Documente Academic
Documente Profesional
Documente Cultură
FU
LL- F
SIZ R
EP E
ATT
ERN E
S IN
SID
E
65
Time-and
Money-Savin
g
Tips!
Wood Joint
Torture Test
15 Smokin New
Tools for 2008
p.50
Easy mix-and-match
Modular
Bookcase
l d Th i s !
/
You CAN Bu i
p.64
s
l uawesome
PMore
projects!
p.32
Harvest Table
Wall Sconces
Box-Joint Jig
$6.99 U.S. / $7.95 CAN.
in this issue
58
32
PROJEC TS
42
TO O L S & M AT E R I A L S
TECHNIQUES
D E PA R T M E N T S
8
10
88
108
Sounding Board
Shop Tips
Ask WOOD
Whats Ahead
22
78
Dec./Jan. 2007/2008
Issue 181
on the web
woodmagazine.com
N O W T H AT S
CO O L !
18
50
46
64
PEEK T H R O U GH
T H E K E YH O L E ...
...as Matt Seiler builds this
beautiful walnut credenza.
Matt builds custom furniture in
suburban Chicago. Follow his
progress in this photo-laden blog
at woodmagazine.com/msblog.
A H EL PI N G H A N D
Free online slide shows detail how
WOOD magazine projects come
together. This month, get extra
in-progress photos of the Harvest Table
(right, p. 58) and Modular Cabinets (p. 32)
at woodmagazine.com/slideshows.
M I GH T Y D U CK S
I N YO U R SH O P
woodmagazine.com
December/January 2007/2008
W
e asked our staff:
What is your best finishing tip?
Editor-in-Chief
BILL KRIER
Managing Editor
MARLEN KEMMET
Art Director
KARL EHLERS
Techniques Editor
BOB WILSON
Projects Editor
OWEN DUVALL
Design Editor
JEFF MERTZ
Deputy Editor
DAVE CAMPBELL
Senior Design Editor
KEVIN BOYLE
Tool & Techniques Editor
BOB HUNTER
Projects Editor
JAN SVEC
Master Craftsman
CHUCK HEDLUND
Administrative Assistant
SHERYL MUNYON
Photographers
MARTY BALDWIN, JASON DONNELLY, DEAN SCHOEPPNER, JAY WILDE
Inspect and
remove
dust before
applying a
stain or clear finish. Build
up light coats and sand
between each coat.
C O R P O R AT I O N
WOOD magazine
December/January 2007/2008
Sounding Board
Our bulletin board for letters, comments, and timely updates
Plywood circle
Article update
HOW TO REACH US
n For woodworking advice:
Post your woodworking questions (joinery, finishing,
tools, turning, general woodworking, etc.) on one of
14 online forums at woodmagazine.com/forums.
n To contact our editors:
Send your comments via E-mail to
woodmail@woodmagazine.com; or write to
WOOD magazine, 1716 Locust St., LS-221,
Des Moines, IA 50309.
n Subscription assistance:
To notify us of an address change, or to get help with
your subscription, visit woodmagazine.com/service.
Or write to WOOD magazine, PO Box 37439, Boone, IA
50037-0439. Please enclose your address label from a
recent magazine issue.
n To find past articles:
See our index at woodmagazine.com/index.
WOOD magazine
December/January 2007/2008
Shop Tips
Hose clamp
Screw to workpiece.
Workpiece
Trowel
Screw to workpiece.
continued on page 14
10
Shop Tips
Runners attached
with " x 20 flathead
machine screws into
threaded inserts
All-weather runners
for a tablesaw sled
Sled
bottom
Expansion
slot
Runner
22
21
20
19
18
17
16
15
14
13
12
11
10
1204
1
e d it
8
Runners attached
Dado
with " x 20 flathead
set
machine
screws into
threaded inserts
Workpiece
22
21
20
19
18
17
16
15
14
13
12
11
10
continued on page 16
14
WOOD magazine
December/January 2007/2008
Shop Tips
Fences
Plunge router
A surefire way to
clean aerosol nozzles
Paper towel
16
Finishing School
Fill Pores
Even open-grained oak can be smooth as glass when you plug those pesky pores.
Finishing School
the same thing for less money. Choose
mineral spirits to slow the fillers drying
time and let you work longer on large
surfaces. Use naphtha to speed up the
drying time for smaller projects.
Test the filler color on scrap thats
been sanded and sealed the same as
your project. If youre dissatisfied with
the color, change it by adding pigments. (See Choose fillers for a custom
color right.) We added Mixol to a
natural-color filler, but you also can
add universal pigments or japan colors.
Medium-brown walnut
Natural color
Custom-tinted natural
Sources
Wipe using
cross-grain
strokes.
C
20
RuleJoint
Router Bits
A
ule-joint
bits add both form and
W
function to a drop-leaf table,
X
Ksuch as the one above and on
Y
page 58. They
round over table edges for
L
a traditional
look and let you lift up
Z
table leaves
to seat more guests.
M
Most rule-joint router-bit sets (see
Sources) come with a " round-over bit
and a mating " cove bit, like those in
Photo A, for cutting joints in "-thick
material. The " size works with either
mortised or surface-mounted hinges. To
leave the correct-size shoulders in
material 7 8" to 1" thick, step up to a set
with 5 8" round-over and cove bits.
Buying the bits in sets saves money.
For example, the set shown below costs
about $9 less than buying the same bits
separately. And because both bits have
common profiles, you can replace a
damaged bit without buying a new set.
J
" round-over
For the "-thick parts
" gap
" cove
shown, begin by
"
mounting a "-radius
Tabletop
round-over bit into
" Table leaf
" groove
"
either a table-mounted
" deep
or handheld router.
Longer
Shorter
Use a router table for
leaf
leaf
tabletops small
enough to maneuver
safely. Set the cutting depth to leave a
Regardless of the method you use,
3 16" shoulder [Photo B] , and move the
record your perfect profile by routing
one edge of a setup block the same
fence flush with the bits bearing. Test
thickness as your tabletop. For future
the fence setting and the bit height in
reference, mark it with the thickness of
scrap before routing both ends and
the material and the specific bit used.
edges of the tabletop.
If the top is too large to manage on a
router table, place a table leaf beneath
Rout a cove on the leaves
and flush with the top to guide the bits Table leaves are often narrow enough to
Filename: 181hinge
FILENAME:181HngAtt_#100505251.eps
bearing
handle on a router table. Using the
Date:
7-07[Photo C] as you rout.
R LeMoine
continued on page 24
7-6
Lorna J.
Cove bit
cuts the
leaves.
Tabletop
Roundover bit
profiles
the table
edges.
A
22
Table leaf
" shoulder
3 16
C
WOOD magazine
December/January 2007/2008
att
" shoulder
3 32
D
tabletops round-over profile or the
setup block as a guide, adjust the "
cove bits height to leave no more than
a 1 32" gap between the setup block
profile and the edge of the cove bit.
Using a straightedge, adjust the routertable fence flush with the bits bearing.
Test your settings on scrap before
routing both leaves [Photo D] . Then rout
that profile on the opposite edge of the
setup block, and save it along with the
bit set for future projects [Photo E] .
Setup block
Sources
Rule-joint bit sets. Set no. 26318 (shown) with a "radius, "-high round-over bit and a "-radius, 58"-high
cove bit; $50, Rockler Woodworking and Hardware, 800279-4441; rockler.com. Set no. 100-5465 for " tabletops,
$42.49, Eagle America, 800-872-2511; eagleamerica.com.
Set no. 33-116 for " tabletops, $51, Freud, 800-334-4107;
freudtools.com. Set no. 00-124 for " tabletops, $53,
Infinity Cutting Tools, 877-872-2487; infinitytools.com. Set
no. 8401 (58" set for surface-mounted hinges), $42, MLCS,
800-533-9298; mlcswoodworking.com. Set no. WL-2033,
$39, Woodline USA, 800-472-6950; woodline.com.
24
Workshop Savvy
" groove
38"
1 Z-shape clips
A Nonto the
One end screws firmly
tabletop, while theBother
O fits a saw kerf
along the table apron, as shown above.
P
Advantages: LowCcostless
than a
dime apieceandDeasy
Q installation.
Disadvantages: Metal hardware
R
E some
doesnt complement
traditional
table styles for purists Swho prefer solidF
wood mounting systems.
