Documente Academic
Documente Profesional
Documente Cultură
com
Vol.26/ No.153
lllllli
PleasedisplayuntrlAug.2
lookinqinside
Tableo
departments
fromourreaders
smallshopsolutions
Tips& Techniques.
..............4
Extra
WorkSurfaces
. . . , . . . . . . . . 42
toolsof thetrade
O n e - H aBnadC
r | a m p s . . . . . . . . .8
...
These
c amps
aresoeasy
to usqyou'llwonder
howyouevermanaged
without
them.
all about
Perfect
Plane
Performance..
.. .. .. 10
5 shop-tested
tune-up
techniques
formakirg
thishandy
toolworkeven
better.
techniques
fromourshop
AnInvisible
Plywood
Edge.
.. . . .. . 12
A plywood
edqe
thatwon'tbenoticed?
We'
youhoweasy
show
it istodo.
tipsfromourshop
ShopNotebook.
.. .. . .25
Can'tfinda space
to doanassembly
oreven
set
downa tool?Take
a lookatsome
easy-to-b!ild
problem.
solutions
to thiscommon
workingwith tools
T h r e e E a s i c R o u. t. e. .r.B
. .i.t.s. 4 4
Youprobably
already
have
thebltsyo!need
to
profi
rnake
a hostofdecorative
es.
finlshing
room
Solving
Finishing
Problems
.. .. . .45
shellac
canhelpyouavoid
common
finishing
problems
andgiveyoubefter
resuJts.
in the mailbox
Q&A...
............48
hardware
andsupplies
Sources..
,.,.........49
Knock-DownBookshelf
features
editor'snote
weeKenoprojecl
P d n e l e d W i n d o.w
. .S
. .e. .a. t. . . 1 4
Sawdust
plywood
luststartwith
a simple
boxandgoflom
there.You
won'tbelieve
theendresult.
Dtl|cr|l
ltotroor
Knock-Do
Bw
oo
n k h e.l.f. . . . . . . . 2 0
great,
It'sfunctional
andlooks
butthebestpart
withnotrouble.
isitgoes
together
ffinmt
. .
projeci
nerfloom
P e n cPi ol sBt e d
........28
Thi5
classic
bedfeatures
sirnplejoinery,
hand
hardwafe.
catued
detailtandtraditional
Dtltottl|
Lolroor
D||tm!||otllool
Choosing
theBestJoinery
f\"
Fl
38
Learn
theinsandoutsofhowto selecting
the
rightjoinery
foryour
nextproject.
.la1:il< ^{.r>{i<m)n<hi^
A Lamb's
Tongue
Chamfer
.. .. .. .50
A chisel,
carvinq
knife,
andfileareallit takes
to
create
thisgrcat-looking
traditional
detail.
opporhmity to try our hand at somediffrent woodwoiking tchniques.Espcialy when it cameto making the tal, tapeied po6ts.
The initial plrn was to taper them on the band saw,then plane
the edgesto createan octagonalslupe. This method works Fst
fine. But, SteveJohnson(our shop aaftsman) cameup with a jig
which allows you to do most of tlte shapingon the table saw.
But the po6tsareiust part of th pmjct You stil nedto connect
them with a headboard and rails. Like the Shakers,we used a
draw bolt systemto hold th rails to the posts.And th headboard
just slips into mortisBbtwentt tal posts.Nothing is glued in
place.This meansthe bed can be completely taken apart which
maks getting the ta[, tapered posts throuSh a dooMay much
easier.Made snsether! stil makessensetoday
-rrr,\
ffiffi
online
at
These
twosymbols
letyouknowthere's
moreinformation
you'llseestep-by-step
www.Woodsmith.com.
There
videos,
tehnique
and
anda Iotmore.
hardware
animation,
bonus
cutting
diagrams,
PencilPostBed page28
No. 153
fromour readers
Tips& Techniques
BondSowArcJig
I likedthe tile toptable in issuers2
so much that ldecidedto makea
few ofthem as giftsforfrisndsand
family.And whenbuildingmultiple,
identicalpieces,it's importantto
findwaysto makecutting
andshatr
ing p6rts as quickand effident as
possible.One placethat I needed
to find a way to save
some rme was culting andshapingthe
arcs on the lower
rails of the table
shown in the photo
at left. Cutting each
arc free hand on the
band saw and then
sanding it smooth
would be a difficult,
time'consumingjob.
To speed things
along,lbuilt a simple arc-cuning jig
for my band saw, as
shown in the photo
SUBilITYOUR
TIPS
lf you have an original shop tip, we would like
to hear fiom you and considerpublishingyour
tip in one or more of our publications.
Just
write down your tip and mall il tot Woodsmith,
Tips and Techniques.2200 Grand Avenue, Des
Moines,lowa 50312.Pleaseincludeyour n6me,
address,and daytimephone number in case
we have any qustions.lf you would like, FAX
it to us at 515'282-6741or send Lrsan email
messageat woodsmith@woodsmith.com.
We
will pay up to $200 if we publjsh your tip.
4
|r
woodsmidr
No.153
DdllPrereStorugeftrr
In a smallworkshop,makingthe most of
everysquareinch of spaceis important.
Oneareathat hasalwaysgoneunused,is
the spacearoundmy floor modeldrill
press.Then I found the solutjon in my
kitchen-a rollingpantrycart,as shown
in the drawingat right.
What makesthe cart so perfectis that
it's not much wider than the drill press,
and it rolls out otthe way if Ineed more
space.The shelveshold boxes of bits,
clamps, and other accessorieswithin
e6syreach.And the wire shelveslet dust
6ndchipsfall rightthroughto the floor.
EmbStziw
200
June/Juln
No. 153
Publishe.
Donald B.Peschk
Todd Lambirth
David Kreyling
Dirk Ver Steeg
HarlanV Clark
Illustrators
Dave Ka emln
Goodr@, 1fi\@
SpinYourFilterCleon
Minmoia
CREATI\,'ERESOURCES
R'dW'fuEd.9q.'fu*
.i"
yPj b4]rs
SPECIAL PUBLICATIONS
. n'
L H&
Dk,']
o4gh.
