clamp pressure, location, or both.
Still not equal? Find out why your assem-
bly is racked: Machining orjoinery may be
the villain.
Finishing touches
In some cases, you may need to stain
and/or finish parts prior to assembly.Here
are common examples:
I When project parts would prove hard to
accessafter assembly. For example,many
woodworkers stain the center panel of a
raised-panel door before assembly; doing
so avoids drawing attention to unstained
wood around the panel's edgesduring cli-
mate changeswhen wood shrinks.
I In order to minimize glue squeeze-out,
which could affect your finish alongjoints.
Prestained pieces won't show any telltale lines from shrinking and expanding. However,glue
won't stick to finished wood. So before you apply a stain or finish, tape over surfaces to be I When finishing interior surfacescould
glued. Blue painter's masking tape won't leave adhesive residue on the bare wood. result in runs or brush strokes that would
be difficult to fix.
To protect joints during such the pre-
assembly finishing processes, mask the
Let's dry up a few glue myths surfaceswhere you'll later apply glue, as
Our testing of woodworking glues MYTH 2: I*t glue joints sit overnight shown in Photo E. Most glues will not
revealed the truth behind some popular before removing.the clamps. Two hours stick well to finished surfaces.
misconceptions.Such as: of clamping time is enough to setjoints, Although some literature recommends
MYTH 1: Only by applying glue to both then you can remove clamps safely. stuffing mortises with pieces of paper '-
mating surfaces can you get a good MYTH 3: Buy large quantities of glue to towel, it's our experience that this tech-
bond. Actually, you'll get great results last a lifutirne. Woodworking glues have nique can compound the problem with a
by spreading glue on just one side. expiration dates-about 1-2 years after wicking action that draws more finish into
Covering both piecesdoublesthe risk of manufacture. (See the woodworking the mortise. We've had best results with
excess squeeze-out.When possible, a glue chart in issue #156 for details.) For brushing finish carefully around mortises.
wiggle or twist of one part helps ensure this reason,avoid buying it by the gallon; Finally, if you apply a finish before
a reliable transfer of glue to both pieces. get only what you need now. assembly,follow the manufacturer's rec-
ommendedcuring time.
88 WOOD rnagazlne October 2004

It's showtime! out too much glue, you'll starvethe joint the mortise.Then apply glue on all but the
Just repeat the assembly steps you and weakenit in the long run. last Vz"of the tenon. Glue buildup within
rehearsedduring dry-clamping-this time To preventyour assemblyfrom twisting, thejoint will automaticallycover that area.
with glue. Apply glue to one surface,and allow the glue to dry while your project is Before walking awayfrom the assembly,
draw togetherthe mating surfaces. supported on the workbench or other flat deal with the glue squeeze-out.After it
For 20 years in our shop, we've had surface.The riser blocks help circulate air skimsover (gluelosesits shinein a period
great results by spreadingglue with Vz"- all around the assembly, producing an that varies with the amount, type, and
wide acid brushesfound in woodworking evendrying time. room temperature),remove glue puddles
catalogsand the plumbing sectionof hard- A couple of precautionswill help reduce with a spatulaor plastic putty knife. Then
ware stores and home centers. Another squeeze-outwith mortise-and-tenon joints, dampena rag in clean water, and remove
inexpensive(or free) glue spreaderis the and avoid the frustration of hydraulic excessglue.If you missa spot,sometypes
plastic core of used, disposable foam problems created when the glue has no
brushes,as shown in Photo F. placeto go within a tight-fitting joint. This
For evenapplication,somewoodworkers particularmessyproblem makesit impos-
rave about glue bottle rollers, but they sible to draw togetherthe joint.
requirecleaningafter eachuse. For starters,chamfer the tenon corners,
What's enough clamping pressure? as shown in Photo G and in the mission
When the wood pieces are touching and bed project story on page 40. Ditto for the
the glue starts to squeeze out, that's mortise; you'll gain additional space for
enoughclamping pressure.If you squeeze glue to escapeby knocking off the edgeof
Clamping with tape