T the screw end
How to use them:G Press
of the clip firmly against a flat surface
H U
and measure the rise at the other end
(usually about 3 8").I AtVthat measurement, cut a groove onWthe top inside
J
face of each apron piece using a router,
X
tablesaw, or biscuitK joiner.
Mark the
locations of mountingYscrew pilot holes
about 812" apart,Land drill with a
Z
depth stop to avoid
M boring through the
tabletop. Then attach the clips to the
apron sides and ends, as shown.
28
2 Shop-made blocks
block blank
"
"
1"
"
Shank hole
F
"
"
F
2"
continued on page 30
WOOD magazine December/January 2007/2008
Workshop Savvy
Figure-Eight connectors rotate as the wood moves
Center
mounting
hole
Forstner bit
spur hole
Top
edge
Expansion
slots
Inside face of
apron end piece
Apron side
" slot
Stretcher
(built-in)
Tabletop
(underside)
Centered
mounting
screw
lot_#100505342.eps
" slot
3 Slotted stretchers
Fasteners rotate as
the wood moves.
4 Figure-eight connectors
4
[Photo 2] , to allow the connector to
rotate back and forth about one-eighth
of a turn.
Screw the figure-eight connector to
the apron just loosely enough to allow
it to rotate [Photo 3] . Check that the
connector sits flush with or a little
lower than the apron edge. Repeat these
steps to mount the remaining connectors. Do not mount them on the side
pieces of the apron.
With the tabletop upside down on
your workbench, center the apron/leg
assembly on the underside of the
tabletop, and mark the mounting screw
locations. Drill pilot holes into the
tabletop using a depth stop and insert
the mounting screws [Photo 4] .
Sources
Shuffle n Stack
Modular Cabinets
This super-flexible system transforms to meet your needs, big or small. Add, subtract, or
reconfigure as your needs change. Shown here are just four of the endless possibilities.
32
WOOD magazine
XXXX 2007
DOUBLE CABINET
36"W x 33"H
x 15"DSYSTEM FROM
DESIGN
YOUR
TheSE 8 ComponeNts
O
P
Q
R
VERTICAL
CABINET
18"W x
33"H x 15"D
S
T
U
TRIANGULAR
CABINET
15"W x 15"D x 33"H
(Left cabinet shown.
Flip end for end for a
right cabinet.)
R
S
W
X
Y
DOOR
17"W x
31"H
I
J
K
L
M
V
I
HORIZONTAL
CABINET
J W
36"W x
16"H x K
15"DX
Y
L
Z
M
VERTICAL
CABINET
18"W x
33"H x 15"D
CUBE CABINET
18"W x
16"H x 15"D
DOOR
17"W x
31"H
RECTANGULAR BASE
36"W x 3"H x 15"D
V
W
2 Double cabinets
4 Triangular cabinets
(2 visible)
1 Rectangular base
2 Triangular bases
(1 visible)
2 Doors
DOUBLE CABINET
36"W x 33"H x 15"D
TRIANGULAR
CABINET
(Front view)
SHOWN LEFT
J
K
L
M
V
W
X
Y
Z
VERTICAL
CABINET
18"W x
33"H x 15"D
TRIANGULAR B
15"W x 3"H x
DOUBLE CABINET
36"W x 33"H x 15"D
TRIANGULAR
CABINET
15"W x 15"D x 33"H
(Left cabinet shown.
Flip end for end for a
right cabinet.)
DOUBLE CABINET
36"W x 33"H x 15"D
DOUBLE CA
36"W x 33"H
VERTICAL
TRIANGULAR
SHOWN LEFT
A N CABINET
CABINET
FILENAME: 181ModShlv_#100505216.eps
18"W x
1 Double cabinet
15"W
x
15"D
x
33"H
Date: 7-07
33"H x 15"D
R
VERTICAL
EVERTICAL
O
(Left
cabinet
shown.
1 Vertical cabinet
B
TRIANGULAR
Lorna J.
CABINET
TRIANGULAR
Flip end for endCABINET
for a
1 Horizontal cabinet
CABINET
TRIANGULAR
S
right cabinet.)
F 18"W x
C P CABINET18"W x
15"W
x
15"D
x
33"H
2 Cube cabinets
CABINET
x 15"D
15"W x 15"D33"H
x 33"H
33"H x 15"D
DOOR
(Left cabinet shown.
(Front view)
2 Rectangular bases
(Left
cabinet
shown.
G T
D
Q
17"W x
Flip end for end for a
Flip
end
for
end
for
a
FILENAME: 181Mod
31"H
rightHORIZONTAL
cabinet.)2 Doors
CUBE CABIN
Date: 7-07
H U
VERTICAL CABINET
E R right cabinet.)
18"W x
TRIANGULAR
Lorna J.
CABINET 36"W x
16"H x 15"
CABINET
V
S
18"W x 16"H x 15"D
I
TRIANGULAR
F
15"W x 15"D x 33"H
33"H x 15"D
CABINET
(Left cabinet shown.
J W
G T
DOOR
(Front view)
Flip end for end for a
A N
17"W x
right cabinet.)
X
TRIANGULAR HORIZONTAL
31"H
K
H U TRIANGULAR
C
CABINET
CABINET
O
CABINET DOOR
B
Y
(Front view)
V (Front view)17"W x
36"W
x
L DOOR
1
I
17"W
x
16"H x 15"D
C P
HORIZONTAL
Z
31"H
HORIZONTAL
M 31"H
CUBE
CABINET
J W
CABINET
RECTANGULAR BASE
CABINET
D Q
18"W x
36"W xx 15"D
TRIAN
36"W xTRIANGULAR
3"H
36"W x
X
16"H x16"H
15"D x 15"D
15"W
K
16"H x 15"D
CABINET
R
VERTICAL
E
Y
DOOR
(Front view)
CABINET
L
17"W x S
18"WHORIZONTAL
x
F
Z
31"H
33"H x 15"D
M
CABINET
G T
RECTANGULAR BASE 36"W x
36"W x 3"H x 15"D
16"H x 15"D
H U
SHOWN ABOVE
1 Double cabinet
2 Vertical cabinets
2 Triangular cabinets
2 Rectangular bases
2 Triangular bases
2 Doors
FILENAME: 181ModShlv_#100505216.eps
Date: 7-07
Lorna J.
V
SHOWN
RECTANGULAR
BASE LEFT
I
36"W x 3"H x115"D
Horizontal cabinet
J W
1 Double cabinet
2 Vertical cabinets
(1 visible)
Y
2
Cube cabinets
L
(1 visible)
Z
M
2 Triangular cabinets
FILENAME: 181ModShlv_#100505216.eps
(1 visible)
Date: 7-07
2
Rectangular bases
Lorna J.
(1 visible)
FILENAME: 181ModShlv_#100505216.eps
FILENAME: 181ModShlv_#100505216.eps
2 Triangular bases
Date: 7-07
Date: 7-07
Lorna J.
(1 visible)
Lorna
J.
woodmagazine.com
2 Doors (1 visible)
K
RECTANGULAR BASE
36"W x 3"HBASE
x 15"D
TRIANGULAR
15"W x 3"H x 15"D
DOOR
17"W x
31"H
33
proJEcT HIGHLIGHTS
The components are sized to
maximize use of 48' plywood sheets.
The components are a snap to construct, thanks to the simple design,
biscuit joinery, and common parts.
We built the cabinets using maple
and maple plywood, covering the
exposed plywood edges with iron-on
maple veneer edging. (White birch
edging, available at your local home
center, also matches well.) But you
can use a different hardwood and plywood with a matching edging, if you
wish. The cabinets will still look great.
As an option, install 14" glass instead
of the plywood panel in the door.
To easily round up the hardware,
edging, and edge and end trimmers
for the project, see Supplies and
Source, page 40.
Biscuit-slot
centerline
story stick
2 14"
A
paTTErNS MakE pLaNNING EaSY
Lay out the scaled parts on the plywood to
find the number of sheets you need. Be sure
to align the grain and allow for saw kerfs.
34
7 18"
December/January 2007/2008
2
3
FINISHED SIZE
15"
36"
MP
sides
34"
1414"
3112"
MP
back supports
34"
3"
3514"
back
14"
3514" 2614" MP
shelves
34"
1212" 3438" MP
shelf trim
34"
114" 3438"
doorstop
34"
1 Double cabinet
exploded view
34"
Materials List
top/bottom
Part
A
34"
3"
36"
A
"
P
10"
1"
Veneer
edging
"-diam.
rubber
bumper
#17 x "
wire nail
1"
34"
2"
C
31"
F
"
"
14"
34"
26"
2"
" rabbet
" deep
#20 biscuit
#20
biscuit
slot
3"
35"
12"
15"
Matl. Qty.