^ Eh'.
s&6',H
qlrctwbstu.
CIRCULATION
idFl
cGtu
hsd
h,
siLh r rrur
4i PrF rs
. .JE .!4rMi
{y
5k
COR?OR-IIIE SERVICES
r]lt)lD.h.}kk}J$d'.b,d
,'6cfude.rhB(fuDiifu4EM'Be.sJrd
'ss'!'.'nR*!o
.Ebqb.Na'M!119.'rfu.c
&is
. M eiFa
b6 Br6ds . *,
tu
(cb..farrr,
kh
NrdEl-l,dtu
/#,k'&{ld]er,fu.NRp@4hRb'M|
Edgebonding
lupporl
No.153
lvoodsmit1l
Tetu
st|cPdq'Qtd@lvd!bnl#4P
Ehail woodsmith@woodshirh.com
Write to Woodsritl, PO. Box 842, D6 Moines, tA
5030!L9961oi call 1-80G333-5075,8:00 m ro 5:00
pm, Cotral Tme, w@kdays. Or sd m emil to:
ordeB@woodsmirh.@
I
AucusrHolc
\ PrBri3Hinii conF;ni
Prinidin u.s.A.
a
moretipsfromourreaders
ShopllodeBarh Doga
Benchdogs come in handyfor all
kindsoJjobsattheworkbench,like
for routclampingalongworkpiece
ing or planing.
Butwhattheycant
do is hold somethingdown on the
top ofthe bench,for example,the
planingstopshownin the photoat
right.Forthjsjob,lturnto a diffeF
ent "breed"of benchdogs.
These dogs can be locked in
placewitha sjmpletwistofa wing
knob. The secret is a stove bolt
loted in the stem,as you can
seein the drawingat rightThe taperedhead of the stove
bolt rests in a countersunkhole
drilledthroughthe lengthofa 3L"dia. hardwooddowel. Twistinga
plasticwing knobatthetop ofthe
dog draws the head of the bolt
into the stem.A slit in the dowel
allowsit to expandand hold fast
in the dog hole, as illustratedin
detait ,a., A 3/4"ptywood cap is
glued around the dowel and
anchorsthe jig or workpiece.
MeruaVanftle
Behe,OhD
Rouferftble llold.Down
While working on my router table
recently, I noticed that the workpiece
had atendencyto ride uponthe bit.
The way to solve this problem is to
use a hold-down, asyoucan see in
cRosssEcnoN
2U,
-l_
c
No.153
BondSowDustColle(tor
Resawing
andcuttingthickstockontheband
saw createsa lot of dust that seemsto get
everywhereandcanbedifficulttocle6nout.
Althoughmy saw hasa buih-indust collection pon, l've nevrbnrealhappywith it.
Itiustdoesn'tseem
to be big enoughto catch
muchofthe saw dust.
To overcomethis problem,I built a new
dust collectorattachmentfor my saw,6s
shownin the drawingatrightand below.lt!
just a small box madefrom %' hardboard,
with an openingatthe top and bottom.Th
upper openingfits under the lower blade
go;des.The loweropeningis sizedto fitthe
hosefrom my dust collctor.
When makingthe collectorattachment,
you want to makesur the joints are well
sealedto makeitasairtightas possible.The
top of the collectoris angledat 45" so that
the sawtablecanstill be tihedwithout hav
ing to remove the collector attachment
{detail'a').I sizedthecollectortofit overthe
dust port on the band saw. To attachthe
QuiokTipe
SEIT.ADIII'IYE
IEfl PI.AIIS
l'vehadtrouble
inthepastkeepi
papertemplates
in placeon a work
piece-Tosolvethis problem,I now
copy the templateson clearlabe
stockavailableat officesupply
storcs.Thaiwaylcan peelandstick
the templaterightwhereI needit.
lin Hedd
Gr@e,Okhn ro
sl t PnooHltc
ctaflPs
dust collectorto the saw,I boltedit to back
of the band saw case (not the door) with
somealuminumL brackets,bolts,washers,
and nuts.Thisway lcan still openthe door
to accessthe bladeand lowerwheel.
CLrt Urnsla
SieleruPonr, U/6.min
Pltoto EfioRYflD
Remembering
howto setup a iig or
tool
for
a particularopera
Power
tion cansometimestake
a littletria
a n de r r o r B u t l f o u n dt h a tI c a n
jump startmy memorybytakinga
photoofthe setupwith a digitalor
,nstant
camera.
lcanthentapeth
phototothejig or keepit in a filefor
Tm Coo
Fdirore, Pmtullmid
WnrTI{ls
BruocB
Crrv
Br.ocr<PreuB
lhe Winner!
Congratulations to CarlWood
of Burleson.Texas.His tip on
making6 bandsawarc-cutting
jig wasselectedto
bethewinnerofa BridgeCityBlockPlane
just likethe one shownat left.
Carl designedthe jig to
build sevoraltile-toptables
and found that it had many
other uses6swsll. To find out
how you couldwin one,see
the box on page4.
toolsof thetrade
lwo-way Levez Theslidingkw advancingleveron the
quickand
?:::';;-;:"H:::v;:iilbardam
eaSV
BarClamps
One-Hhnd
BEssEy
P,OlilrERGRlP
ai.ilE:";ltjf";k
l&-1.
toRGEISEil
-.:..
Woodsmith
No.153
- outfl(REtPot{tE
EDtUn
DUIY
Not everyjob requnesa healy-duty clamp. For el<ample, when you're clmping a jig to the workbench or
holding smal partstogether.That'swhereihe medimduB' .lamps aF hmdy. The jaws on these.lamps are
made tuom glass-fiberreinforced composite.But that
doesn'tmeaniheseclmps areweaklings.They'recapable of exertingr.rpio 300lbs. of forceIn the photo ai right ald in the box below you can
seethe threet1?esof medim-duty clamps available.