For some projects-such as boxes and
smallframes-maskingtape can handle
chorestoo tiny for even the smallest
clamps.You can use this on standard
four-sidedprojects,such as the one
shownto the right.lt also worksfor small
hard-to-clampprojects,such as an octag-
onal box. Here'show:
First lay the box piecesso that the top
or bottomis alignedagainsta straight-
edge with outsidecornerstouching.Tape
the pieces, as shown at bottom, left.
Applyglue,and rollthe segments
around the base, as shown bottom, right.
Finishby tapingthe beginningand end
segments,and allowthe assemblyto dry
on a flat surface. Save those worn disposable foam brushes.
Strip off the foam to expose the plastic back-
ing, which makes a perfect glue spreader.
'4..:
' ,,,&
.
s
i41'
woodmagazine.com
89
I
of dried glue can be loosenedwith a dab of If you haven't yet applied finish, don't glue dries completely,and you'Il wind up
xylol or toluene.With porous-grainwoods make the mistake of hurrying to sand with a long, hard-to-fix recess once the
such as red oak and ash, be careful that freshly glued, unfinished surfaces.Water- wood fibers dry and shrink.
you don't force glue into the pores. To based glues-including all the yellow Before you apply stain or finish, wipe
avoid transferring glue to other surfaces, glues-will temporarily swell the sur- down all surfaces with naphtha to reveal
changerags frequently. rounding wood. Sandtoo soon,before the glue blemishesyou'll needto remove.i
2 simple jigs for flatter, quicker glue-ups

Sure,you could
fiddlewith odd
scrapsfor clamp
blocks,but these
quick-and-easy jigs
will makeglue-ups
go more smoothly. \*,,
I For edge-glued
projects,cut a scrap
from the same thick-
ness of stock you'll
be gluingand sand-
wich it betweentwo
long stripsof 3/4"
ffi4/#i
plywood,as shown
s/+x 1sl+"strip
at right. 3l+x 131+"
I Screwinghard-
boardtabs onto U-
shape clamp blocks,
as shown below,helpsyou hold the blocksin placewhile stripwith #6 x 1Y4"F.H.
arrangingclampsfor a glue-up.The tabs also providea resting wood screws. (Offsettop
placefor the clamp bars to keep them off the glue-up,while the and bottomscrews.)
blockswithoutthe tabs distributeclampingpressureacrossa
widerarea than the opposingclampjaws alone.
13/ta"
Yz"bevel
3/c"-diam.
self-adhesive
z', l=0" _ cork pad
th" n"ronJrf
2"
3v"""
'--_Z
Ye"saw-kerfcutlines 2Y2"
WOOD magazlne October 2004

90
askwood
to yourquestions
Answers fromletters,
GAMI
800 -
FEPA
P2000
andW00D
e-mails, Onlineo Pl 200
500 - Pl 000
-:" 400 - PBOO
Making the grade on abrasirrcs ili'o 360 -

P600
P500
320 - P400
|Ff I At d woooworKlng snowI numberon the
X r boughtsomesandPaPer in the backof the 280 - P360
grit numbers I normallyuse,butthe sandpaper, as P320
abrasives didn'tmatchthe textureof the shownat right. The "P" prefix by the grit 240 - P280
products frommy localsupplier. I think If there'sno number means this coated P240
thesandpaper I boughtis imported. prefix,you can abrasiveconforms to the 220 - P220
Doesthatmakea ditference? assume thatit's FEPAgrading system.
-Neal Harrison, Va. a CAMl-graded
Blacksburg, 1 8 0- Pl80
product.As you can seein the chartat rigltt, 1 5 0- P150
I (the
a Coatedabrasives technical particlesizesin thetwo systems closelypar-
P120
{f r name for sandpaper) follow one of allel eachother up to about220 grit; then 1 0 0- P100
two commongradingsystemsusedin North FEPA numbersincreaserapidly.If thereis a -
America:CAMI (CoatedAbrasives letterafter the number,it ref'ersto the weight P80
Manufacturers Institute)andFEPA of thepaperol fabric.
(Federationof European Producers Manufacturers may useoneor bothsys- A second key difference is that the CAMI
of Abrasives). temsfor variouslinesof abrasives. For standardspermit greater variation in pafticle
FEPA productsare sometimescalled"P example,KlingsporusestheFEPA scale sizesused within each grade.That may be
grade"becausethat letterprefixesthe grit exclusively, while3M usesbothscales. the texture difference you noticed.
on page 94
Corrtintted