2
"
" round-overs
Z
15"
2 vertical cabinet
exploded view
18"
"
17"
" rabbet
" deep
#20 biscuit
G
C
" hole
" deep
10"
26"
Materials List
#17 x "
wire nail
1 DOUBLE
" shelf
support
1"
12"
CABINET2"EXPLODED VIEW
31"
O
16"
" round-overs
"
woodmagazine.com
34"
15"
18"
MP
sides
34"
1414"
3112"
MP
back supports
34"
3"
1714"
back
14"
1714" 2614" MP
M shelves
34"
1212" 1638" MP
34"
114" 1638"
shelf trim
Matl. Qty.
16"
2"
FILENAME:181ModCab1_#100505252.eps
G
MDate:8-07
3"
Lorna J.
top/bottom
1"
FINISHED SIZE
Part
B
#20 biscuit
slot
14"
"
Veneer edging
35
No glue
Rabbeted
edges
10
C
B
Glue THE cabinets and back supports together in two stages
Glue, biscuit, and clamp the case (horizontal case shown) together. Add the back supports (F)
(without glue) to keep the assembly square. Then glue and clamp the back supports in place,
ensuring theyre tight against the case top/bottom and the rabbeted sides.
3 horizontal cabinet
exploded view
A
Veneer edging
Part
15"
36"
MP
15"
MP
" rabbet
3" " deep
Matl. Qty.
top/bottom
sides
34"
1414"
divider
34"
14"
15"
MP
back supports
34"
3"
3514"
back
14"
3514" 934"
MP
3"
14"
34"
#17 x "
wire nail
35"
" rabbet
" deep
Materials List
FINISHED SIZE
35"
9"
D
14"
15"
"
F
D
3"
T
U
V
W
X
Y
Z
15"
F
B
G
#20 biscuit
18"
"
A
36"
18"
"
"
17"
"
" rabbet
" deep
"
F,G
" rabbet
" deep
9"
"
" rabbet
" deep
#20 biscuit
slot
15"
FILENAME:181ModCab3_#100505254.eps
Date:8-07
14"
Lorna J.
"
36
5 back support
rabbet detail
15"
4 cube cabinet
exploded view
"
H U
Veneer edging
V
I
17"
J W
3"
X
G
K
Y
L
" rabbet
Z
M" deep
#20 biscuit
Materials List
for Filename:
Cube Cabinet
181MOD
cabinets 3
FINISHED SIZE
PartR
LeMoineT
7-30-07
top/bottom
34"
15"
18"
Matl. Qty.
MP
sides
34"
1414"
15"
MP
back supports
34"
3"
1714"
back
14"
1714" 934"
MP
Q
Q
E
F
assemble THE triangular cabinet sides, AND add the top/bottom
D
cut tHE top/bottom
Use the triangle-cutting jig to safely hold and
crosscut the triangular top/bottom (Q) from
the 1616" blank along the marked lines.
Assemble the sides (C, R) for the triangular case together with glue, biscuits, and clamps.
Check the assembly for square. Then, with the side assembly (C/R) on a side, glue, biscuit, and
clamp the top/bottom (Q) to the assembly, flush with the backs of the sides.
To form the top/bottom (Q) [ Drawing 6 ], lay out two right triangles
with 15"-long sides at opposing corners
on a 1616" piece of 3 4" plywood. Make
the simple triangle-cutting jig [ Drawing
7] from 3 4" plywood, using a bandsaw or
jigsaw to cut out the 90 opening and
the 1414" corner relief notch. With the
workpiece cradled in the jig, crosscut
the top/bottom pieces to size [ Photo D ].
To ensure that the grain of the top and
A N
bottom flows from left to right (not
front to back) to
the grain direcO
B match
tion of the other cabinets, flip the parts
C P
as needed to correctly
orient the grain
for a right- or left-side
D Q unit. Identify the
top faces to ensure correct orientation
E R
during assembly.
3
4
F
G
6 triangular cabinet
H U
exploded
view
7 triangle-cutting jig
13"
14"
J
K
45
10"
16"
12"
1"
2"
2"
45
"
Veneer
edging
" hole
" deep
31"
2"
" shelf
support
2"
Mitered end
12"
T
181532"
12"
"
#20 biscuit
#20 biscuit slot7 TRIANGLE CUTTING JIG
15"
" round-overs
side
Q* top/bottom
R
side
15"
S* shelves
Q
FILENAME:181ModCab7_#100505258.eps
Date:8-07
"
Lorna J.
Veneer edging
woodmagazine.com
1"
Materials List
FINISHED SIZE
34"
W
L Matl. Qty.
1414" 3112" MP 1
34"
15"
15"
MP
34"
1312"
3112"
MP
34"
12"
12"
MP
181M
R
LeMoine
*Parts initially cut oversize. See the instructions.
Materials key: MPmaple plywood, Mmaple.
7-30-07
T
shelf trim
34"
114" 1815Filename:
32" M 2
37
X
V
U
Y
W
V
G
assemble the rectangular base
Glue and biscuit the rectangular-base front and sides (U,
V) together. Use the front cleat (W) as a spacer to keep the
assembly square.
H
mount the rectangular base
4
5
8 rectangular base
exploded view
X
Mitered ends
1"
R="
34"
3"
"
Y
V
1"
15"
#20 biscuit
36"
Materials List
34"
334"
36"
34"
334"
15"
34"
114" 3412"
114" 1214"
Q X side cleats
34" 334"
Y supports
334"
R
*Parts initially cut oversize. See the instructions.
SMaterial key: Mmaple.
A
B
C
D
E
I
J
N Part
U* front
O
V* sides
P W front cleat
34"
Matl. Qty.
8a support detail
3"
Countersunk
shank holes
1"
"
3"
Y
"
1"
V
W
3"
#8 x 1" F.H.
wood screw
WOOD magazine
December/January 2007/2008
AA
BB
CC
2
3
4
A
B
C
D
E
F
G
H
I
J
K
L
M
5
6
J
attach THE triangular base
I
screw THE Triangular base
Band-clamp the triangular-base front (Z) and
sides (AA, BB) together. Drill the mounting
holes, and screw side AA to BB.
Materials List
Part
Z* front
Matl. Qty.
34"
334" 21316"
AA* side
34"
334"
131516"
BB* side
34"
334" 13316"
CC cleats
34"
114"
4"
9 triangular base
exploded view
#8 x 1" F.H.
wood screw
13"
13"
CC
Mitered ends
CC
AA
" rabbet
" deep 1"
Shank hole
countersunk on
bottom face
4"
CC
3"
#8 x 1" F.H.
wood screw
1"
21"
R="
BB
#20 biscuit
slot
#20 biscuit
3"
1
2
3
4
woodmagazine.com
I
J
K
L
M
" hole
3"
DD
1"
W 1"
17"
12"
2"
1"
3"
"
1" hole
" deep
" to
centers
of slots
GG
26"
EE
25"
26"
FF
HH
10a DOOR-RAIL
BISCUIT-SLOT DETAIL
#10 biscuits
FILENAME:181ModCab10a_#100505263.eps
Date:8-07
"
Lorna J.
DD
"
#10
biscuit
slots
GG
11 Door-hinge mounting
Draw centerline here
for aligning hinge-drilling jig.
12 hinge-drilling jig
C
5"
"
DD
3"
1"
EE
1ModCab10_#100505262.eps
"
"
hardboard
" holes
Hinge-clip
mounting plate
"
Filename: 181MOD
cabinets
3" 5
Supplies and Source
R
LeMoine
1"
" stock 1"
78"-wide iron-on veneer edging; 1"-long
1"
Supplies:
7-30-07
1
wood roller; #10 and #20 biscuits; 4" spoon shelf supports; 14"-diameter rubber bumpers; #1712" wire nails;
#1734" and #171" wire brads; #8114", #8112", and
#8212" flathead wood screws; 100 full-overlay clip
hinges (2 per door); hinge-clip mounting plates (2 per
door); 78" satin-nickel knob (1 per door).
Blade and bits: Dado-blade set; 38" rabbeting, 18"
round-over, and 34" straight router bits; 14" brad-point bit;
138" Forstner bit.