The most common are the pistol-grip style Irwin
QrirckGr,p (seebox below) and cmfs,,na (middle at
right). The other two clanps are ihe JorSensen
E-Z
Hold lI and the BesseyKl,fth,?,p.lnstead of a pistol
grip, the E Z HoldII usesm inline gdp aid lever (top,
,ORGE SEfl
E.Z HO!-D ll
CRAFTS|uAIC
Fixedjawr car bellippd
areund to act ar tpreadmak$ clamplightweight
WorthALoolcCla
withVersatili
their smaler size and light weight can flip the jaws aiormd to use
males medium-duty clamps such them asspreadeis(photo below).
asthe kwin QrLlr-Grp Fetty handy
Also, you can remove drc stanto have in your shop.
dard, soft rubber pads that com
One of the best featuresof most with the Irwin Qlt.k-Grp clamp
medium-duty clamps is that you and replacethein with deep reahing padr as shown in the photo at
right. Thesepads can apply pressur from the tip of the jaw an the
way down to th bar.
llTtn (LA[PlllG.Another accessory is a miter clamping set. A
lar8e,V-shapedfaceattachesto the
fixed jaw to hold th outside of a
miter joint. A matching rubber
block fits over the sliding jaw. As
the clamp is brought together it
Sqeader lhe jaws on medium- forcesthe joint iogether A rclief in
duty bar clamps can be easily the V-faceprotects ihe comer and
rcveRedto useasa spreader
alows foi glue squeeze-out.
No.153
lvoodsmith
BE55EY
KLIKI.A|I|P
5steps
forperfec[
PlanePerformance
I still remember my tust aitempt at
using a hand plane. It was a Pal lsson in frustration. No maiter how
much I fiddled sith ihe plane, I
CherkOutYourSole
nealonqthe bottom
\#{,,
. As you ap the '<n o
rhe npn
np(
wrLwearaway.Once
theyreqon,
thesoe isfat
10
ti
No.153
ReplorcBhde ondCoplron
One of the easistand simplest upgrades you can make to
you plane is to replace the blade
that came with th ptane. Most
stock blades ar fairly thin.
lnstead of slicing through the
wood, they may tend to flex and
dlatter giving you a poor{uality
cut- But ihere are a handtul of
manufacturers who make highquality rplacement blades for
bench planes. Typically, these
blades are thicker and made out
Q lr"poringtheBtode
No.153
Lie-Nielsen
Toolwork5
(Blades)
800-321-2520
ldiurr lrog
HockToolr
(8adesand
capirons)
848-282-5233
v
frco fowrd d ba.k
with tdg adj5tins new
7
r-n"*or.rop *'or. ui'glouprane ,' .oaojusr
the blade. And there are two adjustmentsto be concemedwitn. To adjust the depth of fte blade,tum the
adiusthg knob unril * bladejust barcly startsto Proi
ectfmm Orcmouth opning.Thenusethe lateraladiustment lever to position thebladeso&at the cutting edge
is paralel with thefront openingof themou& (seedetail
'a'). AJter initally adjusting the blade,give the
Planea
the
blade
sef
go on a pieceof ssap wood and fine-hme
tings until you get wispy-thin shavings.N
11
techni uesfromoursho
getaninvisible
PlywoodEdge
Youwantto hideLheedgesof
yourplywoodpanels.
butyou
don'twantthe edgingto show.lt's
not ashardasit sounds.
A thickeredging
a rnn eoge.
.4,
: ",i:''
I usehardwoodp\1!'ood in my proi
ectsaI tlLetime. It makestlrc iob go
easierand tlrc quality of Orcproject
better.But threis onedrawba& to
pl'aa/ood- drc exposededges.To
put it simply, the edgesof pry"wood
can be downright ugly.
./::;:Al
i
1
{l
l A thick edginqpiece
car-"fuy joinedto the
prylvooo nor onry
hidsthe "core,"but
apaneled
'WindowSeat
Somebasicmaterials
andsimplejoineryadd
prolect,
up to a great-looking
r Thlsbeadboardpaneled
noragecheststartswth
rh" ." na'fr" nao pl,alooo
oo Jr.-dnqeoa
fewofthe detas fora lssformallook
14
No.153
-13
il'p,ryll,
The drai{ing at right shows ho*' to
gei started on the window seai bv putting together a sturdy plyi{ood bot. To ke.? weight down,I
deciddto use Yr" p\a'ood.
T[t JolillnY.The box needs io be
solidly builibutalso easyio assemble, so I used some basic joinery
ihai se^,esboih puryoses. As you
'a,'
can seein detail
ihe ends of the
box sides are rabbeted to hold ihc
box ends. This gives vou pleniy of
glue surfaceand alo$,s you io easill, Une up the comers of ihe box
during th assembly.
The bottom is firnrly captured in
grooles cut into th inside faces of
all four panels (detail'b'). So it $'ill
stay put under the heaviest loads.
And woodscrelr's take the place of
clamps during the glue up.
IHt RA8[[T5.Once the ti\,o ,oi stdcs
rA) and the two bor crds (B) are cui
io size, the next siep is to cut the
rabbets in the box sides. For this job
I nrstalleda dado blad on the iable
"buried"
saw and
it in an auiliarv
fence as sholr'n in the box below
The widih of these rabbts
should match the thickness of fte
pllvood you're using. (The plys'ood is often a bit undrsized.)
And just as important is a consis-
How-To:
Cutti Rabbets
and
Grooves ShopTip
.,
a
'
cut to
thi<knettof
ptywoad
:novrcw
o
with toD edae
ot b6t--
@
I
rOP
ENDRAiL
'
fruming
the
Box
1l[
theBrads
-..t-z
T h e o n l y d r a w b a c k t ou s i n sb r a d sl s
t h a t y o u h a v e t oh i d e t h e m .B u t t h i s
i s s i m p l y am a l t e r o f" s e t l i n g "t h e m .