92
www.logunofools.(om
Circle No. 640
e r a n dh e a v i e0rp. t i o nssu c ha ss l i d i n
: 1 ? l ' b L a cd ae p a c iet yu r o - s t yr li e h
ving
d,tlnewl or vourtreevi deo.
l '
." ,,".1
ask wood
Now,turna $5 roughboard Tqning a bucking dri[ press
into $75 worthof straightor
(|| . frn,,. helpinga friendwitha proiectin his shop,I was
curvedmoldingin justminutes!
Makeover500 standardmold X r amazedby the quiet,smoothrunningof his drill
ings,tongue& groove,picture press.lt mademe realizethatthe vibrationsin my machinemay
framestock,any custom be causingthe less-than-perfect resultsI typicallyget.Howcan
I improvemy drillpressperformance? lt's a standardbelt'drive
floor model'
-Fredstein, Kan.
Atchison,
a You're on the right track, Fred.Reducingvibration will

r make your drill presslast longerand give you more preclse-
ly roundedholes.Misalignedpulleysor worn-outbelts arethe prime
suspects, so here'show to dealwith both problems.
12" , 18" Unplug the drill press,and pop openthe lid that concealsthe pul-
2 5 "M o d e leys. Here,you may find black dust: rubberparticlesthat usedto be
part of the drive belts.To checkfor excesswear in the thicknessand
Variable Feed width of eachbelt, removethe belts and slowly run them between
Just a twist of the dial adjuststhe your thumb and forefinger.If you noticeany inegularities,buy
Woodmaster from70 to over1,000cutsper inch. replacementbelts at your local auto-partsstoreor from a tool suppli-
Produces a glass-smoothfinishon trickygrainpatternsno otherplan- er. We don't recommendusinga belt dressing.This might alsobe a
er can handle.Plentyof American-made "muscle"to handlelow-cost, good time to replaceyour standardV-belts with link belts madefrom
lumber.S-YearWarranty,MADElN USA!
"straight-fromthe-sawmill" interlockingsegments.Thesewon't form humpswhen left curved
aroundpulleysfor long periods.
Call Today for Free Facts With the belts still removed,plug in the drill, and switch it on to
1-800-821 -6651ext. RW53 checkthat the motor runs smoothlyand the drive pulley doesn't
com
www.woodmastertools. wobble.Replacethe motor if the bearingshaveworn to the point
Woodmaster City'MO64120
Tools,Inc. 1431N. ToppingAve.Dept.RW53,Kansas wherethe shaftwobbles.Replacethe pulley if it hasbeenworn or
damagedby a misalignedbelt.
The next stepis aligning the pulleys so the beltsrun in a straight
horizontalline. In manydrill presses, you canadjustthe heightof
only the drive pulley. To do this, raisethe motor by looseningthe
bolts throughits baseor merely adjustthe verticalpositionof the
pulley on the motor shaft,as shownin the photo below.
A straightedgehelps you align the height of the drive pulley on the

motor with the center pulley,called the idler pulley because it trans-
fers energy from the motor to the drill shaft.
Gollection
Arb-and-Grafb Plan
MonisGhairWoodwoilting
lf you'relooking to a woodworking
forananswer question, writeto AskW00D'
Believed withWilliamMorris,
to haveoriginated ArtsandCraftsmovement,
fatherof theEnglish
theso-calledMorrischaircombines comfortwithsimplystatedgoodlooks.Trueto form,our 1716LocustSt.,GA-310, DesMoines,lA 50309-3023 or sendusane-mailat
versionfeatures
loosecushions,curvedarms,andanadjustable back.Weevenshowhowto [email protected]. feedback
Forimmediate fromyourfellowwoodworkers, post
makethecushions. plansincludestep-by-step
Allof ourdetailed materials
instructions, list, yOUfqUeStiOn OnOneOfOUfWOOdWOrking fOfUmS8t i'u,;'.,vifvtjrir,inlAliazirte.c6nl.
cuttingdiagram,how-tophotography drawings.MD-fin$
andwoodworker-friendly $13.95