2"
Materials List
for Door
Part
FINISHED SIZE
Matl. Qty.
3"
1778"
3"
25516"
1258" 26116" MP
NG
DD rails
34"
#100505264.eps
EE stiles
34"
FF panel
14"
panel
GG horizontal
stops
14"
38"
1178"
panel
HH vertical
stops
14"
38"
26116"
K
R LeMoine
drill THE hinge-clip7-30-07
holes
40
2
3
" groove
" deep
4"
EXPLODED VIEW
d from back)
11"
A ,B
100 full-overlay
clip hinge
Finish up
HH
EE
FILENAME:181ModCab12_#100505265.eps
Date:8-07
Lorna J.
Source
cabinets
SHOP-TESTED
General-Purpose
Tablesaw
Blades
We put 28 of
the leading 10"
models through
rigorous trials in search of
the perfect do-everything
blade. The good news: We
found several that qualify.
42
A
General-purpose blades, like this DeWalt
(front), have 40 evenly spaced teeth. Combination blades, like this Freud, have 50 teeth
in groups of five separated by deep gullets.
WOOD magazine
December/January 2007/2008
Tenryu GM-25540
Amana PR1040
Bosch PRO1040GP
CMT 213.040.10
Irwin Marathon
Vermont American
These chalked rip-cut (left) and crosscut samples show an edge with no scoring (top), slight
scoring (middle), and substantial scoring (bottom).
Test Edge
Systimatic 51821
Test Edge
Jesada 110-440
Test Edge
D
Top-side tear-out on these melamine
samples helped us to see which blades
produce the cleanest cuts.
E
Blades with large carbide teeth, like the
Forrest Woodworker II (bottom), can be
sharpened more times than those with small
teeth, like the Irwin Marathon (top).
woodmagazine.com
F
ITP/H.O. Schumachers pattern of three different intervals between successive teeth disturbs
the air less, resulting in a noticeably quieter cut.
43
Forrest WW10407125
89
93
87
92
94
FREUD
P410
40
30
18 0.126
86
90
93
Amana TB10400
N UM B
INFINITY
010-044
40
30
18 0.125
83
86
89
RIDGE CARBIDE
TS21040
40
15
15 0.125 N
96
98
102
RIDGE CARBIDE
TS21040TK
40
15
15 0.093 N
86
89
92
TENRYU
GM-25540
40
15
20 0.111
87
92
94
TB10400
40
10
15 0.090 N
89
95
98
JESADA
110-440
40
20
18 0.126 N
82
87
90
CMT
213.040.10
40
20
18 0.130
97
101
104
SYSTIMATIC
37437
40
20
10 0.093 N
95
99
102
SYSTIMATIC
51821
40
20
15 0.125 N
101 104
106
ITP/H.O. SCHUMACHER
40-HATB-VP
40
40
12 0.125 N
78
83
85
AMANA
610400
40
10
15 0.126 N
94
97
100
AMANA
PR1040
40
20
18 0.134 N
95
99
102
OLDHAM
1007740
40
10
17 0.115 N
92
96
98
BOSCH
PRO1040GP
40
15
15 0.128
96
99
102
DELTA
35-7657
40
15
20 0.118 N
90
94
97
CMT
251.042.10
42
15
15 0.098 N
88
92
96
CRAFTSMAN
32808
40
15
15 0.100 N
87
91
94
MAKITA
A-94459
40
15
20 0.091 N
87
91
94
FREUD
LU86R010
40
10
13 0.094 Y
88
93
96
VERMONT AMERICAN
27831
40
12
13 0.098 Y
88
97
99
DEWALT
DW7140PT
40
10
20 0.098 Y
86
91
95
HITACHI
310878
40
20
0.098 N
84
89
92
FREUD
D1040
40
15
15 0.098 Y
86
91
94
DEWALT
DW3114
40
10
10 0.095 N
86
92
95
IRWIN
14070
40
10
20 0.095 N
88
93
97
NOTES:
Amana PR1040
1.
2.
Excellent
Good
Fair
Poor
44
WOOD magazine
Craftsman 32808
OOD
A PLE
AR D M
HICK H
G 1"-T
85
RIPPIN
RIPPIN
G BIRC
/NO)
D? ( YE
S
AD
COATE
N O LO
20 0.100 N
20 0.125 N
PLATE
20
20
TEE TH
40
40
TEE TH
WW10407100
WW10407125
model
FORREST
FORREST
H PLY W
EE S
S
INCHE
K ERF W
IDTH,
, D EG R
AN G LE
AN G LE
HO OK
BE V E L
ER OF
FAC TU
R
ER
TEE TH
, D EG R
EE S
NOISE LEVEL,
DECIBELS (1)
BLADE SPECIFICATIONS
M ANU
December/January 2007/2008
ITE
WEB S
E N UM
BE R
FAC TU
R
M ANU
G PRIC
RY OF
E (5)
PH O N
CROSS
E (4)
ABSENCE OF:
SELLIN
ABSENCE OF:
AR-OU
T ( TO P
)
AR-OU
T
(BOTT
E A SE O
OM)
F FEED
(CONT
R AC T O
E A SE O
R SAW
F FEED
)
(CABIN
ET SAW
RIP-CU
)
T S CO R
ING
CROSS
CUT S C
ORING
CROSS
CUT TE
AR-OU
T ( TO P
CROSS
)
CUT TE
AR-OU
T (BOT
E A SE O
TOM)
F FEED
(CONT
R AC T O
E A SE O
R SAW
F FEED
)
(CABIN
ET SAW
RIP-CU
)
T S CO R
ING
CROSS
CUT S C
ORING
CROSS
CUT TE
AR-OU
T ( TO P
CROSS
)
CUT TE
AR-OU
T (BOT
E A SE O
TOM)
F FEED
(CONT
R AC T O
E A SE O
R SAW
F FEED
)
(CABIN
ET SAW
CUT S C
)
ORING
TEAROUT ( T
OP)
TEAROUT (B
O T TO M
)
E A SE O
F FEED
(CONT
R AC T O
E A SE O
R SAW
F FEED
)
(CABIN
ET SAW
WARR
)
ANT Y
(3)
ABSENCE OF:
34"-THICK MELAMINE
CUT TE
ORING
CUT TE
CROSS
CUT S C
CROSS
RIP-CU
T S CO R
ING
ABSENCE OF:
CONTACT INFORMATION
CO U N T
LD/30
$110
800-733-7111
forrestblades.com
LD/30
$110
800-733-7111
forrestblades.com
LD
IT $100
800-334-4107
freudtools.com
LD
IT $100
877-872-2487
infinitytools.com
LD
$97
800-443-0992
ridgecarbidetool.com
LD
$97
800-443-0992
ridgecarbidetool.com
LD
$90
800-951-7297
tenryu.com
LD
IS
$65
800-445-0077
amanatool.com
LD
$62
877-898-6657
razorwoodworks.com
LD
$60
888-268-2487
cmtusa.com
LD
CZ
$60
800-343-1616
simondsinternational.com
LD
CZ
$57
800-343-1616
simondsinternational.com
LD
$55
866-537-0700
itptooling.com
LD
IS
$55
800-445-0077
amanatool.com
LD
IS
$52
800-445-0077
amanatool.com
oldham-usa.com
30
$50
800-433-9258
LD
$45
877-267-2499
boschtools.com
30
$43
800-223-7278
deltaportercable.com
LD
$40
888-268-2487
cmtusa.com
None
IT
$40
800-383-4814
craftsman.com
B 1 year
$40
800-462-5482
makitatools.com
LD
IT
$35
800-334-4107
freudtools.com
LD
$35
800-626-2834
vermontamerican.com
LD
$35
800-433-9258
dewalt.com
30
$30
800-829-4752
hitachipowertools.com
LD
IT
$30
800-334-4107
freudtools.com
30
$28
800-433-9258
dewalt.com
LD
$28
800-464-7946
irwin.com
3. (30)
30 days
(LD) Lifetime replacement for defects in material
or workmanship
(LD/30) Lifetime replacement for defects in material or
workmanship; 30 days full refund if not satisfied
woodmagazine.com
4. (C)
(CZ)
(F)
(G)
(IS)
(IT)
(J)
(N)
(U)
China
Czech Republic
France
Germany
Israel
Italy
Japan
New Zealand
United States
45
Skill Builder
Youll have fun with this project when you build it and each time
you add the most recently released presidential coin.