F i r s t ,L t r y t o a v o i d " h a m m e r
d i n g s " b y l e a v i n gt h e n a i l ss l i g h t l y
p r o u d o f t h e w o o d s u r f a c eT. h e n a
fine-poinrnail set takes over to
d r i v et h e n a i L f a re n o u s hb e l o wt h e
sudace to be comp etely hidden
w i t h w o o d p u t t y( a b o u t r / r 6) .
Il]]
r a b b t t h e s i d e s t i l e s .J u s t m a t c h
theNiclth of therabbet t(r the ihick
nessof the end siiles fof a ilush fit
lvhen vou re throughal the iabic
sar', the stiles can be asscnblcd
(glue and L'rads)inLoconcF. ?\rld
finall)', the cornefs arc glucd and
naile.l in dace on thc bo\, flush kl
t h e t o p e d S e( d e t a i l ' a ' ) .
IHt rRAMt.Completnlg ihe haming goes cluicklr First, ctrt the iop
nrcl l)ott.,r st,turdjis f/, Cl and the
nils (tt, I) ro
lo/r and r(r1i.,r tt
$'idth and rough len8ih. Then clrt
ach rail to fii snr8 h beta'een L\c
corners.Use glue and L'radsio fas'
ten them in place. Finall), vou can
cut the sri?r'd;i,i?,T(/) to fit and add
A CAP.
To complte the haming, I
applied a cap to the iop e.1gofthe
tro\. This piece lrides the Fltalood
e.lge and the joint befu'een the
Iram g.rnd the bo.-. Cut the l,or
c/rt l() to size from i/r' thick siock
and then chamier both edges
blirre iteringit io iitasdescribcd
'b'
'c').
ai right (cltirils an.l
N o .1 5 3
,q
{r ftimming
it
OUI
I
L
I
I
How-To:
MiterMoldin
toPerfection
\
,$
l ' o
odding
o
1n
ri}
How-Tor
Getthe
Rihtrit
0psidedow,
Lid nalding
an lid
atauhd bo\
i o - @'oi'3,'u
box.enteted an the lid andsome spacesin
pla.e, simplymiter the lid maldingto fit and
installit just asyau havethe othernoldings.
BUIID
l T .T h e s a m e Y : p l y w o o d
that you used for the box will do
nicely for the lid. So get started by
by cutiing the l;d pflrsl (|,, io size.
Nexi, vou'll want tohide dreedges
oi thc ply&'ood. You can make
cnough cdginS (I used leilover
framing scraps) io wrap the iid
palel md L\en applr it as you did
dre prevjous mitered pieces one
piece at a iime, gluing and nailing
as you go (details'a' an.l 'b').
LIDrlotDlilG.After fie edging is in
place and sanded ilush, the lid
molding can be added to the bottom of the ]id. The box at left shorls
the process. Working ('ith i]le box
and lid upsidedown nakes thejob
of filting the nolding a loteasier.
You !\'antthe lid to fithghtly but
shll b easy to Lifi on and off. So I
used spacersto createa Yr6 clear
anceon allsides.Thistumed out to
be a good conpromise.
Once the lid molding has been
insialled, all you need to do is fill
the brad holes and do a liitie sanding and vou're ready to paint. 0
No.153
Utoffi
a different
Look
Todownloada
materiah
lisiand
crlting diagranfor thh bad
boardpaneledchen, go to:
"caet-)al"
Tne
beadboarache6l,int"he
Arawinq
atrriqhLha6r,heoar.e ba.ia
6lruaLve ag ilg r.areformalcau6in,
Bulta fev:/.imple chanLeeqiveiL a
veryAifre.ert ap?earance.
Fir6L,I lrada^ the wrap?eaba6e
far a ein?le chamleran lhe bot"
taYr'ol Lhe e6b:' And the frame
a?enit1q' are covereAwilh beaa
board,Finally, Na?pedLhe che6t
y-flni'he^ pine liA
with a natrural
laaaelyhela in paeilion by c eata,
'fhi.
vereionioiroL ao ea6yLc ^il^
ana bok6iu.t a6 trice.
No.153
Woodsmith
19
knock-down
rO
CheryBookshelf
A classic
design
that
looksgreat.Anda
few woodworking
techniques
thatjust
you.
mightsurprise
%'i20
CoIITRUGTIOI{ DHAIL3
OVERALL
DlMEl,lSlOl'lS:4AW x U"D x 63th"H
h'x20
No.153
Woodsmith
21
fl
@l
fl,
!
t
lo
buildinq
fte
Sni
TS
lo
a
I
o
I
J
i 3rr
How-To:
&Tenon
QuickMortise
t/i souata
,p rpn.i:..J..----=----..-L
r,r
Filler Strip Blank. fa make Square Tenons. Use a dada
cansistent ltller stflps, I cut blade butied in an auxiliary fence
nat.hes inta a wide blank and ta aacuratelycut the tenons an
th. ahtt. ^l tha.^'^.1t..
then npp-ac!it into sLrips
No.153
.,\
mndc this a
'-/a"
Stron
jatnerycanbe a quickalter
Btscuit
The Layout. Layingout biscuit
nattveta traditianalmartiseand
locatiansgoes quickly.A line
tenanjoinery.strang,peffedly flush squared
acrassthe stilesand rails
jaintsanly takeminutes.
marksthe centers
af thecuts.
No.153
connectinq
fie
4a
$irs
SIDE
SIDE
43Ib
No.153
fte
1"roddino
Silrrvrs
o
I
SIDESECTIONVIEW
Chamfers
and
Cleats
i t How-Tor
o.
_
dep
SECTION
A 30" Bevel. Theshallowangle af the bevelan the under' Cleat Supports. With the shelf restingan a cauple af long
side af the top makes a vetlical table saw cut a necessity. cleats, the holes far the threaded insert can be ac.urately
With the saw blade set to 30" and a tall fence in place ta locatedin the endsofthe shelveslust clampthe top edge af
steadythe tap, thiscut isn't a prablem.
the cleatflush to the bottam edge af the ratls.