passed
wares
woodworking
These ourshoptrials
contractor-style
tablesawsunder $550
For about the sameprice as a high-end crowd the undersideof the
benchtoptablesaw,you can have your table, so I bangedmy
choice of two full-blown contractor-style knuckles on every turn.
saws: Gnzzly's G0444 or G04442. The Secondly,the throat-plate
ffi4442, shown at right, sportstop-dollar insert spells out "Gizzly"
features,suchas a2-hp motor, cast-iron in letters that sit flush with
extensionwings, a stout miter gaugewith the tabletop. Cool to look
adjustable-widthbar, and a 4" dust- at, but I soondiscovered
collectionport. that a workpiecepassing
This saw had plenty of power to cut any- over the insert would
thing I threw at it, including 2"-thick white sometimescatch on the
oak, with barely a complaint. Although it edge of a letter.
comesfrom the factory wired for 220-volt For $90 less,you could
operation, tIrc G04442 canbe rewired buy the scaledback version
easily for a 1lO-volt circuit. (Due to the of the "T' saw,fi19@Q!,/,,
high amperageatthe lower voltage,you'll The money savedearns
need to dedicatea 20-amp breaker to it.) you a clearly less-powerfultVz-hpmotor Grizzly saws
10"contractor-style
I found the aluminum fence well-built and stampedsteelextensionwings (which I G0rttl4Z wings)
(2hp,cast-iron
and easyto align with the miter slot, and I had a dickens of a time leveling to the table- Performance *****
didn't observeany deflectionin my tests. top). I also had difficulty aligning-and Price $525
T-slots on both fencefacesmake it easyto keeping aligned-the blade to the miter slot.
G04tt4(172hp,steelwings)
attachjigs or a sacrificialface. Truthfully , the ffi444 is no befter or *****
Performance
The GO444Zalmost delivers on its worse than some$600 sawsI've seen,so
Price $435
promise of the "ultimate" contractor-style it's still a good deal.But I'd put my money
saw, savefor two things: The large hand- on the G04442. GrizzlyIndustrial
wheelsfor adjustingbladeheight and tilt -TestedbyPatLowryi ; grizzly.com
800I 529-4777
Donlt tie-thpsepowef,cords'
tem-
Qwik-Iok
Don'tcha hate it when the power tool
you're working with-whether a drill,
sander,shop vacuum, or leaf blower-
comesunpluggedin the middle of the
job? If you're like me, you quickly learn
to tie the tool's power cord and an
extensioncord in a knot, but that
practiceis bad for both cords.Replace
the female end of your extensioncord
with a Qwik-Lok electricalconnector, Catch hooks
and power cords disconnectonly when
you want them to.
This cord lock works like the quick con- Curious about the tenaciousgnp Qwik- addsanotherbenefit: it tendsto slide past
nectorson pneumatictools: Pushthe male Lok provideson electricalplugs, I cut into obstacles,rather than hanging up on them.
the socket and discovereda pair of catch -TestedbyLarryChristensen
plug into the female socketuntil it clicks
and the two becomeinseparable.(I pulled as hooks that latch into the holes on the plug
hard as I could on the junction, and stopped prongsfound on most power tools. (See Qwik-Lok locking 120Uconnector
photo, above.)Pulling back on the collar Performance *****
becauseI thought I might actually tear the
releasesthosehooks. Price $17
cord of my shopvacuumfrom its plug.) To
unlock the cords,pull back on Qwik-Lok's The beefy, bullet-shapedbody of Qwik- Ltd.
Qwik-Lok
sliding collar and the plug pulls right out. Lok makesit comfortable to use,but also 866t94-5565;qwiklok.com
Continued on page 100
WOOD maEazine October 2004