Start with the frame
To form the built-up frame top/bottom and sides (A, B) [ Drawings 1 and
2 ], cut two pieces each sized 1 2 138"
for the inner members, 3 4 238" for
the center members, and 1 2 11 2 38"
for the outer members to form two
blanks. Youll cut a frame top or bottom
and a side piece from each blank. To
avoid glue squeeze-out when laminating
5
6
7
WOOD magazine
December/January 2007/2008
Miter-gauge
extension
Outer
member
A,B
Inner
member
A,B
Center
member
A
Stopblock
On to the stripes
1
2
2
3
13"
1
2
45 bevel
1"
x 9 x 13" glass
A
15"
Turnbutton
45 bevel
" wood star
13"
Wall anchor
#8 x 1" F.H. wood screw
9"
B
Dollar coin
A
Brass plaque
woodmagazine.com
19"
#20 biscuit
1 EXploDED viEW
47
Cut along
these lines.
7"
6"
D
Masked area
D
With spray adhesive applied to the 67" star
portion of the flag pattern, align and press it
onto the masked area of the flag backer (D).
1 4"
U
Wrap
it up
A
B
C
D
E
F
I
J
K
L
M
2
48
Start here.
"
Outer
member
10
"
"
20
"
"
2a bevel-ripping the
frame outer member
Outer member
3"
"
2"
Center member
2"
A, B
A, B
Back
Inner member
1"
Blade angled 10
from vertical
" rabbet
" deep
" cove
" glass
"
"
"
E
C
1"
Stripes
Flag
2a BEVEL-RIPPING
THE
backer
FRAME OUTER MEMBER
E
Wall
"
45 bevel on
top cleats only
FILENAME: 181CoinFlg2a_#100504272.eps
Date: 8-07
Lorna J.
#8 x 1" F.H.
flush. Secure the stripes together with a
wood screw
Wall anchor
Filename
R LeMoin
7-26-07
C
Indentations
C
apply adhesive-backed 14" round colorcoding labels centered over the marked
indentations for the stars in the backer (C/D).
4
5
Materials List
FInIsheD sIZe
top/
A* frame
bottom
112"
3"
1914"
LO
B* frame sides
112"
3"
15"
Part
matl. Qty.
2
LO
mounting cleats
14"
112" 1334"
flag backer
14"
912"
BP
1334"
Source
J
With the stripes tightly together and aligned
with the edges of the flag backer (C/D), join
the stripes together with masking tape.
17891797
17971801
18011809
18091817
2012
CHESTER A. ARTHUR
GROVER CLEVELAND
BENJAMIN HARRISON
GROVER CLEVELAND
18811885
18851889
18891893
18931897
2008
JAMES MONROE
JOHN QUINCY ADAMS
ANDREW JACKSON
MARTIN VAN BUREN
18171825
18251829
18291837
18371841
2013
WILLIAM MCKINLEY
THEODORE ROOSEVELT
WILLIAM HOWARD TAFT
WOODROW WILSON
18971901
19011909
19091913
19131921
2009
WILLIAM HENRY HARRISON
JOHN TYLER
JAMES K. POLK
ZACHARY TAYLOR
1841
18411845
18451849
18491850
2014
WARREN G. HARDING
CALVIN COOLIDGE
HERBERT HOOVER
FRANKLIN D. ROOSEVELT
19211923
19231929
19291933
19331945
2010
MILLARD FILLMORE
FRANKLIN PIERCE
JAMES BUCHANAN
ABRAHAM LINCOLN
18501853
18531857
18571861
18611865
2015
HARRY S. TRUMAN
DWIGHT D. EISENHOWER
JOHN F. KENNEDY
LYNDON B. JOHNSON
19451953
19531961
19611963
19631969
2011
ANDREW JOHNSON
ULYSSES S. GRANT
RUTHERFORD B. HAYES
JAMES A. GARFIELD
18651869
18691877
18771881
1881
2016
RICHARD M. NIXON
GERALD R. FORD
19691974
19741977
49
Leigh Industries
800-663-8932 ; leighjigs.com
50
WOOD magazine
December/January 2007/2008
COMPUTER-CONTROLLED ROUTING
COMES TO SMALL SHOPS
Large-scale professional woodworking shops
often use CNC (computer numerically
controlled) equipment for precisely cutting,
routing, and drilling piecesthink of it as hightech template-routing. Now, CNC-toolmaker
ShopBot has downsized that technology to fit
into a garage or basement shop. Requiring a
working footprint smaller than a sheet of
plywood, the PRTstandard BenchTop can
automatically cut, rout, carve, and drill project
parts up to 2432" in a fraction of the time it
would take to do them by hand.
Price: $3,995, not including spindle. Add
$365 for 3-hp router package, or $1,195 for
2-hp 230V spindle package.
ShopBot Tools
919-680-4800; shopbottools.com
IF YOU HAVE TOO MUCH ROOM IN YOUR SHOP, SKIP THESE ITEMS
Wouldnt the world be a better place if you could face-joint material as wide as you can
thickness-plane? Space-starved woodworkers in Europe have long used jointer/planer
combination machines, and now you can afford one too, thanks to two new 12"-capacity
machines from Grizzly and Jet. Both combo machines have jointer beds that tip out of the
way, revealing a planer bed that must be raised about 8" to plane 34"-thick stock. They take
up about as much floor space as a 15" planer, require 220-volt electrical service, and cost
hundreds less than similar European-made combination machines.
Jointer
bed
Planer
bed
Planer bed
Jets 3-hp combination jointer/planer makes the transformation from jointer to planer 510
seconds quicker than the Grizzly. You simply tip up the entire jointer bed, secure the dust
hood, and raise the planer bed. It features straight knives and weighs 529 lbsabout 150 lbs
less than the Griz.
Price: $2,000, stock no. 708475
WMH Tool Group
800-274-6848; jettools.com
woodmagazine.com
51
0 pin
hole
5 increments
Indexing
pin
Saw kerfs
Storyboard
Woodline USA
800-472-6950; woodline.com
52
WOOD magazine
December/January 2007/2008
Join pattern
(Section 2) here.
Drop-Leaf Table,
Page 58
K
L
A
F TABLE LEG
E PATTERN
tion 3)
K
2"
M
4 x 8' plywood
Section 1
5"
2" diam.
3"
FF
W
X
R
Q
Modular CabinetsDROP-LEAF
Cutting Diagram, FULL-SIZE
(Secti
Page 32
2" diam.
2"FILENAME:181ModCabCD_#100505266.eps
diam.
Date:8-07
2"Lorna
diam.
J.
Section 2
29"
Better Homes and Gardens
12"
PAT TERNS
2" diam.
2"
2" diam.
1" diam.
2" diam.
3"
1" diam.
1"
2" diam.
2" diam.
1" diam.
December/January 2007/2008
Issue 181
Section 3
53
White E
E
1" holes
" deep
Red
Locations of
" stars
Blue
White
Red
White
ENAME: 181CoinFlgPP_#100505273.eps
54
e: 8-07
na J.
Red
Presidential
Coin Flag,
Page 46
White
Red
E
White
Red
55
Join pattern
(Section 1) here.
Join pattern
(Section 1) here.
LEG
RN
DROP-LEAF TAB
FULL-SIZE PAT
(Section 2
DROP-LEAF
FULL-SIZE
(Sect
Join pattern
(Section 3) here.
Join pattern
(Section 3) here.
Join pattern
(Section 2) here.
Join pattern
56
Classic Styling,
Simple Construction
Drop-Leaf
Table
Big enough to seat six or small enough for two, this table expands
to fill a dining room or shrinks to fit a cozy breakfast nook.
Build the
matching Hutch for
your table, coming up
in our next issue,
March 2008!
58
WOOD magazine
December/January 2007/2008
proJect hiGhLiGhts
Overall dimensions: leaves up, 48" wide
60" long 2978" high; leaves down,
3114" wide.
Purchased legs, corner brackets, and
leaf supports make this an easy-to-build
project. (See Sources for these items.)
For those who wish to turn the legs,
see the full-size pattern on the WOOD
Patterns insert.