No.153
:5
tipsfromourshop
sH@p
HffiFBOOK
Cutting the tapersof tlrc pencilpost
bed legs on ihe band saw and thn
creatingd chamferswith a spokeshave and plane is a great way to
get some"hands-on"expedence.
But if you want to do the job a little
quicker,the table sawjig you sein
the photo at right is the answel
This unique jig is designed to
ride on the rip fence of the table
saw and funchons in two ways.
Fnst it actsasa taperjig - holding
the leg blanl at an angle as you
feed it through the blade. Second,
(this is the best part) it alows you
to easily duplicate this taper cut to
quickly oeate both the tapers and
chamJerson tlrc pencil post legs.
lilDtIlilS810(|{.The key to accu
raiely duplicatin8 the cuts is the
indexing block (the numbered
block in the drawing below). This
block has eiShtindexing holescorresponding to the eight cuts you'lt
mal on the leg blanl. wlen fas
tened to the bottom end of the
Buildithe
-2.i
,.,'lii
2 i"2
woodsmior
,,
-.^
Chamfers
NOTE:Cehtet suobort
\
t u s e do n f i R t . h ; n f e r . u t _ , . 4
trs
OVEF,ALL
DIMENSIONS:
55."1u.{
x AS"Dx B3h-ti
Woodsmith
rhe
Posrs
t h c t h i . k n s so r t h e m a i i r c s sa n d
bo\ .pfing dter ine ihe lo.ainD
oi thc hcadbdrrd. lntntc1 ihc
hca.ttroard to be iLrout an nlch
b!l(\ thc bF ot the nrattrcss,as
THt POSTS.
\on vou'fc
IT^A|(ING
rcadr- to get st.rr1e.l.firsl, \1u'll
nccd to nr.le bl.rls ior thc posis.
Surccthcs! parts.i so lon8, vollll
r!.ni n) iakc sonre e\trn tinre nl
selcciing stf.ight gr.ined shrck
ihai is pfcttv dry )'ou don't lvani
ihc B,si b de\ eloF nn) 1\,afpir18.
Onc. ihc Fosts \\'efe sizcd, I
dillcd a hole jn tl) top anLlt\nknn
oicach post. Tl) top holc '!illhdd
i finirl th,rt is mr.le laicr Yu u \
nccd to drillih lroiidn holc ii vou
dan on using the spe.ial i.llnc saw
tapcr jig sho$lr on tage 26.
\c\i, you'll.ut two s-.tsoi nntrtiscs. Th. first st holds thc L'.Li
rails. The.llnrensions n)r ihcse
n o r t i s e s . r e i n t h ed r a s h g a t l c f t .
The olher set of nrcrtiscs vou'll
c r t $ i l l h o l d t h c h c a d l . o a r da n c l
nre clt in onlt hlo oi the posts As
I nrntioned .arlicr ihe locatiolroi
thes moftiscs d.l.cnds on thc
ihi.knss oi ih. mattr:s .n.l bo\
sping. C!tting ihcse moriises
no$, r!hil. ihc l.osts ire siilL
stt!.r., nikcs thnrgs i krt e.sicr
Final\: I rutcd a rcun.lolcr on
'this
is
the Lroinrn oi each post
nrrc ihan n dcco(rti\e dciail. Thc
rcundolcr i!ill kep tlle c.tgcs
frcnr sFnli. lg ol,t (hen (not ii)
the Lrellis dragged n.ross thc iloor
Post
Ends
Treatthe
How-To:
!
i
2h
2h
,l
-lh
CleaniU theTa
'.
Y o uc a n. u t b o t ht h e t a p e r sa n d , : h a m f e r s
on lhe tab e saw with this s mp e I g To
b L d o n e ,t u r n t o p d g e2 6
<
2r/,
I
Suppartbl.ck ptops
up rdpeteoeno
and keepsit stable
TADEN
IEMFLAE
(Fun the)
f*
t
I
I
3l
the
tooling
hond
Cmrurns
v block holds chanfeR
Since all
ttllllc UPIHI WoRKP|t(t.
the l\'ork will trc done at thebench,
I stat.l b)' nraking a sirnple Vbbck to holct ihe posi, as you can
see in the drawing above. The
block has a couple of advantages.
Fnsi, itholds the posi steadvsnlih
I'n 'vorking. Second,it positions
ihe post with the chamler lacing
up so it s e.sier b $,ork onWith the (orkpiece secure,Ilaid
oui the chamfers on the taPercd
sides of the posts like I did before
when cutting the tapers,as shos'n
in ihe drawingat leit and detail'a.'
(UTTIlicIHI (NAlUlR.Begin shaP"
hg the chamfcrs *'ith a spoksha\,eset for a hca\,y cut. I uscd a
Lay Out Chamfet Mark the end paintsaf the chamfers spokeshavelrre bca!6eit lcis me
an the end ancJedgesaf the past. Cannectthe points remove a lot of material .ittickly, as
in the box below. As you approa.h
with a lang straightedgeto guide theshaping.
rJ
St
How-To:
Cuta
,t
Rough Out Waste,A spokeshavesetfar a Snooth With Block Plane Next,a block Finish Stopped End. Tacleanup the ends
hea\,ycut is grcat way to quickly rcmave plane set for a fine cut straightensand af the (hamfers,I useda chisel.Takelight
smaothsthe chamferup to the layoutlines. cuE aarassthegrain ta awid tearcut.
mostof the wastealang the chamfer.
32
No.153
1...-
&
o
' llrlii
'?l
'${
InstallDraw
BolR
",?\,
Drilling the Recess.Staft by drilting a 11h'- Flatten One Side.Cuta flat facei, the recess
Dri ing Rolt Hole. Usea drillbitto
dta. recessin the insideface af the bed raits. an the tenanside. Theflat pravidesa bearing
lo.ate
the hole in the rail. Dtill the
Therecessis 1I/4"deep
3/s.dia hale wnh a dawelingjig.
suiace for a washerand nut.