',!
shop-proven
products
Th_isrouter accessory
helps you cope
If you've worked much with baseboard
molding, you probably alreadyknow that
copedcorners(cutting one side of the joint
to matchthe contourof the mating pieceof
molding) is smarterthan mitering them.
Copedcornersfit betterthan miteredones,
and the copedpieceholds the noncoped
piecedown. Unfortunatelyit takespractice
and patienceto cut the cope cleanly with a
coping saw and shapeit with a rasP.
However,with The Coper,you now can cut
perfectlymatchingcopesquickly using a enoughcastingresin with the kit to make work with crown molding.) You can even
router and flush-trim bit. aboutten patterns.) "back cut" the molding slightly to accom-
The Coperconsistsof two-part casting With the molding-to-be-copedclamped modateout-of-squarecornersby placing a
resin and a mold (left photo),and a basethat into the base,I simply routedthe copeusing thin shim underthe molding beforecutting.
-TestedbYJanSvec
supportsthe router and clampsthe molding the included /+" flush-trim bit with its bear-
for cutting (right photo). Skepticalaboutits ing riding againstthe pattern.The result
The Coper
capabilities,I challengedThe Coper with was perfect,exceptthat I had to chisel out *****
Performance
53/8"-tallpoplar basemolding with an inte- the %"-radiusfillet left by the bit in one Price refill,$11
$115;casting'resin
gral ogeecap separatedfrom the rest of the inside corner.
baseby a niurow 3/zz"reveaLAfter creating The Coper works with any flat-mounted TheCoperCorp.
-4461
403/381 ; thecoPer.com
a patternof the molding's profile using the trim up to 1" thick and 6" wide-baseboard,
castingresin,which hardensin 30 minutes,I chair rail, quarter-round-and the detail it
picks up is impressive.(Sorry,it doesn't Continuedon Page 104
installedmy patternin the base.(You get
100 WOODmagazine October2004
.
o
THEKlT INCLUDES:
PocketJig with ClamP
3/8'Steel Step DrillBit
rrffi.'x Sqecitic
WeAnilerstanil
orlinglpplications.
Woodw
o AdjustableStop Collarfor Drill Bit For over 2 decadeswe've been working
o HexWrenchforDrillBit Collar
with woodworkersto formutate the
. A Supplyof Square Drive Screws
o 6'Steel SquareDriveBit highest quatity epoxy adhesivesand
coatings for their specific applications.
We specificattydesigned MirrorCoatto
create a high gl.oss,decorative coating
on wood and other materiats.
Perlaction.
Poarablc
MirrorCoatis speciatty to
formutated
createglossy,high buitdresinsurfaces
on bars,countersandtabtetoPs.
The POCK'IT JlG" KIT is available at these dealers: Poura perfectdurabte,smooth,gtossy
r AMAZON.COM 800-635-5140 I EAGLEAMERICA 800'872-2511 finishon manysurfaces suchaswood,
r HARTVILLETOOLS 800-345-2396 I WOODWORKERS SUPPLY800+[t9292
ptasterandmasonry'
ceram'ics,
r MoFEELYS800-443-7937 r wooDWoRKERS WAREHOUSE 800-767-9999
r PRICECUTTER888-288-2487 I WOODWORKERS CHOICE 800-892'4866
r WOODCRAFT SUPPLY 800-225-1153 I ROCKLERTOOLS 800-279'4441 $Y$TIilIIIRTI
-slip rebate, cllp & mall us thlsad wlth Prool of purchase.
To recleve your
(Your sales or package bar code will do the trick) Finda dealernearyouat: systenthree.cqn
0r call 800.333.5514
SIMP'L PRODUGTS Inc. zt BertelAvenue,Mount vernon, NY 10550 02@ svdom nre RodB. lm. All Bighb Reryd.
Web Site: woodiigs.com E'Mail: [email protected]
shop-proven
ecE Gol
Woodworkerproducts
lection
This
SetContains ofBits
AGreatSelection Liqhten up and
.4 Straight Bits ' 1 Bevel Bit
.2 Dovetail Bits
.2 ChamferBits
. 1 Roman Ogee
. 1 PlungingPanel
cui the cl6ud of dust
O r c l e r . 1 Mortising Bit A woodworking shopcan neverhave too
' I LaminateTrim
NOW
While
. 1 "V" Groove Bit
. 2 RoundnoseBits
Supplies
.4 Roundovers
much space,light, or cleanair. Delta's
.2 RabbetingBits
I-aSt .2 Cove Bits
24 Great Bits AP100 air-filtrationsystemdoessome-
Shank W L - 2 O O 5 - 1 / 4 " S h a n k thing aboutall threeby building in
fluorescentlighting to this compactunit.
B '.TXJ,if^'on". Tongrre and Groowe Ratedto move 400 cubic feet per minute
ONLy 31c< S;zsterrr of dirty air throughits 5-micron filter, it
:i#[*i#$89
packsenoughairflow to keep the air in my
12x20'shopclean and recirculating.
2016isl/2" Shank WL 2038is 1/2" Shank The AP100'striangularshapepermits
hangingthe unit by chainsfrom only two
IHls!
DoN'Ilt'1155 points,while traditionalbox-styleair
OODLINEUSh
cleanershang from a more stablefour
points.The airflow was sufficient to set
the whole unit gently swinging back and
forth over my bench-a minor irritation.
Over the bench,the AP100'stwo
15-wattfluorescenttubesdidn't supple-
FALL N % ment my existingshoplighting much,but