Skill Builders
V
W
X
Y
Z
B
Credit card
Straightedge
" roundnose bit
Hinge-barrel
centerline
Self-centering bit
Groove
end lines
Rule joint
1 tABLetop
(Bottom face shown)
30"
61"
Centerline
B
10"
19"
10"
B
10"
Centerline for
hinge and barrel slot
R=40"
15"
Template
Centerline
SHOP
TIP
A N
10"
1a hinge-BArreL groove
"
O
WhenBrouting
the shouldered round-over along the edge of
the tabletop
(A/B), the small gaps (about 132") between the
C P
top (A) and leaves (B) present possibilities for chip-out. To
Q cut a 1"-wide strip of cardboard about 8" long, and
avoidDthis,
adhere double-faced tape to one face. Then, with the leaves
R
E adhere
down,
short pieces of cardboard to the top (A) part of
the rule joints
at the four places where the joints intersect the
S
edge,Fas shown below left. Then with the leaves supported in
the up
trim the cardboard flush with the top and end
G position,
T
surfaces, as shown below right. Now you can rout the edge
U
H without
profile
fear of chip-out.
V
I
A N
J W
Cardboard
B OX
K
C PY
L
D QZ
M
E R
Cardboard
S
pressed
F into
corner with a
G knife
T
putty
B
H
I
U
V
1 TABLETOP
(bottom face shown)
Doublefaced
tape
FILENAME:181HrvstTbl1_#100505240.eps
Date: 8-07
Lorna J.
Cardboard
protrudes
"
A
A
B
19"
to tabletop
centerline
2"
Hinge location
1b LeAF hALF-teMpLAte
(Bottom face)
27"
6"
22"
14"
8"
8"
59
10"
Beam compass
A
B
A
40"
Tabletop
centerline
Curve on B aligned
with curve on A
B
Second
halfcurve
First half-curve
E
With the top (A) end curves and the leaf (B)
side curves drawn, cut the tabletop to shape
with a jigsaw.
B
A
B
" round-over with
a " shoulder
Leaf support
" grooves " deep
" from top edge
#8 x "
panhead screw
15"
F
C
9"
13"
Shank hole,
D
centered
#10 flat washer
3"
24"
4"
"
#8 x 1"
panhead screw
13"
13"
1"
" bead
22"
" dadoes
" deep
1" from ends
15"
4"
"
D
44"
Turned
leg
2 exploded view
2 EXPLODED
VIEW
Lay out
the centers of
the 4078" top
Flip the assembled tabletop (A/B) Make the base
(A) end radii [ Drawing 1], and draw
over, and support the leaves in the
Cut the end skirts (C) and side skirts
FILENAME:181HrvstTbl2_#100505243.eps
14" hard38" round-over bit
up
position.
Chuck
a
(D) to size. Then, with a dado blade
them [ Photo
C
].
Then,
from
Date: 8-07
tablesaw,
cut 14"Table
board, make
into your handheld router, adjust it
to in your181
grooves
Lorna J.a template for the leaf (B)
Filename:
Harvest
6 into the
curve [ Drawing 1b]. (For help, go to form a 316" shoulder [ Drawing 2a], R
inside
faces
of
the
skirts [ Drawing 2 ].
and
LeMoine 1
woodmagazine.com/irrcurves.) Use the rout the edges of the top (A) and leaves Next cut 8" dadoes for the corner brack8-2-07
template to draw the curves [ Drawing 1 (B). To prevent chip-out as the bit passes ets [ Drawings 2 and 2b]. Now rout a 14"
and Photo D ]. Cut the top to shape [ Photo over the gaps between the top and bead along the outside bottom edge of
leaves, see the Shop Tip on page 59.
each skirt [ Drawing 2c].
E ], and sand the edges smooth.
60
WOOD magazine
December/January 2007/2008
D
Extension
#81" panhead screw
#10 flat washer #81"
panhead
Slot
screw
E
"
Outside faces
face forward
1"
D Q
Location of corner
E R centered
bracket,
1"
H
Center the leaf support rail in the side skirt (D)
notch, and square the support bracket to the
skirt. Drill pilot holes, and drive the screws.
Table leg
Fence
" hole
2" from top
" dado
" deep
C
D
"
bead bit
V
I
A N
J W
Corner bracket
B O
X
K
Hanger bolt
P
C Y
L
#8 x "
D Q
Z
M
panhead screw
E R
Washer
Nut
S
F
2b corner bracket
Bracket
Center hole
" dado
blade
Square
3"
Router
table
" chamfer
2d stretcher tenons
2a round over
J Wdetail
1"
X
K "
Y
L
AZ , B
M
"
E
1"
"
FILENAME:181HrvstTbl2c _#100505246.eps
Date: 8-07
Lorna J.
Filename: 181 H
8-2-07
R LeMoin
8-2-07
61
3 tabletop fasteners
15"
" dadoes " deep
Cutline
6"
8"
9"
11"
"
1"
"
1"
F
"
"
1"
F
"
"
2"
"
12"
"
1"
" hole
13"
3
4
Materials List
Part
Cutting Diagram
A
*F
E
x 5 x 96" Oak (4 bd. ft.)(2 needed) *Plane or resaw to the thickness listed in the Materials List.
62
B* leaves
34"
9"
412"
3034" 60"
Matl. Qty.
EO
54"
EO
end skirts
34"
22"
side skirts
34"
412"
44"
stretchers
34"
3"
2434"
58"
2"
114"
Sources
34"
A* top
F* top fasteners
FINISHED SIZE
December/January 2007/2008
Wood Joint
2
t
s
e
T
e
r
u
t
r
To
Doors & Drawers
Need a frame joint that doesnt break when kids mistake your cabinet door for
playground equipment? Or a drawer joint that can survive tugs and slams
without coming apart? We tested 72 samples to discover the best of both.
64
64
pull-apart test
shear test
Force
Force
WOOD magazine
December/January 2007/2008
door joints
#1 Half-lap
Stile
Wood failed before
the rest of the glue
joint failed.
#2 Mortise-andG T
haunched-tenon
H U
FINDING: On
V each pull-apart test,
I stile split along its length
the mortised
W cracked at the tenon
before theJjoint
shoulders. LESSON:
The tenons faceX
K
grain-to-face-grain
glue bond adds
A NY
strength,butlessthanahalf-lap.
L
B OZ
FINDING:Inpull-aparttests,thestile
M
of each sample
split at the base of the
C P
mortise.LESSON:Longertenonsreduce
Q
(seebelow),butnotbeforesplittingthe
stilealongitslength.LESSON:Usethis
joint where durability matters. The
tenonsgluestrengthmorethanoffsets
thisweakspotinthejoint.
FINDING: One weak spot occurs
wheretheendofthetenondoesnt
touch the bottom of the mortise.
LESSON: Gaps meant to collect
excessglueweakenthejoint.Aim
forwood-to-woodcontact,and
dontoverapplyglue.
Stile
V
W
Tenon X
K
shoulder
Y
L
Z
M
Rail
Wood splits at the
bottom of the mortise.
woodmagazine.com
Stile
Wood remains
attached to the
glue joint.
Dado blade
score marks
Rail
D Q
Glue joint failed here
E R
smoothforastrongergluebond.
FINDING:Despitebeingabasic,
easy-to-makejoint,half-laps
outlastedthemoreelaborate
alternatives such as copeand-stickjoints.
LESSON: More work wont
resultinmorestrength.
The haunch
grips the
The tenon didnt
groove
pry loose this
edges.
FILENAME: 181Joint4_#100505346.eps
area.
Date: 9-07
Rail Lorna J.
STILE
RAIL
#3 Stub-tenonand-groove
FINDING: Like the mortise-andhaunched-tenon joints, the stile split at
the bottom of the groove during the
pull-apart tests. In all tests, the 38"-long
tenons held onto
the
surrounding
wood.
LESSON: Because
these tenons dont
extend deeper than
the groove, be sure
to strengthen the
joint by thoroughly gluing the tenon
shoulders and ends.
#4 Cope-and-stick
Rail
Stile
The joint
holds along
its length.
Groove edges
bond to the
tenon.
Wood splits at
the tenon end.
Stile fibers
bond to the
tenon end.
Rail
Wood splits at
the tenon end.
Routed profile
Conclusions
Stile
Wood splits at
the base of the
rail-end tenon.
Rail
Its no coincidence that the two strongest joints are the ones with the most
_#100505346.eps
face-grain-to-face-grain glue surface
area. Choose half-laps for frames holding thick glass or mirrors, especially if
the frames width exceeds its height.
Mortise-and-haunched-tenonsFilename:
handle 181
the same jobs, and have grooves
already
R LeMoine
cut into the stiles and rails as 9-11
you make
the joint, not added after you cut the
joint. Use these on doors youll open
frequently or that will face abuse on a
daily basis.