No.15ii
Woodsnr;th
33
fte
odding
Hrnosonno
Ancnro
l{
ft
Tenons
theScooped
area
Thetenonson the headboaro
detailloundon manyShakerstyle
bedslis a greatwayto lit thetenon
to the narrowmortseswithouthav
Ingto get a tight fit on the tapered
post Sometmes,it3 done on Y on
the backsldeof the headboardBut
IthoLqhtil ookedso goodthat I
appledit lo bothndes.
To make lt, I rout the shouLder
wth a corebox bri on tfre router
table. Beca!setrre workplece s
long,t'sa goodidea10setuPsorne
sidesupport.Thento removethe Routing the Shoulder TheftRt steptn mak'
ren of the wane, I took the head- ing the tenansis to tout the shaulderwith a
1/!'dia catebax bit an the rautet table
boardoverto the tabLesaw
34
'J
completing the Tenon. To cut a$/ay the
wastean the .heeksof the terron lused a
dada bladeon the tablesaw
No.153
,li\
\o. 153
the
odding
Frrun
foucnrs
Thcre'sjusta.ouFLeoi thnrgsleft to
do Lrciorcthc becl is compLi,t.Th
firsi is b cap off the tops of thr'Fef
cil posts ivith a hrNecl iini.l. Th
sccond is io co\cf th dnrs bolt
headsaf cl coLhtrbores.
l N l A t .A l t h o ! g h
T U R n ErD
fnrcl nrail orLler
cnn
)oL,
sour.es fof iinLrls, I
>
col,lLln't iincl ofe
that lookeclj!st filiht,
soI hrmcd \osr)
If !1rLrhavc .r l.the,
thb rs Frettr ns\.
B!t e!nit vou don't,
JII
)uL, ..,n ifill rLnl
forr orvr nnrlls or1
t h e c lr i l l p r e s su s i n g
t h e t e m p L r t es h o w n
rr, .t leltlor. glriLle
To do this, vo!'ll
necd a te$' t(]olsr n
gorge, i
urghmg
s p i n ( l l eg o i r g e . n d a
p.rrting tool. I.lso
Lluilt a simfle tool
rcst (se bo\ bel !)
How-To:
TurnitheFinialon
aDrillPress
31,
ir
tt,
.j,
ti
i:
$,
Dti Prcss Tuning Jig. 1bullt the taal restout af t/r' thick hardwoad.lt's
then clanped in pla.e an the dril presswith the -.dge af the tool rcst
pointing at the centerlineaf the warkpiece
No. 153
NOry
qIDESIGT{EKS
ooK
stor
traditi
Ti"t',
o ' , )
j._=1
, t
NOTEresiat
pafts nadenon
7' rht.trto.k
!
i:
4 AddedMaterials& Supglrgp
A TestorSde Rails(2)
B TestorEndRaits
(2)
C TestorSlats(2)
No.153
1x1t/2-84
1x11/r-64
1x1/,-64
'
.'
ir_ <
.
Tettot hahe
pdtts.anne.ted
ni11)hall lan
ano tap lot.ety
37
NOTfEBOOK
DESIGNEKS
theBestJoinery
Choosing
pro1ect
your
for
ne>ct
ClseConstru.lion
Whethei you are building a bookcas,a disser,or a cabinel rnostturniture proiects are really nothing
more than a basicbox (or maybe a
group ofboxes). But in ordrfor the
pieceof fumiture to standuP to the
l=-----)
t\VI
r l
l\t
I
Woodsmith
tI
No.153
Jorelrcme
With the basicbox completed,the
nextstepis to add a facfiame.Face
framesareoften usdro concealthe
joinery or pry-woodedgesartlle fionr
of a cabinet - or simply tjo give a
pieceof furnitur a morc rraditionat
look. And becauseof this, I thinl
there's a tenden.y to vie'/ face
framesaspurly de.orative.But th
truth is thar face frams serve an
impoitant strutural puryose as
well Justlik the backof th case,a
faceframekepsthecasesquarand
prventsit Iaom ra&ing.
Faceftames are constructed our
of stilesand rails rllat arc joined ar
right angles. But in order for rh
face fiame to be effective at preventing racking, the joints need to
be strong.For this reasorLmortise
and tenon joints are usualy mv
first choice when U"nai"e tu"u
ftames. They are mecharLicaXy
No.153
r \ i
Doors
When it comesto doors,the t}?e of
door you us wil depend largly
on th style of the project. Fof this
cabinel I chosea frame and panel
door with a plywood panel (see
drawing). The advantage of this
tt?e of door is that sincethe panel
is pl''wood and won't expand and
contract (asa solid panel would) it
can b glud into the frame. And
gluing th panel rnto the frame
makes lor a stonger, mor rigid
door Becauseof this, I was abl to
us stub tenon md Sroovejoinery
to build the door frame.
Stub tenons and grooves aren't
quite as stong as traditional mortise and tenon joints, but they are a
lot lesswork to male. Youiust cut a
groove on the inside edge of the
door mils and st es to hold the
panel. Thn cut stub tenonson the
ends of th rails to fit in the
grooves. The whote thinS can be
done on a table saw or a router
table.Orce the shib tenonsand the
panel are glued inro th grooves,
Orcdoor becomesa solid unit.
Stub tenons and grooves work
geat when the door panel can be
-ti
\
Drowerr
Drawers are always a chalerge to
"project
build. In a sense,they are a
within a pmject." Not or y do they
havto be caretullymadesothey fit
accurately,
but theyhaveto bestrong
enough to widrstand tlrc stressof
rpeatedopeninSand dosing. this
is especiallytrue for thejoints at the
Sincethis cabinetis a faidy tradihonal style, I went with a tradi-
TH^NMORflsEANDTENON5,
tut NorourEA5sllor.{6
No.153
ilr1
LOCKING
RA9AET
JONTPRO1IDE9
_ 6OOD
NENTYOF6!UE SURFACE
cltolcE FoRDaAmRgWTHOW
No.153
HALF-'LIIIDDOVETAILS
ARE
5rtoN6 ANt ATT!rcnyE G{N EEUSEOWTh OR
'-
---1r:T"l
D&\WER..lYI
'Ro|.r
f+
l, l -.
l.dd
srDE
lsw;
15 HIDDEN6Y FALgEFRONi
,z
lL RS **"
smallshopsolutions
savlng
space
Work
Surfaces
) great waysto get
the most out of
your shoP.