I found the perfectplacefor the unit: over
my sandingstation.Thereit provides
)ELUXE6pc %CLASSIC#
*.q
15 PieceStarter
Collectiorr
decenttask lighting and air filtration
whereI needit most.It alsominimizesthe
150f OurMost impact (mostly on my forehead)of the
LI.'SH TFIIM
Two FIute Blts
SET
1 ", 1-112",2" L€ngth

ANOID
#sALE
ss9.oo
Popular RouterBi z}"-tall cabinet,which hangsabout8"
lower thantypical ceiling-hung
Three Flute Bits
TOP ATTHE
CUTTERS
CARBIDE
OUALITY EIIER!
PNCIES
LOI|IIESI wL-2022 air-filterationsystems.
SAIE
Afi1{0t{!
P',N'hffi5+S 11/01/0f
EI{DS OR
One advantage the AP100hasover
wL-2021'3'nllt' thoseboxy steelunits is portability. The
built-in carrying handle,triangularshape,
and soft cornersmake it easyto take
.a .a Al
onsitefor home-improvementprojects.lF
'\'\|,rcCES -TestedbyLarryChristensen
uXtb Kit
Dovetail
Spc
:Vr'' tffi"? WL2017112'Shank
Master Make PerfectDados
trveryTFfimneU
9pcMASTER
(ollection
Woodworking This Set Includes
9Two Flute Straight Bits
Undersized for Plywood
Standard for Hardwoods
Oversizedfor Melamine
orVeneered Materials,
o'wL-2065'gilli;'
wL-2066'ti.ll,;
In 3 PopularSizes
1 /+ ' ;1/2" & 3/4" llrh.1,0"t"?$39
andWorkLight
APl00Air Gleaner
ffirus s'il';# Pedormance ****tt
Price $180
DeltaMachinery
deltamachinery.com
800/438-2486;
r.eooqz.ogs0 \i1/o0DLtNE.coM
ontoc0NT0 T0oRDER
ToDAyt AFREE
0RT0RECEIVE - WooDLINE
CATALoG St, LaVergne,
111Wheeler
USA. TN
at your Serr/lGe
Below are labelsyou can copy for the spicebottlesand bin
tops of the "Tilting-Bin SpiceCabinet" onpage 50. Along
with labelsfor 30 cornmonspices,we've includedfour blank
spacesfor making labelsfor your own specialseasonings.
Allspice Italian
SeasoningPeppercorns
Basil Mustard
Seed PoppySeed
BayLeaves
Nutmeg Rosemary
BBQ Spice 0nionPowder Sage
CayennePepper 0regano Sesame Seed
CelerySalt Paprika Tarragon
ChiliPowder Parsley Thyme
Cilantro
Cinnamon
Cloves ' I see youveqotten rid of
NHhffiIII
Cumin t hedr 6aded"ilumberb Butt"
Thanksto o9r gfig'Idl
Ditl Longtqil f@
/
Fennel
4
GarlicPowder
GarlicSalt
Ginger vVe wonderful, usef iprnentqnd
sfoq,[
,@"'
ulEou
T
6oods
designed
ond testedby Trode'srnenfor Builders
ond
q FreeCotolog
ordentD0.lt.Y0urselfer5.6ef at 800-
5o5'8888 line- www,DuluthTro-ling.corn
ororderon
woodmagazine.com
;- i. = = o
q
rrvhatrg ahead r=o

EI
"
-sEs-
sEg
preview
Your oftheNovember (onsale0ctober
issue 12) E3d
+ db-:
sF
E
x E3
issrre: riltalre the tnost of your rorrter EEa
Special EBg
o o N
3 Router E€F
o . - =
Expefts' 3ag
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BestTips .98=
.E-Ee
andJigs H CE5
Tapintothe ESs
collective Fs=
wisdomof
nfE
FHF
=x=
Patrick
Spielman,
PatWarner,and
FsE
s Es
CarolReedfor E EF
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quicker,
more = B€
preciserouting. s3E : = C
a€E
EEE
@:'!u
? = F
F :Y (/J
;EF
TableFence
Router
TheUltimate Multi-Base
i: AL
Nomatterwhattypeof routertableyouhave,chances
areit wouldbenefit froma B:E!
Routers -E-
to do it all-with precision.
andaccessories
betterfence.Thisonehasthefeatures E 6=
Reviewed F-o
andRated c= g
a,o
E
Howto SmartlyChoose Nowyoucan
purchase a EgE
Table
a Router fig-
plungeand 6 i 6 )
Looking foryourfirstrouter = d F
fixed-based aE2
tableor consideringan s=;:
!P<€
upgrade? Fromsimpleto routerin onekit. E9u
= b v
deluxe,hereareyourchoices Wetesteightof 5€N