But dont give up on stub-tenon-andgroove or cope-and-stick joints. Multiply
their strength by four on an actual cabinet doorthen add the reinforcement
provided by the doors paneland these
two joints will survive all but the worst
abuse. To increase the strength of any
joint, use straight-grain stock, and make
certain the gluing surfaces are smooth.
WOOD magazine
December/January 2007/2008
dRAWER joints
#1 Box joint
#2 Lock miter
#3 Lock rabbet
One glue
joint held
enough to
crack this
finger.
Glue joints
pull away
wood fibers
from the
fingers.
Insert a brad
here for
reinforcement.
Glue joint
strength
outlasts
the fingers.
apart strength. LESSON: Consider reinforcing this joint with #181" brads in
the edges of the end fingers.
End grain
weakens
glue bonds.
0505345.eps
67
#4 Through-dovetail
#5 Sliding dovetail
Dovetail piece
(drawer side)
The joint shape holds pieces
together mechanically.
Pin piece
(drawer
front/back)
Dovetail piece
(drawer side)
Pin piece
(drawer
front/back)
Pins pull
tightly
against
dovetails.
Joints separated
at the glue lines.
Dovetails broke
at the corners
between the pins.
FINDING:Allsamplesinbothseries
oftestsfailedwhenthe1 8"-longstripof
woodbetweenthedovetailgrooveand
the end of that board broke off.
LESSON:Considerthisjointfordrawers
SLIDING DOVETAIL
wherethedovetailpiececanbemounted
fartherfromtheendoftheslotpiece.
FINDING:Inboththepull-apartand
theshear-strength
tests, this joint
was weaker than
the similar lockDOVETAIL
rabbet jointSLIDING
that
can be cut with
just a tablesaw.
LESSON:Consider
Theres less
than "
between the
dovetail slot
and this end.
drawerbottom,andyoumayfindyoure
betteroffwithlock-rabbetjoints.
9-11
WOOD magazine
December/January 2007/2008
End grain
lessens
the gluing
strength.
This strip
measures
just ".
This strip is
too narrow
to withstand
being pried
free.
apartteststhatwerestoppedaftercrackingatpeakstrength,thejointstillheld
together.LESSON:Carefullyreglueend
woodmagazine.com
grainofthedadoedpieceatthefirstsign
of cracks, and you may still be able to
salvagethejoint.
Dovetail
piece
Pin piece
5
leasthalfthewidthofthefulldovetails.
FINDING: Joint parts remained connectedwellafterthegluejointcracked.
LESSON:Mechanicalstrengthexplains
why woodworkers have made dovetail
jointsforcenturies.
500
0
Lock miter
1,000
Lock rabbet
1,500
Through-dovetail
2,000
Box joint
End grain
splits easily.
CONCLuSIONS
mitersifyouwantajointyoucancuton
a tablesaw. Half-blind dovetails lacked
the strength of the other joints, but
theyreattractive,leaveasmoothdrawer
front, and like the through-dovetails,
Rabbet (nailed)
#8 Half-blind dovetail
Sliding dovetail
FINDING:The5 32"-longstripbetween
the end of the dadoed piece and the
dadoweakensthisjoint.LESSON:Useit
fordrawerswherethedadocanbeplaced
awayfromtheendofthesidepiece.
FINDING:Tenonswerejust5 32"thick,
but none tore
apartineither
set of tests.
LESSON:Glue
bondsprovide
evenaskinny
tenon great
strength.
F I N DI NG :
On two pull-
POUNDS OF FORCE
_#100.eps
#7 Shouldered dado
Shouldered
dado
Half-blind
dovetail
69
Set-the-Mood
Wall Sconces
proJect highlights
Overall dimensions: 412" wide 5"
deep 16" high (tall sconce), 12" high
(medium sconce), and 8" high
(short sconce).
Materials needed: A 3451260" cherry
board, a 18 1212" piece of birch
plywood, and three pieces of
.025410" copper sheet.
Form the copper trays with ease by
cutting and gluing in place separate
bottom and side pieces rather than
bending a pattern-cut piece to shape.
Skill Builder
1
2
WOOD magazine
December/January 2007/2008
Back assembly
H
A , B , C
Blade start
hole
112"
final
groove width
3"
B
scrollsaw the back openingS
C
SCREW-mount THE trays
1 exploded view
Wall anchor
Countersunk shank hole
O
B 1"
#8 x 1" F.H. P
C
wood screw
D
1" groove
" deep, centered
L
A
1" "
"
T
9"
H U E
1" "
1"
1"
4"
4"
"
45 bevel
"
Mitered ends
H
I
"
5" G
3"-diam.
maximum
pillar candle
8"
15 32
Y
#8 x " F.H.
L wood screw
Z
Shank hole,Mcountersunk
on back face
1"
N
4"
1"
1"
12"
7" F
16"
1"
1"
"
1"
1"
1"
1" groove
" deep, centered
.025 x 1 xD5" Q
copper
E R
F
45 bevels
D
"
4"
H
4"
71
woodmagazine.com
SHOP TIPS
5 tips to ensure
your copperwork shines
Tip 1 You can cut copper sheet with tin
snips or shears, but youll wind up with
curled edges that rarely look smooth after
flattening, and youll find it a challenge to
make identical-size parts. Instead, use your
bandsaw, fence, and a piece of 14"
hardboard for a zero-clearance backer to
get perfect results. After cutting a kerf into
the backer, adhere it to the bandsaw table
using double-faced tape, as shown below.
The backer prevents the copper from
curling, and it raises the copper so it cant
slip under the fence.
Tip 2 For a smooth cut, use a blade with
at least 14 teeth per inch, and feed the
copper slowly.
Tip 3 Use the eraser end of a pencil to
safely guide the copper through the cut,
as shown.
N Tip 4 Remove the burrs and sharp edges
from the copper pieces using a mill
O bastard file or a piece of wood wrapped
with 150-grit sandpaper.
P
Tip 5 To get a uniform, bright sheen, rub
Q the faces of the copper with 400-grit
sandpaper, moving in one direction for the
R best appearance.
S
Finish up
1
2
K
Instant-grab adhesive
D
install the copper tray siDes
Apply an approximately 14"-wide bead of
adhesive along an edge of the tray side liners
(K), and press them into place in the trays.
Written by Owen Duvall with Chuck Hedlund
Project design: Kevin Boyle
Illustrations: Roxanne LeMoine; Lorna Johnson
*B
*A
Materials List
B
C
medium back
short back H
FinisheD siZe
matl. Qty.
12"
C
41*2"G 16"
*D
12" 412"
*F
C
12"
1H
2" 412"
8" * EC
14"
Cutting Diagram
118"
*D
6
D* mounting cleats
x 5 x 60" Cherry (2.5 bd. ft.) *Plane or resaw to the thicknesses listed in the Materials List.
1
1
7
C
1
E* tall-back filler
4" 1 2" 9 8"
112"
14" 112"
C
1
F* medium-back
758"
filler
J
* JD K
V
* D 14" 112" 538" C 1
G*
* F short-back filler
I
.025 x 4 x 10" Copper
*B
*A
34"
12"
*
C 12
H*
tray
sides
412"
*
H
H
C
W
EK
1
BP
3
I tray bottoms
4"
N 8" 4"
M
X
x 5 x 60" Cherry (2.5 bd. ft.) *Plane
or Iresaw to the thicknessesJlisted
List.
I
K inKtheKMaterialstray
L
bottom
J
.025" 312" 312" CS 3
Y
x 12 x 12" Birch plywood
.025 x 4 x 10" Copper
.025 x 4 x 10" Copper liners
Double-faced
K tray side liners
.025" 34" 31532" CS 12
Z
tape
J
J K
CS 1
L tall-back insert .025" 112" 5"
I
.025
x
4
x
10"
Copper
Backer
M medium-back
.025" 112" 314" CS 1
K
insert
N
M
I
N short-back insert .025" 112" 112" CS 1
J K K K
I
L
*Parts initially cut oversize. See the instructions.
x 12 x 12" Birch plywood
.025 x 4 x 10" Copper
.025 x 4 x 10" Copper
Materials key: Ccherry, BPbirch plywood,
H
H
H
H
CScopper sheet.
*G
*D
Supplies: #834" and #8112" flathead wood screws,
*D
*F
double-faced
tape, .025410" copper sheets (3), instant*B
*A
*C
*E
H
H
grab adhesive, wall anchors (3), 312"-diameter maximum
pillar candles (3).