HANDLE9
FLIP.UP
MOVEMENT
tloke if tlove
3/aaDlA.lRON
HEA!'/-DUTY
570RAAE
LOCKTNO
CAgTER9
CART15 9UILT
U9INO LIOHTWEIOHT
1xCON9TRUCIIoN
fi
The sturdy storageworktable in
the lower drawing rests o'1 large,
locking casten This allows it to be
easily moved around the shoP and
ihen firnny locked in Placc for dte
task at hand. You might *'ant to
build ii to maich iheltightoryour
tablc sas and use it as m ouiteed
table,as shown in ihc drawrng
The bon s is that ii's designedto
do doublc-duiy as a lunter sior
age ra.k. Stort horizontai PtPes
below the worksurface createeasY
to get to, trut out of the $'a, storage
"t'\'o
sDace.Ard wi*l heav-v duty
b;" conshlction, it i\rillhandle all
that you can Ptle on
lf you ilink somcthnrg a liitle
smaller and easier b move about
would betier lit yolt needs,take a
look at the hvo-handle.t shoP ca
shorql above. Storage sPacebelo$'
and a small bui soLjd toP make uis
caii a Practical solution io Your
extra surtacenecos
The two fliP-uP hdldles and the
fixed cast.rs on the hont legs make
steering the lightweiSht cart
arolmd a crampd sl1oPa breez
No.153
Usethe CornerSpote
The comcrs oi ihe shop can be a
tough space lo get a handle on.
Oiher ihan maybe a ddl press, no
ldrg machine fits welL into a corner and often ihis space ends up
not being used very effectivelv.
Well, one way io make good usc
orihe comrs of fie shop is to add
a cornr workstation as shown in
the drawing at right. A sturdy 2x4
frame \\,itl a 3/r'plfvood top creates a large worksurface thai can
be usd for arv number of tasks.
Here you see the workstation
suPPorted by base cabineis (and
the lvals)on eidrr side. Butifdns
arran8emntdoesn't work in your
4' AUl\
HINOE9
10? CREAIE'.
WORKSURFACE
OUTOTUNUSED
5?ACE
LAROEAREAEELOW
CORNER
9IATION
CANBE UgEDFOR
A lold.AwoyBenrh
SOLIOLY
FASTEN
?x4 CLEAI
LEAYINO
SPACEoELOW
CLEAR
Si [eKnock-Down
Table
KNOCK'DOWN
TAELEI5 MADE
FROMONE 9HEET
43
--
workin withtools
makealltheseprofiles
andmorewith
ThreeBasicRouterBits
Beating an be
renovedfar_
OvertheyearsI've accumul,ated
alot
of dilferent router bits. The "workhorse" bits that have standardpmfiles get used over and over aganr
while the more exotic"big money"
bits usualy just gatherdust. This
finally led me to the realizationthat
you don'i need a drawer full of
expensivebiis to rcut fdcy profiles.
yi
/aund over
trit
- e
A = c l
#S*;.
44
.ore box
How.Tor
7EasProfiles sh Ti DesiYourO
As you can see,the layouttools I usedto designtheseprofiles are pretty basic. A section ofrr" dia. dowel works
sreat as a template for a r/a"roundover or a r/a"cove (%"
core box bit). And a 1'Ld'a.dowelwas my r/r" found-over
bit. Chancesafe if you can draw it on paper,you can find
a way to make it with a few common router bits.
Onagieup
Irrc S.lupr
m a kn q a d d l t i o n a l
modededqetqo to
l
\.::-'
p-j
-a) /'
r-!q,!d$"t
I
l-
.J.,''aTn
1," l
No.153
yourfinishing
solve
problems
with
Shellac
AJierspmding a lot of time building
a piojci, the last thing I want is to
wipe on somestainandend up with
a blotchy mess.ff you've ever had
this happen, you know how frustrating pioblems like thjs canbe.
There are quite a few produ.ts
that you canbuy that claim to solve
finishing problems. But chances
are you hav the solution to most
of theseproblemsin your finishing
cabinetakeady - shelac.
sAilDlxG
stAlEr.One way shellac
can prevent finishing problems is
when it's used as a sealerbefore
applying a fiLn finish to a project
(instad of an oil finish). \ r'hen
using a film finish, I'm
looking for a glass
]| Toprevent
stan
blotchng on p ne (top
board),applya thin coatof dewaxedshelacto
evenout the colorandcontrolabsorption.
rl|
Unifnithed(herryispale
or lightpink,but gradually
How-Tol
MixYourOwnor
lf there's one downside to using premixed shellac,it's that it has a limited
shelf life, usually about one year. So
whenlonlyneedtouseasmallamount,
I
liketo mix it upfrom driedflakes.
The unmixedflakeshavean unlimited
shelf life, so you never have to worry
aboutthe age.Thellakescomein a range
of colors,as you can see in the photos
belowTomb(it.lfilla pintjaraboutquaF
terfullwith llakesandthen pour in denatured alcoholtoflllthe jar (photoat left).
This makesit a littlethinnerthanif lwas
using it as a finish. Then cover the iat
shakingoccasionally.
The flakesshould
dissolvein abouttwo hours.
--t{
Suus EYE
$l|Euc
' lFoler&
I rhish"rpl
Forevenfasterdrying
times,tryspray-on
shellac,
whichis
always
dewaxed
and
safefor allfinishes.