andwhatyouneedto know themto helpyou o
€c) H
G , =
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buythebest.
abouteachof them. ?E -E
9=
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More great proiects arnd woodworking teclrniques €HE

gEF
-c= E
Bookends
Picture-Frame 9kR
Buildthesein a weekend,
andthen € s*
. =* E
photos.
pairthemwithyourfavorite =-cc
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DeskClock
Nightstand Easy-Build
Mission-Style S E'€
Thisstylishprojectmatches
the A few scrapsof woodandan Child'sLapDesk TurnedSaladBowls *aE
E €E
E.!: E
bedon page40,aswellas a inexpensivemovement areallyou Thisrugged travelingcasestores Here's a simplewayto turna wholeset €Ee
dresserandhopechestin needto makethisniftypresentfor all of thefavorite
drawingand in notime.Cutyourownblanksor use =oo
bF o
upcoming issues. someone youlove. writingsupplies a kidcouldwant. oureconomical source. H E d@
r*e
= N
110 WOOD magazine October 2004 xSdi

E*E

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What tools and techniques are discussed for improving joinery?

What tools and techniques are discussed for improving joinery?

What finishing methods are highlighted?

What finishing methods are highlighted?

ffiffiffiffi 1-

No lathe?No problem.Readersprtnrccreatirrc. Teachercountsthe ways

r Editorialquestionsandfeedback: W00D P.0.

WOOD magazine October 2004

With the workpiece

flun.tioning much like a fulcrum, this as shownabove.Easeyour workpieceaway

10 WOOD rnagazine October 2004

WOOD magazine October 2004

Resawand plane a3Aex3/sx8"

e/tx3t/zx 12" Maple (.3 bd. ft.) bar

WOOD rnagazine October 2004

hen you want a fast and eliminating "thicknessof line" errors.It

WOOD magazine October 2004

Engaging the gauge

20 WOOD magazine October 2004

for cleaningbladesandbits. (We've heard l Bladesaver.which is virtu- &;*t'

/ orrr?.uo9fffiLlortoo W/!/s/ 'AFETY

Nonflammable. Eye and 8001962-1732

CARBURETORCLEANER D .o G G-: "c B

WOOD magazine October 2004

ago for the purposeof designingand building customfur- o

niturewith an original,often unconventional twist. Says ?

Big news:Black & Decker buys Pentair power tool group

WOOD rnagazine October 2004

Testyour workshop smarts A n s w e l sto thequesti ons

fls ing gauge,markinggauge,

finishes by using the appropriate solvents. square.

"&t6ut tu".' "hn.g;

Mold, such as this, can be washed off

26 WOOD magazine October 2004

rrnottto alignment woes

fust say To solvethese

It'sa tricky,time-consumingbusinessto spacingconsistent. o

installoverlaydrawerfronts.Thetough problems, I usea verysimPleandfast ;

parts:aligning thefrontswitheachother technique-spacers. o

andanyadjacent doorsandkeeping the First,installthedrawerboxesin the a

cabinet.Pre-drill thefastener holesin the

thecenter-pull boltlocations in thefalse

Role reversal for sanding drum helps sleerrcsslip on

WOOD rnagazine October 2004

Workbench table set for messy company Drop-down tools preserve

WOOD magazine October 2004

_Kl ,l i r ijKli. .:ii-tl

Dovetait iiq does an

Everv qood bench vise

WOOD magazine October 2004

Towelson tools rub out rust problem

Dri-l[ gride spaces f,oles,

Seea new \-,

Frommachiningto bit selection,

34 WOOD magazine October 2004

Flush-Trim and Pattern Bit Sampler

Flush-trim Spiralflush- Spiral flush-trim Downshear Gombination Double-bearing Pattern

36 WOOD rnagazine October 2004

his handy divider lets you TABLESAWBLADE