Cutting
Diagramlisted in the Materials List.
x 5 x 60" Cherry (2.5 bd. ft.) *Plane or resaw
to the thicknesses
Bit: 34" straight router bit.
72
WOOD magazine
J
I
*G
J K
FILENAME:181SconceCD_#100505208.eps
December/January 2007/2008
Box-Joint Jig
Waiting until the price is right to acquire a box-joint jig? By using shop scraps, we got the cost down to
zero, and came up with a method that makes adjacent box sides interchangeable for foolproof assembly.
interchAngeABLe
Box Joint
Ends of workpiece
complement each other.
December/January 2007/2008
7"
Pencil-marked
edge
D
(Dont pull the extension backward
through the blade and dont move the
rip fence after the cut.)
To make the indexing pin, start by
planing a 12" length of hardwood scrap
(we used maple) until you have a perfectly square section that fits snugly into
the notch in the extension [ Photo B ]. As
you approach the 14" thickness on the
pin, lower the cutterhead in tiny increments to sneak up on a snug fit and
rotate the stock 90 for a second pass at
each height setting to keep it square.
When youre satisfied with the fit,
crosscut the strip in half. Place the two
strips side by side against the fence
[ Photo C]. Holding the extension against
the strips, cut a second notch. Again, cut
only on the forward stroke.
Turn the extension upside down and
insert one of the hardwood strips into
the second notch, leaving about 1" projecting from the front, [ Photo D ]. Drive a
nail to hold this indexing pin in place.
(To avoid splitting, drill a pilot hole
first.) Set the second hardwood strip
aside: Youll need it later.
Finally, apply double-faced tape to the
back of the extension. With the end of
the extension against the rip fence, slide
woodmagazine.com
E
the miter gauge squarely into position
against the back of the extension, adhering it with the tape. Use screws to secure
the extension to the miter gauge. After
double-checking the set-up, you can
remove the rip fence.
F
dead-on, you simply trim away the
excess after cutting the joint. If they
dont, each joint still sports a full set of
identical pins and sockets.
Step 3 With the jointed edge against the
miter gauge, cut the box pieces to length.
An extension with a stopblock ensures
identical lengths.
While youre preparing your project
stock, its a good idea to give identical
treatment to some extra scraps that you
can use for test cuts.
Pencil-marked
edge
Spare pin
Indexing pin
Pencil-marked
edge
G
cut socket onto the indexing pin until
the joint is complete.
Consistency counts when you make
the multiple passes required to make a
box joint. For the best results, try to keep
your body mechanics identical on each
stroke. For example, your miter-gauge
bar has a small amount of clearance to
permit it to slide. To prevent that slight
allowance from introducing a problem,
exert the same amount of sideways pressure on the gauge as you make each cut.
SHOP TIP
How a mirror
saves your neck
Practice using the jig and refine your box-joint making technique by building this handsome
trio of boxes from the step-by-step plans starting on page 78.
WOOD magazine
December/January 2007/2008
Tempting Trio
Box Ensemble
These catchall containers,
with beautiful finger joints,
are deceptively simple
to make.
PRoJECT HIGHLIGHTS
Overall dimensions: 714" wide
1958" long 558" high.
The staggered arrangement of the
boxes shows off the corner joinery.
Make it with odds and ends you
already have in your shop.
Skill Builders
3
4
A
Clamp each box together without glue, and
use a 14" box-slot bit to rout a slot around the
inside for the bottom (B).
WOOD magazine
December/January 2007/2008
28mm knob
1 EXPLODED VIEW
" cove
" hole
" rabbet
" deep
C
" grooves " deep
" from the bottom
routed after assembly
5"
5"
Cut screw to " long.
"
" hole
23mm
ring pull
A
J
K
L
M
A
A
5"
A
B
Cut screw
to " long.
2"
4"
4"
4"
A
R="
"
"
1"
V
W
2"
"
Y
"
D
"
"
E
"
Location of D
"
E
5"
1"
Mitered ends
5"
SHOP TIP
How to form perfect
corner radii
Using a box-slot bit to form grooves in
the box sides for the bottom saves you
1 EXPLODED
VIEW
the trouble
of filling in gaps at the
corners, made by cutting the grooves
FILENAME:181BoxSet1_#100505267.eps
on the tablesaw or router table with a
Date: 8-07
straight bit. The trade-off is that you
Lorna J.
must round the corners of the bottom
to match the radius of the slot bit.
Heres a simple way to quickly form
perfect corner radii:
A
Chuck a round-over bit that matches
the radius of the slot cutter into your
table-mounted router (516" for this bit).
Position the fence flush with the bit
pilot bearing and parallel to the mitergauge slot. Then attach an extension to
B
the miter gauge with the end just
To protect the glue surfaces of the box sides
grazing the face of the fence. Now,
B
Filename:
181 3Box set 1
R LeMoine
7-31-07
" round-over
bit
Miter-gauge
extension
79
B
Cauls
A
A
Glue brush
C
Protect the inside faces of the sides (A) with
A Nglue onto the
masking tape. Then brush
fingers, and assemble the box.
B O
5
6
"
Notch for glue
squeeze-out
"
1
2
Materials List
Part
A* box sides
FINISHED SIZE
14"
4"
5"
Matl. Qty.
M
12
bottoms
14"
434"
434"
BP
lids
12"
5"
5"
14"
1"
5916"
12
14"
12"
5116"
12
D* base sides
E
cleats
Source
Filename:
R LeMoin
7-31-07
B
B
2 squaring jigs
FILENAME:181BoxSet2_#100505268.eps
Date: 8-07
Find more
Lornagift
J. project plans at
woodmagazine.com/gifts.
Cutting Diagram
*A
*D
*D
*D
*A
*A
*A
*D
*A
D* *E
*A
*A
*E
*A
*E
*A
*E
*A
*E
*A
*C
*C
*C
x 7 x 96" Mahogany (5.3 bd. ft.) *Plane or resaw to the thicknesses listed in the Materials List.
80
WOOD magazine
December/January 2007/2008
Just-Right Joinery
Install corner
connectors for
sturdy tables
These easy-to-install brackets
speed up making and moving
your tables.
Table leg
top end
84
Apron parts
centered on the leg
Connector
flanges
cut deep enough to accept the connector flanges. Then cut kerfs at both ends
of all four apron pieces [Photo E] .
continued on page 86
WOOD magazine December/January 2007/2008
Just-Right Joinery
cut kerfs for flanges
Miter-gauge
extension
Drill this
distance
from the
top of
the leg.
V-groove jig
Sources
Jam
nuts
Selfcentering
drill bit
I
86
K
WOOD magazine December/January 2007/2008
Ask WOOD
Q:
A:
Two-way slides
Q:
A:
Wooden
strips
continued on page 90
88
Ask WOOD
Resuscitate purplehearts color
Q:
A:
Viva viraro
Q:
A:
Mahogany
continued on page 92
90
Ask WOOD
Q:
A:
HAVE A QUESTION?
For an answer to your woodworking
question, write to ASK WOOD, 1716
Locust St., LS-221, Des Moines, IA
50309-3023 or e-mail us at askwood@
woodmagazine.com. For immediate
feedback from your fellow woodworkers,
post your questions on one of our
woodworking forums at
woodmagazine.com/forums.
92
woodmagazine.com
95
A sneak peek inside the March issue (on sale January 15)
featureD project
Bunching tables
Country hutch
tool TEST
Dust collectors
Man Vs.
Machine
Dovetail showdown
Better Homes and Gardens WOOD magazine (ISSN-0743-894X) is published seven times a year in March, May, July, September, October, November, and December/January by Meredith Corporation, 1716 Locust St., Des Moines, IA 50309-3023. Periodicals postage paid at Des Moines, Iowa, and additional mailing offices. Better
Homes and Gardens trademark registered in Canada and Australia. Marca Registrada en Mxico. One-year subscription prices: U.S. and its possessions, $28; Canada, $41; other countries, $49. Canada Post Publications Mail Sales Product Agreement No. 40069223. Canadian BN 12348 2887 RT. Return undeliverable Canadian
addresses to: Better Homes and Gardens WOOD magazine, 2835 Kew Drive, Windsor, ON, N8T 3B7. POSTMASTER: Send address changes to Better Homes and Gardens WOOD magazine, P.O. Box 37439, Boone, IA 50037-0439.
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