No.153
Woodsmith
47
in the mailbox
& Answers
Questions
Glues you can
use outdoorc
Fmnklinbfnebond I .rhis
is a new formulationfor
the standardwood glue
that makesit waterprcoi
."-"
Theadvantage
of thisglue
o";Hi"g
fit'^
prciec.s is that it works a lot like
Voutdoot
the glue you use every
andfd fiketo know whzk
day. lt cleans up with
the bestghte to useT
Hdt@u waterand it hasa couple
Jash
PhMir, Anztu other advantagesover
yellowglue.
regular
project
isthat it hasa
Euilding
for
The
first
a
A
outdoor use has longeropen time. This
/n
some uniquechallenges. meansyou have more
Outdoor projectsmust time to assemblea projwithstanclrain, extreme ectand getthe clampsin
temperatureand humid- place before the glue
itychanges.andsunlight.
Besideschoosingthe
The secondadvantage
dghtbuildingmaterial,
the is thatit cnbe appliedat
(47").
grue you use can go a a lowertemperature
The downsideis that
longway in makinga proj'
ectsurvivethe weather. thisgluedoesnlfillgaps
lll. The newest sotheioinerymustfrttight
TlllgollD
waterproof g lue is
Do you have
anyquestions
IOr USr
lf you have a question
related to woodwork;ng
techniques,
tools,finishing,
or hardware,we'd like to
Just write down your
questionand mail it to us:
Woodsmith, O&A, 2200
Grand Avenue, Dss
Moines, lowa 50312. or
you can email us the question at woodsmith@wood-
POLIUREIIIIIIE
OIUI.A SECond type of waterproof
glue.
glueis polyurethane
Like n@bondI , polyurcthane glue is prettyeasy
to apply.Thebestfeature
glue is
of polyurethane
that it bonds to most
materials:wood, plastic,
glass,and evenmetal.
Polyurethane glue
needsmoistureto cure,
So it's a good idea to
moistenone of the faces
beforeapplyingthe glue.
As it cures,polyurethane
glueexpandsintoafoam.
But donl worry,onceit's
dry, you can scrapeoff
anyexcesswhha chisel.
(0il5Ttucl0ll lDHl5lvt.
Whilenot usuallyconsidered as a woodworking
9lue, constructionadhesivworksgreatin some
situations.
lf you'rebuildinga deckorgarden
shed,
constructionadhesive
it
comesin handybcause
grabsquicklyanddoesn't
needtight-fittingjoints.ln
fact,it'ssothickthatyou'll
needto allow plentyof
roomforsqueeze-out.
tPoxY.The last wateF
proof glue is two-part
epoxy.Although it's the
most expensive,the big
advantage
is that it fills
gaps.This makesit great
for patchingholesand
replacing
damagedor rotten wood, But since it
won't takest.jn, jt needs
to be painted.
Whatyou needto do is
matchthe gluetothejob.
one
To helpdecidewhich
to use,takea look at the
chartbelow.N
C o mp a ri n gWa te rp ro o fGlues
TyPe
,v
Easeof use
StrenSth Weakness
Cost
ff
@d
Apply ||fth e stzndard
Pleaseincludeyour full
name,address,and day'
time telephonenumberin
casewe havequestions.
48
ft
No.153
hardware& supplies
T Sources
P:l|dt P03lttD
talt
ORDER
s0uncE
Similar nroiect
s wnes tnaao(
thefo\dwin!)
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WOODSilIilPNOJECT
SUPPI.IES
Wenow{aturehardwarefom RocK LE R in many
of our newprojectkits.To order,pleaseusour toU-fee
order lin,sebelowIfs openMondaythrough Friday,
from 8 AMto 5 ?M CentralTime. Beforecalling,please
have your talsA,Mastercard, Discover,or Amencan
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Woodsmith
49
detailsof craftsmanship
l,
carvrnga
LambtTongue
Chamfer
Extradetail.That'swhata lamb's
tonguechamferis all about.Sure
you could cut a stoPPedcham"
fr. But on the Pencil Post Bed, I
wantd to add an extra, handmade detail, one that couldn'tbe
duplicated by machine.
The lamb's tongue chamfer
is a traditional dtail that's
rrv
hand
you're
reody
tocnnvt
now
The first step is to rough out th
b a s i c s h a p e .i d i d t h i s r v i t h a
chisel, cutting a V shaped notch
t o f o r m t h e c o n c a v eh o l l o w , a s
y o u c a n s e ei n F i g . 1 . T o p r e v e n t
c h i p p i n g o u t a l a r B ep i e c e , t a k e
small cuts, rYo.klng first from one
s i d e , t h e n t h e L ) t h e r ,s t a d i l y
-nl r ro nu rh- n,,rrlr
SHAPING
THtToP.\{iih ihe hollo$,
roughd out, it's tine to (ork
on ihe round 'rpper part. This
becauseth short grain wood
fibers can chip off priiy easilt'.
There are iwo ihings you can
do io prevent ihis. First, take
ihin, paring cuts cithci across
ihc grain oi diagonal io ihe
8 r a i n , a s i n F i B s .2 a n d 2 a . T h e
second wav to preleni iearnrS is
to moistcn thc grain wiih a
damp rag. This softens ihe
wood fibers making them easier
to slice away cleanly.
!.i.,:
prcventtearout
srDE
vtEw
stDEvtEw
s ' d n L a . ! t i o r h a l d m b \ t o n g u a b ) m d \ i n g d v < h a p F d Shapethe rcond pottian of the detailby taking thin, crossnotch in the hollow of the prafile, cutttng from bath sides. gfttn cuts Moisten the wood to make it easier ta cut.
a
A thin catvtng knife warks well ta reftne the curve aF the
hallaw Again, work fram both directians ta dvotd tearaut
No.153
Knock-Dozon
Boakshelf.
f his sturdybookshell
featuresbiscuitjoineryandeasy'to-install
knockdownhardware.All
of whichmakeitsurprisingiy
simpletobuild.Theinstructions
startonpoge
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lookinginside
FinalDetails
BendBoardSforageChesl.Buildthiscasualbead
board
versionor onethat'sa littlemoretraditional.
Eitheronewill
fit rightinanywhereyou
needtoaddsomestorage
space.
youcan
Withbasicconstruction
andready-made
moldings,
plansbeginpage1.1.
Step-by-step
buildonein a weekend.